阅读说明：本技术 用于制造层压复合部件的系统和方法 (System and method for manufacturing laminated composite parts ) 是由 拉维恩德拉·斯达西·苏里亚拉奇 达雷尔·达尔文·琼斯 于 2021-05-12 设计创作，主要内容包括：描述了一种用于制造层压复合部件的系统和方法。该系统可以包括：切割站,被构造为根据预定图案从复合材料的板层分离部件层；构建站,被构造为根据预定定向堆叠部件层；精加工站,被构造为压实堆叠的部件层并将层压复合部件提供给安装站。(A system and method for manufacturing a laminated composite part is described. The system may include: a cutting station configured to separate component layers from plies of the composite material according to a predetermined pattern; a build station configured to stack component layers according to a predetermined orientation; a finishing station configured to compact the stacked component layers and provide the laminated composite component to the mounting station.)

1. A system for manufacturing a laminated composite part, wherein the system comprises:

a cutting station configured to separate component layers from plies of the composite material according to a predetermined pattern;

a build station configured to stack the component layers according to a predetermined orientation;

a finishing station configured to compact the stacked component layers and provide the laminated composite component to the mounting station.

2. The system of claim 1, further comprising an automated pick-and-place device configured to move the component layer from the cutting station to the build station.

3. The system of claim 2, wherein the automated pick and place device is an automated robotic device comprising:

a robot gripper configured to pick up the component layer separated by the cutting station, rotate the picked component layer, and move the component layer to the build station;

an orientation setting device configured to determine an orientation of each of the component layers picked by the robotic gripper and rotate the component layers according to a predetermined orientation for the build station.

4. The system of claim 3, wherein the build station includes a second conveyor configured to receive the component layer from the cutting station via the robotic gripper, and wherein the component layer is rotated to the predetermined orientation by the robotic gripper en route from the cutting station to the build station.

5. The system of claim 4, wherein the second conveyor comprises an adhesive configured to retain a lowermost layer of the received component layers on the second conveyor.

6. The system of claim 4, wherein each of the component layers is concentrically stacked and aligned over each of the other component layers.

7. The system of claim 6, wherein the finishing station comprises:

a compactor configured to apply compressive pressure to the stacked component layers to form the laminated composite component;

a part marking device configured to emboss the laminated composite part with a visual indicator corresponding to the laminated composite part;

an inspection device configured to perform quality assurance of the laminated composite part.

8. The system of claim 1, wherein the cutting station comprises:

a first conveyor;

a distributor configured to distribute the composite material on the first conveyor;

a vacuum device configured to apply a negative pressure to the first conveyor such that the composite material remains on the first conveyor;

a cutting device configured to cut the component layer from the composite material, wherein the predetermined pattern corresponds to a frame filler.

9. The system of claim 8, wherein the composite material comprises individual plies of prepreg composite material, and wherein the cutting device comprises an ultrasonic cutting device.

10. The system of claim 8, wherein the predetermined pattern comprises changing a size of the pattern such that the laminated composite part forms a tapered frame fill when the part layers are stacked according to a predetermined sequence at the finishing station.

11. A method for manufacturing a laminated composite part, wherein the method comprises:

separating the component layers from the plies of composite material according to a predetermined pattern at a cutting station;

stacking the component layers according to a predetermined orientation at a build station;

the stacked component layers are consolidated at a finishing station and the laminated composite component is provided to a mounting station.

12. The method of claim 11, further comprising moving the component layer from the cutting station to the build station by an automated pick and place device.

13. The method of claim 12, wherein the automated pick and place device comprises an automated robotic device, the method further comprising:

picking up the component layer separated by the cutting station by a robot jig, rotating the picked-up component layer, and moving the component layer to the building station;

determining, by an orientation setting device, an orientation of each of the component layers picked up by the robotic gripper and rotating the component layers according to a predetermined orientation for the build station.

14. The method of claim 13, wherein the step of rotating the component layer comprises: rotating the component layers by the robotic gripper en route from the cutting station to the build station, and wherein the step of stacking at the build station further comprises: receiving the component layer from the cutting station at the build station via the robotic gripper by a second conveyor.

15. The method of claim 14, further comprising retaining a lowermost of the received component layers on the second conveyor with an adhesive.

16. The method of claim 14, further comprising concentrically stacking and aligning each of the component layers over each of the other component layers.

17. The method of claim 16, wherein the step of compacting at the finishing station further comprises:

applying compressive pressure to the stacked component layers by a compactor to form the laminated composite component;

embossing the laminated composite part with a visual indicator or letter corresponding to the laminated composite part by a part marking device;

quality assurance of the laminated composite part is performed by an inspection device.

18. The method of claim 11, further comprising:

dispensing the composite material on a first conveyor at the cutting station through a dispenser;

applying negative pressure to the first conveyor by a vacuum device to hold the composite material on the first conveyor;

cutting the component layer from the composite material by a cutting device, wherein the predetermined pattern corresponds to a frame filler.

19. The method of claim 18, wherein the composite material comprises individual plies of prepreg composite material, and wherein the cutting device comprises an ultrasonic cutting device.

20. The method of claim 18, wherein the predetermined pattern comprises changing a size of the pattern such that the laminated composite part forms a tapered frame fill when the part layers are stacked according to a predetermined sequence at the finishing station.

Technical Field

The present application relates generally to the manufacture of composite parts. More particularly, the present application relates to automated composite manufacturing systems and methods.

Background

In certain manufacturing environments, such as vehicle manufacturing environments, vehicles are assembled at one location, and parts or components used to assemble such vehicles may be manufactured elsewhere, for example at another facility. These parts and components can be manufactured by skilled personnel through laborious processes and the finished parts are placed in the warehouse area so that the parts can be retrieved when needed to assemble the vehicle. Maintaining a proper supply chain in such a manufacturing environment is important to ensure that parts do not run out when they are needed for assembly of a vehicle, reducing productivity. To ensure that productivity is not adversely affected, a large enough warehouse area is required to keep all parts in stock so that they are always available when needed. However, if the production of the vehicle is stopped, terminated unexpectedly or slowed down, and if the parts are prone to spoil and they remain in the freezer for too long, or if the service life of the parts exceeds the service life, the inventory of unused parts in the warehouse may suddenly become an unusable excess of parts, which may eventually have to be discarded, wasting money and resources. Accordingly, techniques for more efficiently manufacturing parts and reducing waste are needed.

Disclosure of Invention

According to one example, a system for manufacturing a laminated composite part is described. The system may include: a cutting station configured to separate component layers from plies of the composite material according to a predetermined pattern; a build station configured to stack component layers according to a predetermined orientation; a finishing station configured to compact the stacked component layers and provide the laminated composite component to the mounting station.

According to another example, a method for manufacturing a laminated composite part is described. The method can comprise the following steps: separating the component layers from the plies of composite material according to a predetermined pattern at a cutting station; stacking component layers according to a predetermined orientation at a build station; and compacting the stacked component layers at a finishing station and providing the laminated composite component to a mounting station.

The scope of the invention is defined by the claims, which are incorporated into this section by reference. A more complete understanding of embodiments of the present invention, as well as the realization of additional advantages thereof, will be apparent to those skilled in the art upon consideration of the following detailed description of one or more embodiments. Reference will be made to the accompanying drawings, which will first be described briefly.

Drawings

Fig. 1, 2A, and 2B illustrate internal views of exposed frames, trusses, and frame fillers of an exemplary aircraft fuselage.

Fig. 3 shows an exterior view of an exemplary aircraft fuselage assembled on a curing tool.

Fig. 4 is an example system layout of a laminated composite component manufacturing system according to various examples of the present disclosure.

Fig. 5 is a side view of an exemplary cutting station including a conveyor according to various examples of the present disclosure.

Fig. 6 is a perspective view of an exemplary conveyor using a vacuum device to prevent composite material from falling off the conveyor, according to various examples of the present disclosure.

Fig. 7-9 illustrate exemplary robotic devices that may be implemented to pick and place composite materials from one station to another according to various examples of the present disclosure.

Fig. 10 illustrates an example compactor apparatus that may be implemented to compact a stack of plies of a layered composite material, according to various examples of the disclosure.

Fig. 11 is a timing diagram for manufacturing a laminated composite component manufacturing system according to various examples of the present disclosure.

Fig. 12 is a flow diagram of a laminated composite part manufacturing system according to an example of the present disclosure.

Fig. 13 is a flow diagram of a laminated composite part manufacturing system according to another example of the present disclosure.

Fig. 14 is a flow diagram of a laminated composite part manufacturing system according to another example of the present disclosure.

Fig. 15 is a flow diagram of a laminated composite part manufacturing system according to another example of the present disclosure.

Embodiments of the present disclosure and their advantages are best understood by referring to the detailed description that follows. Unless otherwise indicated, like reference numerals refer to like elements throughout the drawings and written description, and thus, the description thereof will not be repeated. In the drawings, the relative sizes of elements, layers and regions may be exaggerated for clarity.

Detailed Description

Hereinafter, various examples will be described in more detail with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein. Rather, they are provided as examples so that this disclosure will be thorough and complete, and will fully convey aspects and features of the invention to those skilled in the art. Accordingly, processes, elements and techniques not required by one of ordinary skill in the art to fully understand aspects and features of the present invention may not be described.

The fuselage of an aircraft, such as a commercial passenger aircraft, includes various structural features that provide a generally cylindrical tubular and elongated shape. Fig. 1, 2A, and 2B illustrate internal views of some of the exposed structural features of an exemplary aircraft fuselage 100. The structural features include a cylindrical tubular radial frame 106 forming the fuselage 100, and a truss 102 extending in a longitudinal direction (e.g., forward and aft) relative to the fuselage 100 and perpendicular to the frame 106. In general, a plurality of trusses 102 and frames 106 form the structure of fuselage 100 and are covered by skin 104 to complete fuselage 100.

The truss 102 is a stiffening member of the body of the fuselage and may have different thicknesses depending on the location of the fuselage 100. For example, a truss 102 positioned closer to the bottom of the fuselage may be thicker relative to a truss 102 positioned toward the top of the fuselage. Thus, if skin 104 is disposed directly on truss 102, there may be a gap between skin 104 and the thinner truss 102. To compensate for this gap, a framing filler 108 made of multiple plies of composite material laminated together is used to bridge the height between the thickest truss 102 and the skin 104.

Fig. 3 shows an exterior view of an exemplary fuselage assembled on a curing tool 110 (e.g., mandrel). Thus, in this illustration, the trusses 102 and framing filler 108 are mounted on a curing tool 110 such that the framing filler 108 is disposed between two trusses 102. When truss 102 and frame fill 108 are installed, the skins may then be co-cured on them and bolted to the frame. Thus, aircraft, especially larger aircraft, have many trusses 102 and frames 106, such that thousands of frame fillers 108 (e.g., about 2 inches by 6 inches) are co-cured on the fuselage 100 to erect the gap. However, each frame filler 108 is customized to a particular size, shape, and thickness to fit a particular location of the fuselage. Thus, the shape, size, and/or thickness of each individual frame fill 108 may be different. Thus, conventional techniques for manufacturing frame fills 108 for such aircraft are labor intensive and require that such prepreg stock materials be accurately folded and stacked by hand to form the frame fill 108. Furthermore, due to the manual manufacturing process, the frame fill 108 is manufactured in batches, rather than on demand. In other words, a batch (or group) of frame fills 108 of one gauge is manufactured by hand in a given manufacturing process, and the batch of finished frame fills 108 is placed in a warehouse until they are needed. In the next manufacturing process, different frame filler specifications may be manufactured again in batch mode and then placed in a warehouse. In this manner, a number of batches of frame fill 108 are manufactured and stored as parts (e.g., WIPs) until they are ready to be installed on an aircraft. Thus, the installer of the frame fill 108 must be aware of which frame fills 108 are needed for the day's work on the fuselage and retrieve the appropriate frame fills 108 from the warehouse. In some environments, the manufacture of such frame filler 108 may be performed at a facility other than an aircraft assembly plant. For example, the frame fill 108 may be manufactured by different companies or subcontractors at different facilities or in different countries, thus resulting in increased costs for ordering and transporting such parts.

Various examples provided throughout this disclosure contemplate systems and methods to automatically manufacture laminated composite materials, such as frame fill, by using mechanical and robotic means, and then to manufacture such laminated composite materials on demand at an appropriate rate and in an appropriate sequence as required for installation. For example, if a first size of framing filler is desired, then a second size of framing filler is desired, and then the first size of framing filler is again desired, the system and method manufacture the framing fillers in that particular order. Further, the frame work filler may be manufactured at the same facility as the aircraft being assembled at the mandrel so that each frame work filler may be immediately provided to the installer at the assembly site as it is manufactured. Thus, when the manufacture of the framing filler is complete, the completed framing filler may be retrieved by a technician and installed on the aircraft in a timely manner, thereby eliminating the need for a warehouse location at the facility to store parts since excess framing is not produced, but instead, only the framing filler required at that time is manufactured. Furthermore, in case of damage of the frame filler, for example by an installer when installing the frame filler, or if the frame filler drops and is damaged, a replacement frame filler can be manufactured immediately, thereby preventing or at least reducing production delays caused by damage of parts.

Fig. 4 is an example system layout of a laminated composite component manufacturing system according to various examples of the present disclosure. Although the present disclosure will refer, by way of example, to the manufacture of laminated composite parts as the manufacture of a frame filler, it should be understood that the systems and methods are also applicable to other laminated composite parts and are not limited to frame fillers only.

According to the illustrated example, the system 400 includes a cutting station 490, a build station 492, and a finishing station 494. Thus, a raw composite material, such as a prepreg material, may be processed through various machinery and devices including the system 400 and within minutes, making a finished frame fill, and ready for immediate installation on an aircraft.

The cutting station 490 includes at least a conveyor 404 and a dispenser 402, the dispenser 402 being configured to, for example, hold a spool of composite material and dispense individual plies of composite material 408 onto the conveyor 404. The conveyor 404 may also include a vacuum device configured to apply a negative pressure to the conveyor 404 and a cutting device 410 configured to cut the composite material 408 onto the conveyor 404. According to one example, the cutting device 410 may be an ultrasonic cutter (USK), while in other examples, the cutting device 410 may be a laser cutter or other high speed cutter known in the art. As the composite material is dispensed onto the conveyor 404, the conveyor moves the composite material 408 in the direction indicated by arrow 406 from the first end of the cutting station 490 toward the second end of the cutting station 490. As the composite material 408 moves to the cutting device, the composite material is cut and separated into a part layer 412 that will ultimately become one ply of the composite material laminated with another ply of the part layer. The part layer 412 has a predetermined shape or pattern based on the specifications of the parts being manufactured and moves toward the second end of the conveyor 404. When the pattern is cut, an automated pick and place device picks up the component layers to separate the component layers 418 from the individual plies of composite material 408. The remaining excess composite material 414 continues to move toward the second end of the conveyor and is collected as waste in a waste bin 416.

Fig. 5 is a side view of an exemplary cutting station 490 including a conveyor 404 according to various examples of the present disclosure. As shown, the raw composite material may be in the form of a spool mounted on the distributor 402 and configured to be unwound onto the conveyor 404. The vacuum apparatus applies a negative pressure 502 to the conveyor to prevent the composite material from falling off the conveyor.

Fig. 6 illustrates a perspective view of an exemplary conveyor using a vacuum device to prevent composite material 606 from falling off the conveyor, according to various examples of the present disclosure. For example, the conveyor belt 602 of the conveyor 404 may have holes 604 from which a vacuum device applies suction from the negative pressure 502 to hold the composite material 606 on the conveyor 602. Thus, when plies of composite material 408 are disposed on conveyor 404, composite material 408 is not blown away by circulating air in the environment (e.g., due to movement of personnel or air generated by machinery). Fig. 5 shows one exemplary configuration of a vacuum apparatus, in which a negative pressure 502 is generated near the conveyor belt 602 toward the surface of the conveyor, and a positive pressure 504 is generated in the lower portion of the conveyor 404. In this example, the waste bin 416 is located below the conveyor 404, and a vacuum applies a positive pressure 504 near the waste bin 416, causing waste material to be removed from the conveyor 602 and fall into the waste bin 416.

In this manner, the first layer that constitutes the laminate composite frame fill is cut from the individual plies of the raw composite material 408. The predetermined pattern may be arranged such that a specific size and shape is cut out which corresponds to the required specific size and shape of the first layer of the frame filling. The cutting device 410 is configured to cut any desired shape or pattern. Thus, each pattern cut out may differ based on the size and shape desired for the next layer.

Referring back to fig. 4, the build station 492 includes a second conveyor 428 configured to receive the component layer 412 from the cutting station 490. For example, a robotic device 420 having a robotic arm and/or robotic gripper may be configured to pick up the component layer 418 from the first conveyor at the cutting station 490 and move it to the build station 492 and place it on the second conveyor 428. According to an example, the robotic device 420 may also be configured to operate with an orientation setting station 422 that includes an orientation determining device 424 that determines the orientation of the component layer when the component layer is picked up by the robotic device 420. The orientation determining means 424 may be an orientation scanner, e.g. a camera (e.g. a visible range camera, an infrared camera or a thermal camera), and uses image processing to determine the orientation. The orientation setting station 422 may also include an orientation setting device 426, which may be, for example, a rotatable table that rotates the component layer 418 as it is disposed thereon, and rotates the orientation of the component layer 418 to place it properly on the second conveyor based on the orientation determining device 424 determining the direction in which the component layer needs to be oriented. According to another example, the orientation setting device may be embedded as part of the robotic device 420. Thus, robotic device 420 may also include an orientation determining device and automatically rotate or orient the component layer while the robotic arm or gripper holds the component layer. Thus, the robotic device 420 may pick up the component layer 418 from the cutting station 490, rotate the orientation of the component layer en route to the build station 492 using, for example, a robotic arm or rotatable gripper, and place the component layer on the second conveyor 428.

According to another example of the present disclosure, the build station 492 includes a spool of adhesive layer disposed in an adhesive dispenser 430 at the second conveyor 428. Accordingly, adhesive layer 432 may be placed on second conveyor 428 such that component layer 418 may be placed on the adhesive tape such that component layer 418 does not fall or blow away from the conveyor due to air (e.g., circulating air due to movement of personnel or air generated from machinery). In some examples, adhesive layer 432 may be polyethylene on one side and paper on the other side. Thus, the part layer 418 is removed from the cutting station 490 and placed on the adhesive layer 432 on the second conveyor 428, and the process may be repeated based on the number of plies for the particular laminated composite part being manufactured. For example, if 10 ply frame fillers are to be manufactured, the above process is repeated 10 times, and each time a new component layer is precisely stacked on top of the previous component layer, such that each component layer is concentrically stacked and aligned over each of the other component layers below it. In a particular example, the frame filler includes a beveled or tapered edge, such as a 15 degree bevel or taper. Such a bevel or taper angle may be achieved in the frame filler by varying the dimensions of each component layer cut out so that when the plies are stacked together, the edges are angled. For example, if the frame fill has a pyramidal shape, the lowest component level is the largest, while the next level above it is slightly smaller, and so on. Thus, the bevel angle frame filler can be manufactured without having to precisely cut the frame filler at the ends to create the bevel angle.

According to one example, robotic device 420 may include a controller for handling movements of robotic device 420. In certain embodiments, the controller may be interconnected with the robotic device 420, the cutting station 490, the build station 492, and the finishing station 494 so that the various devices in the various stages of the system 400 may communicate with each other and synchronize processing. For example, the controller may be configured to handle the order in which component layers need to be cut when assembling a particular type of aircraft, and to do so, the controller communicates with the interconnection apparatus of the system 400.

Fig. 7-9 illustrate exemplary robotic devices that may be implemented to pick up and place composite materials from one station to another, according to various examples of the present disclosure. The exemplary automated robotic device shown in fig. 7 includes a clamp 702 supported by a plurality of arms 704 that extend and/or retract. Thus, as the arms 704 extend and/or retract, the gripper 702 is free to move from one location to another and pick and place objects such as the component layer 418. Fig. 8 shows another type of robotic device that includes a gripper 802 and a robotic arm 804. In this example, the robotic arm 804 may move in various directions to move the gripper 802 from one location to another and to pick and place objects such as the component layer 418. Fig. 9 shows yet another type of robotic device, which includes a gripper 1002 and a robotic arm 1004. In this example, the robotic arm 1004 may move in various directions like a human arm to move the gripper 1002 from one location to another and to pick and place objects. Thus, as provided, various types of robotic devices 420 may be implemented to complete the process of picking up the component layer 418 from the cutting station 490 and placing it on the build station 492. Fig. 7-9 illustrate only some examples of pick and place devices that may be implemented, but are not limited to only those shown.

When the desired number of plies are stacked at build station 492, the stacked component plies are then transported in the direction of arrow 434 to finishing station 494, which includes compactor 438, part marking device 440, and inspection device 442. According to one example, compactor 438 is configured to apply compressive pressure to the stacked component layers to form a laminated composite component. In certain examples, compactor 438 may apply a pressure of approximately 20 to 30psi, but in other examples, lower or higher pressures may alternatively be applied. For prepreg composites, the application of pressure compresses and forces the plies to stick together to form a laminated composite part. In other examples, heat may be applied to the stacked component layers to assist in adhering the plies to each other. For example, the second conveyor 428 may have a heating blanket, or the compactor may have a heating device. Fig. 10 illustrates an exemplary compactor that may be implemented to compact a stack of layered composite materials, according to various examples of the disclosure. An exemplary compactor may include a compressor head 902 configured to exert a force on the stack of part layers 436 on the second conveyor 428.

As the component layers are compacted, the second conveyor 428 then moves the laminated composite component to a part marking station where a part marking device 440 impresses a visual indicator on the laminated composite. For example, the embossing may be an arrow or some other visual indicator that informs the installer of the proper direction to install the laminated composite part, or the embossing may be a part number that corresponds to the particular shape and size of the frame fill.

After the part marking of the part layers, the laminated composite part is moved to an inspection section where an inspection device 442 performs a quality assurance inspection to ensure that the laminated composite part meets manufacturing standards and tolerances, such as for example, size, shape, right angles, bevel angles, and the like. In some examples, the inspection device 442 may be a high-resolution camera with image processing. If the completed component (e.g., the framing filler) passes inspection, the framing filler is immediately ready for installation on the aircraft. According to some examples, the frame filler may be placed on another conveyor or conveying device to provide the frame filler to an installer for timely use.

Fig. 11 is a timing diagram of a composite charge manufacturing system according to various examples of the present disclosure. Step 1102 is the start point for manufacturing the laminated composite part and corresponds to a reel of composite material 408 that may be continuously dispensed onto a first conveyor. This is a continuous process and the reel can be unwound continuously. Certain prepreg composites may have a liner paper that is automatically removed when the composite is dispensed onto a conveyor. Next, at step 1104, the composite material may be cut into a predetermined pattern using a cutting device, such as a USK. According to the example cutting apparatus described in this disclosure, this step may take about 5 seconds to cut each ply. Once the component layers are cut, a pick-and-place device picks up the component layers at step 1106. In one example, this step may take about 1.5 seconds. Next, at step 1108, the pick-and-place device may rotate the component layer to the correct orientation before moving it to the build station. This step may take about 1.5 seconds. At step 1110, the properly oriented component layer may now be placed on the second conveyor of the build station. This step may take about 1.5 seconds. The process of picking up, rotating and placing plies of the component layer is repeated until a desired or predetermined number of plies are stacked on top of each other at the build station. Once the plies are stacked, a compaction device applies pressure on the stack and compacts the component plies at step 1112. In some examples, the laminated composite part may be made from 10 plies, and it may take about 10 seconds to compact with the compaction device. In other examples, a laminated composite part may be made from 12 plies, and it may take longer to compact the 12 plies. Next, the compacted laminate part is provided to an inspection device, which verifies the quality of the finished compacted laminate part to ensure that it meets design specifications and tolerances at step 1114. This step may take about 5 seconds for each frame filler. Next, at step 1116, the inspected part is provided to a part marking process, which may take about 5 seconds, and then at step 1118, an additional 2 seconds or so to move the frame fill to the point of use at the mandrel. Accordingly, by using the automated process provided throughout the present disclosure, a finished and easy to use frame filler can be manufactured from raw materials in approximately one minute. The actual time spent may vary depending on the number of plies used in a particular frame fill and the type of machinery used. For example, a particular robotic device may move faster than other robotic devices, a particular cutting device may be able to cut faster, and a particular compaction device may be able to compact a layer of parts faster.

Fig. 12 is a flow diagram of a laminated composite part manufacturing system according to an example of the present disclosure. The system may be configured to separate a component layer from plies of the composite material at a cutting station according to respective predetermined patterns (1202). The predetermined pattern may be configured and/or selected based on the design requirements of the intended component. The size, shape and thickness of the frame filler is thus dependent on the position of the fuselage where the frame filler is mounted and can be programmed into the cutting device so that the USK can cut the appropriate pattern. The component layer is then moved from the cutting station to the build station by an automated pick and place device (1204). As the component layers move to the build station, the component layers are stacked one on top of the other according to their predetermined orientation (1206). For example, certain frame fills include 10 plies stacked together, while other frame fills include 12 or more plies stacked together. Upon stacking the desired number of component plies, the stacked component plies are then consolidated at a finishing station to produce a laminated composite component, such as a frame fill. The completed framing filler is then provided to an installation station where the framing filler is installed on the aircraft (1208).

Fig. 13 is a flow diagram of a laminated composite part manufacturing system according to another example of the present disclosure. The pick-and-place device of the manufacturing system may implement a robotic device having a robotic gripper configured to grasp and pick up the component layer (1302) cut by the cutting device at the cutting station. The orientation of the component layer picked up by the robot gripper is determined by an orientation determination means, such as for example a camera, and the component layer is rotated according to a predetermined orientation for building the station (1304). The component layer is moved to a build station by a robotic device (1306).

Fig. 14 is a flow diagram of a laminated composite part manufacturing system according to another example of the present disclosure. At the cutting station, a dispenser dispenses raw composite material onto a first conveyor (1402). The vacuum device can be configured to apply a negative pressure to a surface of a conveyor (e.g., a conveyor belt) to hold the composite material on the conveyor (1404). As the composite material is conveyed towards the cutting device, the component layers are cut from the composite material by the cutting device. The composite layer is cut (1406) into a predetermined pattern corresponding to plies of the frame fill. Thus, the raw composite material can be dispensed and accurately cut into a desired predetermined pattern.

Fig. 15 is a flow diagram of a laminated composite part manufacturing system according to another example of the present disclosure. The component layer may be rotated by a robotic gripper as the component layer moves from the cutting station to the build station. Accordingly, the component layer (1502) may be rotated en route from the cutting station to the build station. For example, the component layer may be rotated by the robotic gripper itself after it is picked up by the gripper, but before it is placed on the second conveyor. In other examples, the component layers may be placed on an orientation setting device as shown in fig. 4 to first rotate the component layers to the correct orientation, and then the robotic arm again picks up the correctly oriented component layer and moves it to the build station. As each ply of the component layers moves to the build station, the robotic gripper places the component layers one on top of the other on a second conveyor of the build station, each of the component layers being concentrically stacked and aligned over each of the other component layers (1504). In a particular example, the second conveyor may have an adhesive to hold or maintain a lowermost layer of component layers placed by the robotic device (1506). The stacked component layers are then compacted by a compactor by applying compressive pressure on the stacked component layers to form a laminated composite component (1508). Next, the laminated composite part may be embossed with a visual indicator corresponding to the laminated composite part by the part marking device (1510). Quality assurance inspection of the finished laminated composite part may be performed by an inspection device such as a camera (1512). Thus, the frame filler may be manufactured on demand for consumption at a point of use (e.g., an aircraft assembly line). Thus, the aircraft may be manufactured in a manner similar to an automotive assembly line, wherein the continuous flow of components and the materials needed for assembly are provided to the point-of-use in a timely manner, thereby increasing efficiency, reducing waste, reducing costs, and reducing the size of the space needed to manufacture the aircraft.

It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the spirit and scope of the present invention.

Spatially relative terms, such as "under," "below," "lower," "beneath," "over," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the terms "below" and "beneath" of the examples may include both an orientation of "above" and "below". The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

It will be understood that when an element or layer is referred to as being "on," "connected to" or "coupled to" another element or layer, it can be directly on, connected or coupled to the other element or layer or one or more intervening elements or layers may be present. Further, it will be understood that when an element or layer is referred to as being "between" two elements or layers, it can be the only element or layer between the two elements or layers, or one or more intervening elements or layers may also be present.

Electronic or electrical devices and/or any other related devices or components according to examples of the invention described herein may be implemented using any suitable hardware, firmware (e.g., application specific integrated circuits), software, or combination of software, firmware and/or hardware. For example, the various components of these devices may be formed on one Integrated Circuit (IC) chip or on separate IC chips. In addition, the respective components of these devices may be implemented on a flexible printed circuit film, a Tape Carrier Package (TCP), a Printed Circuit Board (PCB), or formed on one substrate. Further, various components of these devices may be processes or threads running on one or more processors in one or more computing devices, executing computer program instructions and interacting with other system components to perform the various functions described herein. The computer program instructions are stored in a memory, which may be implemented in the computing device using standard memory devices, such as Random Access Memory (RAM), for example. The computer program instructions may also be stored in other non-transitory computer readable media such as, for example, CD-ROM, flash drives, etc. Moreover, those skilled in the art will recognize that the functionality of various computing devices may be combined or integrated into a single computing device, or the functionality of a particular computing device may be distributed across one or more other computing devices, without departing from the spirit and scope of the exemplary embodiments of the present invention.

The examples described herein are merely exemplary. Those of skill in the art will recognize a variety of alternative embodiments from the specifically disclosed embodiments. These alternative embodiments are also intended to be within the scope of the present disclosure. Accordingly, the embodiments are limited only by the following claims and equivalents thereto.