System, method, and apparatus for use in ply compaction in forming a composite structure
A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a chassis at a first location along a length dimension of the forming tool, selectively rotating a flange forming device, that is coupled to the chassis, about a yaw axis based on a relative orientation of the flange forming device to the at least one flange surface, applying, with the flange forming device, the ply of material onto the forming tool, moving the chassis relative to the forming tool to position the chassis at a second location along the length dimension of the forming tool, and repeating the selective rotation and the application steps at the second location.
1. An apparatus for use in ply compaction in forming a composite structure, the apparatus comprising:
a forming tool comprising a work surface, wherein the forming tool comprises a length dimension, and wherein the work surface comprises a web surface and at least one flange surface that is angled relative to the web surface;
a chassis extending over the forming tool, wherein the chassis is movable relative to the forming tool along the length dimension; and
at least one flange forming device coupled to the chassis, wherein the at least one flange forming device is rotatable relative to the chassis about a yaw axis based on a relative orientation of the at least one flange forming device to the work surface, the at least one flange forming device comprising a forming head that is laterally movable relative to the forming tool when engaged therewith to selectively apply pressure to only one of the web surface and the flange surface of the work surface, wherein movement of the forming head is defined by a range of motion that traverses the forming head across at least a portion of the web surface and across at least a portion of the at least one flange surface.
2. The apparatus in accordance with claim 1 further comprising a bearing plate coupled between the chassis and the at least one flange forming device, the bearing plate comprising at least one mounting surface configured to receive the at least one flange forming device, and an actuator coupled to the at least one mounting surface, wherein the actuator is configured to rotate the at least one mounting surface relative to the yaw axis.
3. The apparatus in accordance with claim 1 , wherein the at least one flange forming device comprises an orientation sensor configured to determine a relative orientation of the forming head to the work surface, wherein the at least one flange forming device is rotatable based on the determined relative orientation.
4. The apparatus in accordance with claim 3 , wherein the forming head is movable relative to the forming tool to apply pressure continuously across the web surface and then across the at least one flange surface.
5. The apparatus in accordance with claim 3 , wherein the forming head comprises a first end and a second end, wherein the orientation sensor comprises a first sensor at the first end and a second sensor at the second end, the first sensor and the second sensor configured to determine a relative distance of the first end and the second end to the at least one flange surface.
6. The apparatus in accordance with claim 2 , wherein the forming tool is contoured to define a variable radius of curvature in the at least one flange surface along the length dimension.
7. The apparatus in accordance with claim 1 further comprising a ply distribution apparatus coupled to the chassis.
8. The apparatus in accordance with claim 1 , wherein the bearing plate further comprises a friction brake configured to engage the at least one mounting surface to hold the flange forming device in a selected rotational orientation.
9. The apparatus in accordance with claim 2 , wherein the forming head comprises a plurality of holding members and a contact element extending across the plurality of holding members, wherein the plurality of holding members are each independently deflectable relative to each other.
10. The apparatus in accordance with claim 1 , wherein the flange forming device further comprises a base, wherein the forming head is coupled, and movable relative, to the base.
11. The apparatus in accordance with claim 1 further comprising a pitch actuator configured to rotate the flange forming device about a pitch axis that is perpendicular to the yaw axis.