US 11,806,947 B2
Forming system and method for forming a contoured composite structure
Raviendra S. Suriyaarachchi, Kirkland, WA (US); Darrell Darwin Jones, Mill Creek, WA (US); Antonio Martinez, Murcia (ES); and Valentín Forte, Murcia (ES)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Jan. 24, 2022, as Appl. No. 17/583,165.
Claims priority of application No. 21382074 (EP), filed on Jan. 29, 2021.
Prior Publication US 2022/0242064 A1, Aug. 4, 2022
Int. Cl. B29C 70/38 (2006.01); B29C 70/44 (2006.01); B29C 70/54 (2006.01); B29D 99/00 (2010.01); B29L 31/30 (2006.01)
CPC B29C 70/38 (2013.01) [B29C 70/446 (2013.01); B29C 70/541 (2013.01); B29D 99/0003 (2013.01); B29L 2031/3076 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A forming system for forming a contoured composite structure having a complex curved configuration, the forming system comprising:
a receiving station having a receiving assembly designed to receive a composite charge to be formed;
a forming station having a forming assembly comprising:
a gantry assembly comprising a movable upper crossbeam movably coupled to a pair of side beams mounted on a plurality of side support members;
an upper die assembly movably coupled to the gantry assembly, the upper die assembly comprising a plurality of upper actuator assemblies coupled to a pair of lateral pressure plates, and a male die disposed between the pair of lateral pressure plates;
a lower die assembly coupled to a floor support beam positioned between the pair of side beams of the gantry assembly, the upper die assembly separate from, and independently movable with respect to, the lower die assembly, and the lower die assembly comprising a plurality of lower actuator assemblies designed to be vertically aligned with the plurality of upper actuator assemblies during forming of the composite charge into the contoured composite structure, and the plurality of lower actuator assemblies coupled to a lower pallet having a presser apparatus disposed between pairs of die blocks; and
one or more pick-and-place devices movably coupled to the gantry assembly, the one or more pick-and-place devices designed to move the composite charge, and the contoured composite structure formed from the composite charge; and
a tray station having a tray assembly designed to receive the contoured composite structure from the forming station.