US-12623412-B2 - Forming end effector and methods of use

Abstract

A forming end effector and methods of use are presented. Methods of forming a composite material onto a mandrel are presented. A forming end effector carrying the composite material is positioned over the mandrel. The forming end effector is connected to the mandrel. The composite material is swept onto the mandrel using sweepers of the forming end effector.

Inventors

• Jonathan Young Ahn
• Christopher Robert Brown
• Karina Elizabeth Mealey
• Ricardo Andreas Fritzke
• Alexander K. Strait
• Colin Noronha
• Kurtis Shuldberg Willden

Assignees

• THE BOEING COMPANY

Dates

Publication Date

20260512

Application Date

20240212

Claims (20)

1. 1 . A method of forming a composite material onto a mandrel, the method comprising: performing the steps below using a forming end effector comprising: a frame; a number of legs movably connected to the frame, wherein the number of legs comprise engagement pins; forming heads with sweepers each movably connected to the frame, respectively, by a number of actuators movably connected to the frame; a center actuator connected to the frame between the forming heads; and center pressers movably connected to the center actuator; positioning the forming end effector carrying the composite material over the mandrel; connecting the forming end effector to the mandrel; and sweeping the composite material onto the mandrel using sweepers of the forming end effector.
2. 2 . The method of claim 1 , wherein positioning the forming end effector over the mandrel comprises moving the forming end effector using a robotic arm.
3. 3 . The method of claim 2 , further comprising: disconnecting the robotic arm from a utility port of the forming end effector after positioning the forming end effector; and connecting the forming end effector to utilities using the utility port prior to sweeping the composite material onto the mandrel.
4. 4 . The method of claim 1 , wherein connecting the forming end effector to the mandrel comprises locking the forming end effector to the mandrel using engagement pins.
5. 5 . The method of claim 4 , further comprising: supplying at least one utility from the mandrel to the forming end effector through the engagement pins.
6. 6 . The method of claim 1 , wherein sweeping the composite material onto the mandrel comprises urging the composite material against the mandrel using inflatable bladders of the sweepers.
7. 7 . The method of claim 6 , wherein sweeping the composite material onto the mandrel comprises rotating the inflatable bladders prior to urging the composite material onto corners of the mandrel.
8. 8 . The method of claim 1 , further comprising: reacting loads from the forming end effector into the mandrel during the sweeping.
9. 9 . A forming end effector configured to form a composite material, wherein the forming end effector comprises: a frame; a number of legs movably connected to the frame, wherein the number of legs comprise engagement pins; forming heads with sweepers each movably connected to the frame, respectively, by a number of actuators movably connected to the frame; a center actuator connected to the frame between the forming heads; and center pressers movably connected to the center actuator.
10. 10 . The forming end effector of claim 9 , wherein the engagement pins are configured to connect the forming end effector to a mandrel.
11. 11 . The forming end effector of claim 9 , wherein the legs are configured to react to loads from the forming end effector into a mandrel configured to support the composite material.
12. 12 . The forming end effector of claim 9 , wherein the forming heads further comprise vacuum pads configured to hold the composite material prior to forming.
13. 13 . The forming end effector of claim 9 , wherein the sweepers take the form of inflatable bladders.
14. 14 . The forming end effector of claim 9 , wherein the forming heads are connected to the number of actuators by pairs of hinges configured to rotate the sweepers relative to a mandrel beneath the frame.
15. 15 . The forming end effector of claim 9 , wherein the center pressers comprise inflatable bladders movably connected to the center actuator.
16. 16 . The forming end effector of claim 9 , further comprising: a utility port connected to the frame, the utility port configured to interface with a robotic arm for transportation of the forming end effector and configured to interface with utilities for forming operations independently of a robotic arm.
17. 17 . The forming end effector of claim 9 , wherein the engagement pins are further configured to receive at least one utility through the engagement pins and transport the utility to other components of the forming end effector.
18. 18 . A forming end effector configured to form a composite material, wherein the forming end effector comprises: a frame; forming heads each comprising, respectively, sweepers movably connected to the frame by a number of actuators movably connected to the frame and connected to the forming heads by pairs of hinges; a center actuator connected to the frame between the forming heads; and center pressers movably connected to the center actuator.
19. 19 . The forming end effector of claim 18 , wherein the number of actuators is connected to the forming heads by the pairs of hinges such that the forming heads are configured to rotate to form the composite material.
20. 20 . The forming end effector of claim 18 , wherein the sweepers comprise inflatable bladders and wherein the pairs of hinges comprise a first hinge a first distance away from a forming head in the forming heads and a second hinge a second distance away from the forming head, wherein a difference between the first distance and the second distance enables rotation of the sweepers for forming the composite material around edges.

Description

BACKGROUND INFORMATION 1. Field The present disclosure relates generally to shaping composite material and more specifically to a forming end effector configured to shape composite material onto a mandrel. 2. Background Currently, gantry formers can be used to form a composite material onto a mandrel. However, gantry formers have a limited work envelope. Gantry formers cannot accommodate more than a few degrees of tool tilting. Robots are capable of orienting to unique angles for tasks. However, robots are not as rigid as gantries. Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the issues discussed above, as well as other possible issues. It would be desirable to provide an alternative method of forming composite material onto a mandrel. SUMMARY An embodiment of the present disclosure provides a method of forming a composite material onto a mandrel. A forming end effector carrying the composite material is positioned over the mandrel. The forming end effector is connected to the mandrel. The composite material is swept onto the mandrel using sweepers of the forming end effector. Another embodiment of the present disclosure provides a forming end effector for forming a composite material. The forming end effector comprises a frame, a number of legs movably connected to the frame, and forming heads with sweepers movably connected to the frame by a number of actuators movably connected to the frame. The number of legs has engagement pins configured to connect the forming end effector to a mandrel. Yet another embodiment of the present disclosure provides a forming end effector for forming a composite material. The forming end effector comprises a frame; a number of actuators movably connected to the frame; and forming heads with sweepers movably connected to the frame by the number of actuators. The number of actuators is connected to the forming heads by pairs of hinges such that the forming heads are configured to rotate to form the composite material. A further embodiment of the present disclosure provides a method. A composite material is formed onto a mandrel using sweepers of a forming end effector. Loads from the forming end effector are reacted into the mandrel during forming of the composite material. The features and functions can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives, and features thereof will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein: FIG. 1 is an illustration of an aircraft in accordance with an illustrative embodiment; FIG. 2 is an illustration of a block diagram of a manufacturing environment in accordance with an illustrative embodiment; FIG. 3 is an illustration of an isometric view of a forming end effector in an engaged orientation in accordance with an illustrative embodiment; FIG. 4 is an illustration of an isometric view of a forming end effector in an unengaged orientation in accordance with an illustrative embodiment; FIG. 5 is an illustration of a front view of a forming end effector in an unengaged orientation in accordance with an illustrative embodiment; FIG. 6 is an illustration of an isometric view of a forming end effector in an engaged orientation in accordance with an illustrative embodiment; FIG. 7 is an illustration of an isometric view of an engagement pin on a leg of a forming end effector in accordance with an illustrative embodiment; FIG. 8 is an illustration of an isometric view of a composite holding system of a forming end effector in accordance with an illustrative embodiment; FIG. 9 is an illustration of a front view of a forming end effector in an engaged orientation and connected to a mandrel in accordance with an illustrative embodiment; FIG. 10 is an illustration of a front view of a forming end effector in an engaged orientation and connected to a mandrel in accordance with an illustrative embodiment; FIG. 11 is an illustration of a front view of a forming end effector in an engaged orientation and connected to a mandrel in accordance with an illustrative embodiment; FIG. 12 is an illustration of a front view of a forming end effector in an engaged orientation and connected to a mandrel in accordance with an illustrative embodiment; FIG. 13 is an illustration of a front view of a forming end effector in an engaged orientation and connected to a mandrel in accordance with an illustrative embodiment; FIG. 14 is an illustration of a front view of a form