Abstract: Methods for manufacturing composite components having complex geometries are provided. In one exemplary aspect, a method includes laying up each of a plurality of laminates to an initial shape with a substantially planar geometry or a gently curved geometry. Then, a laid up laminate is formed to a final shape for each predefined section defined by the composite component to be manufactured. Thereafter, the laminates formed to their respective final shapes are stacked to build up the complex geometry of the composite component. Next, the composite component can be cured and finish machined as necessary to form the completed composite component.

Abstract: A blade member includes a leading edge, a trailing edge, and a blade body extending therebetween. The blade member also includes a dovetail, a transition region, and a transition relief. The dovetail includes a dovetail chord line extending between an axially forward face of the dovetail and an axially aft face of the dovetail. The dovetail chord line has a dovetail chord length. The transition region is formed between the blade body and the dovetail. The blade body and the transition region form a blade body transition chord line at the interface of the blade body and the transition region which has a blade body transition chord length. The transition relief includes a geometric relief in at least one of a forward and an aft end of the transition region and the dovetail. The dovetail chord length is less than the blade body transition chord length.

Abstract: A system for forming stacked material includes a housing defining an interior space. The housing includes a bottom wall and a side wall coupled to the bottom wall. At least one tool is configured to shape the stacked material. The at least one tool is disposed within the interior space. A membrane extends at least partially over the bottom wall and is spaced a distance from the bottom wall. The membrane is configured to move towards the bottom wall. At least one intensifier mechanism is disposed in the interior space and is configured to induce a force against a portion of the stacked material and against the at least one tool as the membrane is moved towards the bottom wall.

Abstract: Various adaptive apparatus and systems for automated handling of components such as composite plies are provided. In one embodiment, a ply manipulation system is provided that comprises an automated machine having an arm, and a ply manipulation tool attached to the arm of the automated machine. The ply manipulation tool includes a first shuttle including a first gripper, a second shuttle including a second gripper, and an actuator. The ply manipulation system further comprises a processor that automatically controls the actuator to move the first and second shuttles linearly with respect to one another to adapt the first and second grippers to a ply shape. In another embodiment, the first and second shuttles include one or more clamping elements moveable to a position to be deployed outside a perimeter of the ply. Methods for removing a ply from a sheet of material using a ply manipulation tool also are provided.

Abstract: Various adaptive apparatus and systems for automated handling of components such as composite plies are provided. In one embodiment, a ply manipulation tool module is provided that comprises a first shuttle including a first gripper and a first clamping element, and a second shuttle including a second gripper and a second clamping element. The first and second shuttles move with respect to one another along a path to position the first and second grippers to grip a ply and to position the first and second clamping elements outside the ply. In a particular embodiment, the ply manipulation tool module includes a lead screw and nut assemblies, the nut assemblies moving along the lead screw to position one or more grippers for gripping components. Ply manipulation tool assemblies comprising at least two modules also are provided.

Abstract: An apparatus and system for a marine propeller assembly are provided. An aft retention member that may be used with the marine propeller assembly includes a base, an opposing nose and a conic body extending therebetween along a centerline normal to the base. The aft retention member also includes at least one protuberance extending radially away from a surface of the conic body. The protuberance extends axially along a surface of the aft retention member from the base arcuately convergent to a predetermined point between the base and a tip of the nose.

Abstract: An apparatus and system for a marine propeller assembly are provided. In one aspect, the marine propeller assembly includes a plurality of circumferentially-spaced blades that each include a dovetail having a radial inner surface. The marine propeller assembly also includes a hub including a plurality of circumferentially-spaced dovetail receiving portions configured to receive a corresponding dovetail of the plurality of blades. At least one gap is formed between the radial inner surface and at least a portion of the dovetail receiving portion.

Abstract: A system includes a gripper device to grasp a disposable proxy. The gripper device is moveable to position a pressure sensitive adhesive in contact with the disposable proxy and apply a pressure force to adhere the pressure sensitive adhesive to the disposable proxy. The gripper device is moveable to position the pressure sensitive adhesive in contact with an edge portion of a first layer of a plurality of layers and apply a pressure force to adhere the pressure sensitive adhesive to the edge portion of the first layer. The system further includes a cutting device moveable to apply a cutting force to separate a sacrificial corner portion of the first layer proximate the edge portion of the first layer from a remaining portion of the first layer. The gripper device is movable to peel the remaining portion of the first layer from one or more remaining layers of the plurality of layers.

Abstract: A propeller assembly is provided. The propeller assembly includes a central hub including a forward end, an aft end, and a hub body extending therebetween along an axis of rotation of the central hub. The propeller assembly further includes a first retention member including a first radial interference member, the first retention member coupled to the forward end of the central hub and a second retention member including a second radial interference member, the second retention member coupled to the aft end of the central hub. The propeller assembly also includes a fairing platform extending between the first retention member and the second retention member, wherein the fairing platform is retained by the first radial interference member and by the second radial interference member.

Abstract: A method and an automatic layup system for making a stack of a plurality of composite plies are presented. The automatic layup system includes a stacking assembly located in a first plane and a layup tool located in a second plane parallel to the first plane. The stacking assembly and the layup tool are movable towards each other. The method includes the steps of (a) providing one or more composite sheets between the layup tool and the stacking assembly, (b) generating a first composite ply from the one or more composite sheets, (c) placing the first composite ply on the layup tool by the stacking assembly by bringing the stacking assembly and the layup tool close to each other, and (d) repeating the steps (b) and (c) for generating and placing a second composite ply on the first composite ply, which is placed on the layup tool.

Abstract: A wind turbine is presented. The wind turbine includes a tower, a rotor coupled to the tower, and a plurality of blades coupled to the rotor, wherein each of the plurality of blades comprises a root and a plurality of root inserts positioned circumferentially along the root. Each of the root inserts includes a metal bushing including an outer surface and a plurality of grooves formed at least on the outer surface, a core coupled to the metal bushing, and a plurality of layers wrapped around the metal bushing and the core, wherein a layer of the plurality of layers comprises a different fiber orientation from a fiber orientation of another layer of the plurality of layers.

Abstract: A propeller assembly that includes a hub having an outer radial surface and a plurality of wedge retaining members removably coupled to the hub. The plurality of wedge retaining members are spaced circumferentially about the outer radial surface such that a dovetail slot is defined between adjacent wedge retaining members. The assembly also includes at least one propeller blade including a root portion having a dovetail profile. The root portion is coupled to the hub and positioned within the dovetail slot. The plurality of wedge retaining members are configured to restrict radial movement of the root portion within the dovetail slot.

Abstract: An automated in-line feed-through system and method, integrates the ability to control one or more variables during part fabrication with the layup of one or more fiber tows to form a composite part. The system includes an automated layup system configured to receive a feed-through of one or more fiber tows as an input material. The automated in-line feed-through system further includes a controller configured to respond to measurement data obtained by one or more samplings of the input material and/or a plurality of laid up plies that form a laminate. The controller in response to the obtained measurement data provides adjustment of the feed-through of the one or more fiber tows to compensate for a variation in one or more of the weights from a reference weight.

Abstract: An automated fiber placement (AFP) system includes a tool head with a compaction roller and a first variable heat source. The compaction roller is configured to receive at least one of a fiber and a plurality of fibers formed as a laydown tape, and is controlled to apply the laydown tape to a workpiece at a predetermined speed and direction. The first variable heat source is configured to apply a first amount of heat to the laydown tape. The first amount of heat applied is related to the predetermined speed. The AFP system further includes a second variable heat source configured to apply a second amount of heat to the workpiece. The second amount of heat applied is related to at least one of: a position on the workpiece, a thickness of the workpiece at that position, and a separation distance between the second variable heat source and the workpiece.

Abstract: Methods for manufacturing composite components having complex geometries are provided. In one exemplary aspect, a method includes laying up each of a plurality of laminates to an initial shape with a substantially planar geometry or a gently curved geometry. Then, a laid up laminate is formed to a final shape for each predefined section defined by the composite component to be manufactured. Thereafter, the laminates formed to their respective final shapes are stacked to build up the complex geometry of the composite component. Next, the composite component can be cured and finish machined as necessary to form the completed composite component.

Abstract: An end effector is provided that includes a vacuum source and a plurality of gripping surfaces with each gripping surface including a plurality of vacuum zones having a non-smooth portion for distributing a vacuum, and a plurality of openings defined over the non-smooth portion for distributing the vacuum on the gripping surface using the vacuum source. The plurality of gripping surfaces is generally arranged in a polygonal shape. The plurality of vacuum zones are generally configured to grip cut-outs having a plurality of shapes.

Abstract: An end effector is provided that includes a vacuum source and a plurality of gripping surfaces with each gripping surface including a plurality of vacuum zones having a non-smooth portion for distributing a vacuum, and a plurality of openings defined over the non-smooth portion for distributing the vacuum on the gripping surface using the vacuum source. The plurality of gripping surfaces is generally arranged in a polygonal shape. The plurality of vacuum zones are generally configured to grip cut-outs having a plurality of shapes. Methods are also provided for removing a cut-out from a sheet of material using an end effector having a plurality of gripping surfaces.

Abstract: A system includes a gripper device to grasp a disposable proxy. The gripper device is moveable to position a pressure sensitive adhesive in contact with the disposable proxy and apply a pressure force to adhere the pressure sensitive adhesive to the disposable proxy. The gripper device is moveable to position the pressure sensitive adhesive in contact with an edge portion of a first layer of a plurality of layers and apply a pressure force to adhere the pressure sensitive adhesive to the edge portion of the first layer. The system further includes a cutting device moveable to apply a cutting force to separate a sacrificial corner portion of the first layer proximate the edge portion of the first layer from a remaining portion of the first layer. The gripper device is movable to peel the remaining portion of the first layer from one or more remaining layers of the plurality of layers.

Abstract: A wind turbine is presented. The wind turbine includes a tower, a rotor coupled to the tower, and a plurality of blades coupled to the rotor, wherein each of the plurality of blades comprises a root and a plurality of root inserts positioned circumferentially along the root. Each of the root inserts includes a metal bushing including an outer surface and a plurality of grooves formed at least on the outer surface, a core coupled to the metal bushing, and a plurality of layers wrapped around the metal bushing and the core, wherein a layer of the plurality of layers comprises a different fiber orientation from a fiber orientation of another layer of the plurality of layers.

Abstract: Various adaptive apparatus and systems for automated handling of components such as composite plies are provided. In one embodiment, a ply manipulation tool module is provided that comprises a first shuttle including a first gripper and a first clamping element, and a second shuttle including a second gripper and a second clamping element. The first and second shuttles move with respect to one another along a path to position the first and second grippers to grip a ply and to position the first and second clamping elements outside the ply. In a particular embodiment, the ply manipulation tool module includes a lead screw and nut assemblies, the nut assemblies moving along the lead screw to position one or more grippers for gripping components. Ply manipulation tool assemblies comprising at least two modules also are provided.