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EP-4741144-A1 - VARIABLE ROLLER ASSEMBLY AND A METHOD OF CONTROLLING THE VARIABLE ROLLER ASSEMBLY

EP4741144A1EP 4741144 A1EP4741144 A1EP 4741144A1EP-4741144-A1

Abstract

A method and a variable roller assembly (10) for forming one or more radii along a composite material blank includes a roller die configured to form the one or more radii along the composite material blank (12) to form a filler (14). A first actuator (38) is operably coupled to the roller die (32) and configured to move the roller die (32) in a linear direction along a y-axis, and a second actuator (40) operably coupled to the roller die and configured to move the roller die in a linear direction along a z-axis. A controller (50) is in communication with the first actuator and the second actuator to selectively activate the first actuator and/or the second actuator to variably move the roller die relative to the composite material blank to maintain engagement of the roller die with the composite material blank to form the one or more radii along the composite material blank to form the filler (14).

Inventors

  • LAMMERS, David Dean
  • FORSTON, Gabriel Zane

Assignees

  • The Boeing Company

Dates

Publication Date
20260513
Application Date
20251024

Claims (15)

  1. A variable roller assembly (10) for forming one or more radii along a composite material blank (12), the variable roller assembly (10) comprising: a platform (28) configured to support the composite material blank (12); a roller die (32) configured to form the one or more radii along the composite material blank (12), wherein forming the one or more radii along the composite material blank (12) forms a filler (14); a first actuator (38) operably coupled to the roller die (32) and configured to move the roller die (32) in a linear direction along a y-axis; a second actuator (40) operably coupled to the roller die (32) and configured to move the roller die (32) in a linear direction along a z-axis; and a controller (50) in communication with the first actuator (38) and the second actuator (40), wherein the controller (50) is configured to: selectively activate the first actuator (38) and/or the second actuator (40) to variably move the roller die (32) relative to the composite material blank (12), and maintain engagement of the roller die (32) with the composite material blank (12) to form the one or more radii along the composite material blank (12).
  2. The variable roller assembly (10) as set forth in claim 1, further comprising a clevis (42) operably coupled to the roller die (32), wherein the first actuator (38) and the second actuator (40) are operably coupled to the clevis (42) to transfer movement to the roller die (32).
  3. The variable roller assembly (10) of claim 1 or 2, further comprising a third actuator (70) operably coupled to the clevis (42), wherein the third actuator (70) is configured to rotate the roller die (32) about a pivot point.
  4. The variable roller assembly (10) of any one of claims 1-3, further comprising a first rail component (52) disposed in the linear direction relative to the y-axis, wherein the first actuator (38) is operably coupled to the first rail component (52), and wherein the first actuator (38) is configured to control movement of the roller die (32) in the linear direction along the y-axis.
  5. The variable roller assembly (10) of any one of claims 1-4, further comprising a second rail component (54) disposed in the linear direction relative to the z-axis, wherein the second actuator (40) is operably coupled to the second rail component (54) and wherein the second actuator (40) is configured to control movement of the roller die (32) in the linear direction along the z-axis, optionally wherein the first rail component (52) and the second rail component (54) are operably coupled to each other through the first actuator (38) and the second actuator (40) such that movement of the first actuator (38) along the first rail component (52) correspondingly adjusts a position of the second actuator (40) relative to the y-axis, and movement of the second rail component (54) relative to the z-axis does not adjust a position of the first actuator (38) relative to the z-axis.
  6. The variable roller assembly (10) of any one of claims 1-5, wherein the platform (28) includes a track configured to move the composite material blank (12) along an x-axis, and wherein the roller die (32) includes a first roller (34) that engages the composite material blank (12) as the composite material blank (12) moves along the x-axis.
  7. The variable roller assembly (10) of any one of claims 1-6, further comprising an attachment point (56) fixed to the second rail component (54), wherein the clevis (42) is attached to the attachment point (56), optionally wherein the variable roller assembly (10) further comprises a third actuator (70) operably coupled to the attachment point (56) and the clevis (42), and wherein the third actuator (70) is configured to rotate the roller die (32) relative to the composite material blank (12).
  8. The variable roller assembly (10) of any one of claims 1-7, further comprising a feedback device (60) in communication with the controller (50) and operably coupled to the clevis (42), wherein the feedback device (60) is configured to provide force feedback of the roller die (32) to the controller (50), wherein the controller (50) is configured to determine whether to adjust the roller die (32) along the y-axis and/or the z-axis.
  9. The variable roller assembly (10) of any one of claims 1-8, wherein the roller die (32) has a plurality of radii, with each of the radii being different from each other, wherein the controller (50) is configured to move the roller die (32) to vary a contact angle of the radii of the roller die (32) relative to the composite material blank (12) to vary the one or more radii formed on the composite material blank (12), optionally wherein the roller die (32) includes a first roller (34) and a second roller (36) cooperating with each other, wherein the first roller (34) has the plurality of radii configured to form one side (22) of the filler (14), wherein the second roller (36) has the plurality of radii configured to form another side (24) of the filler (14), wherein the composite material blank (12) is disposed between the first roller (34) and the second roller (36) to form the one or more radii of respective sides (22, 24) of the filler (14).
  10. The variable roller assembly (10) of any one of claims 1-8, wherein the roller die (32) has one radius, optionally wherein the roller die (32) includes a first roller (34) and a second roller (36) cooperating with each other, wherein the first roller (34) has the one radius configured to form one side (22) of the filler (14), wherein the second roller (36) has the one radius configured to form another side (24) of the filler (14), wherein the composite material blank (12) is disposed between the first roller (34) and the second roller (36) to form the one radius of respective sides (22, 24) of the filler (14).
  11. The variable roller assembly (10) of any one of claims 1-10, further comprising a heater (62) disposed proximal to the composite material blank (12) to heat the composite material blank (12) before forming the one or more radii, optionally wherein the heater (62) includes a radiant heater and/or a blower heater.
  12. The variable roller assembly (10) of any one of claims 1-11, further comprising a feedback device (60) in communication with the controller (50), wherein the controller (50) is configured to determine whether to adjust the roller die (32) along the y-axis and/or the z-axis.
  13. The variable roller assembly (10) of claim 12, wherein the feedback device (60) includes a strain gauge configured to provide pressure information about the roller die (32) engaging the composite material blank (12).
  14. A method (200) of controlling a variable roller assembly (10) to form one or more radii along a composite material blank (12) to form a filler (14), wherein a platform (28) is configured to support the composite material blank (12), the method (200) comprising: moving (202) the composite material blank (12) relative to a roller die (32); applying (204) pressure, via the roller die (32), to the composite material blank (12) to form the one or more radii of the filler (14); and selectively activating (206) a first actuator (38) and/or a second actuator (40), via a controller (50), to variably move the roller die (32) in a linear direction along a y-axis and/or in a linear direction along a z-axis relative to the composite material blank (12) to maintain engagement of the roller die (32) with the composite material blank (12) to form the one or more radii along the composite material blank (12).
  15. The method (200) of claim 14, further comprising varying (208) a contact angle of a radii of the roller die (32) relative to the composite material blank (12) to vary the one or more radii formed on the composite material blank (12), via selectively activating the first actuator (38) and/or the second actuator (40).

Description

RELATED APPLICATION The present application is a non-provisional of and claims priority to U.S. Provisional Patent Application No. 63/718,911, filed on November 11, 2024, entitled "VARIABLE ROLLER ASSEMBLY AND A METHOD OF CONTROLLING THE VARIABLE ROLLER ASSEMBLY," the complete disclosure of which is incorporated by reference. BACKGROUND Aircraft are being designed and manufactured with greater percentages of composite materials. Composite materials are used in aircraft to decrease the weight of the aircraft. This decreased weight improves performance features such as payload capacities and fuel efficiencies. Further, composite materials provide longer service life for various components in an aircraft. Composite materials are tough, lightweight materials created by combining two or more functional components. For example, a composite material may include reinforcing fibers bound in a polymer resin matrix. The fibers may be unidirectional or may take the form of a woven cloth or fabric. In thermoset composites, fibers and resins are arranged and cured to form a composite material. When composite structural members are joined together, gaps or voids may be present along bond lines between the members which may need to be filled in order to increase the strength of the bond. For example, in the aircraft industry, composite fuselage stiffeners such as stringers may include a composite filler at the convex radius bond line between the stringer and a fuselage skin. The composite filler is applied in the form of triangular cross-section strips, sometimes referred to as noodles or fillers, which fill the voids at the bond line. The composite filler may be formed from composite materials such as adhesive or prepreg tape. Composite fillers may be formed using a variety of different methods. For example, composite fillers may be formed by pulling a composite material through a series of rollers. By pulling a composite material through a series of rollers, the composite material may be incrementally formed along its length. However, pulling composite material through a series of rollers may result in the composite filler having undesirable quality, such as distortion of the composite material or create visual inconsistencies caused by rubbing of the composite material. As another example, conventional techniques may implement tooling that rigidly fixes a tooling angle and radii that may be formed along the composite filler. Therefore, there is a need for an assembly and a method that improves manufacturing processes of a composite material blank being formed into a filler. SUMMARY Apparatuses and methods for variable roller assembly are disclosed. In some examples, a variable roller assembly for forming one or more radii along a composite material blank is disclosed. In some examples, the variable roller assembly comprises a platform, a roller die, a first actuator, a second actuator, and a controller. In some examples, the platform is configured to support the composite material blank. In some examples, the roller die is configured to form the one or more radii along the composite material blank, wherein forming the one or more radii along the composite material forms a filler. In some examples, the first actuator is operably coupled to the roller die and configured to move the roller die in a linear direction along a y-axis. In some examples, the second actuator is operably coupled to the roller die and configured to move the roller die in a linear direction along a z-axis. In some examples, the controller is in communication with the first actuator and the second actuator. In some examples, the controller is configured to: selectively activate the first actuator and/or the second actuator to variably move the roller die relative to the composite material blank, and maintain engagement of the roller die with the composite material blank to form the one or more radii along the composite material blank. A method of controlling a variable roller assembly to form one or more radii along a composite material blank to form a filler is disclosed. In some examples of the method, a platform is configured to support the composite material blank. In some examples, the method comprises moving the composite material blank relative to a roller die. In some examples, the method comprises applying pressure, via the roller die, to the composite material blank to form the one or more radii of the filler. In some examples, the method comprises selectively activating a first actuator and/or a second actuator, via a controller, to variably move the roller die in a linear direction along a y-axis and/or in a linear direction along a z-axis relative to the composite material blank to maintain engagement of the roller die with the composite material blank to form the one or more radii along the composite material blank. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic illustration of tooling equipment comprising a variable roller ass