System and method for manufacturing a textile structure

Abstract

A method and system for manufacturing complex, three-dimensional textile structures is disclosed. These textile structures may be large and heavy and difficult to maneuver without damaging them. The method enables various types of joints to be constructed between textile panels plus the application of patches and details onto the surface of these panels. The method minimizes handling and damage to the textile material. The method also reduces the manpower required during the manufacturing process, thus minimizing manufacturing time and cost.

1 . A manufacturing method comprising:
 causing a textile structure to hover by applying air pressure to an underside of the textile structure;   horizontally displacing the textile structure, while hovering, relative to a manufacturing machine; and   performing a manufacturing operation on the textile structure using the machine.   
     
     
         2 . The method as claimed in  claim 1  wherein the manufacturing operation is performed while the textile structure is hovering. 
     
     
         3 . The method as claimed in  claim 2  wherein the manufacturing operation is performed while the textile structure is also being horizontally displaced. 
     
     
         4 . The method as claimed in  claim 1  further comprising applying a vacuum to the underside of the textile structure to immobilize the textile structure, the vacuum being applied subsequent to causing the textile to hover and horizontally displacing the textile structure but prior to performing the manufacturing operation. 
     
     
         5 . The method as claimed in  claim 1  wherein performing the manufacturing operation comprises welding the textile using a welding machine having welding elements that are substantially vertically aligned with the textile while hovering. 
     
     
         6 . The method as claimed in  claim 1  further comprising inflating the textile structure using air pressure from a same air pressure source that causes the textile to hover. 
     
     
         7 . The method as claimed in  claim 1  further comprising:
 attaching a vacuum cup to the textile structure; and 
 lifting a portion of the textile structure using a lift mechanism connected to the vacuum cup. 
 
     
     
         8 . The method as claimed in  claim 1  further comprising:
 attaching a clamp to the textile structure; and 
 lifting a portion of the textile structure using a lift mechanism connected to the clamp. 
 
     
     
         9 . The method as claimed in  claim 1  further comprising suspending an operator from a gantry above the textile structure. 
     
     
         10 . The method as claimed in  claim 1  further comprising displacing the manufacturing machine. 
     
     
         11 . A manufacturing method comprising:
 causing a textile structure to hover by applying air pressure to an underside of the textile structure;   horizontally displacing the textile structure, while hovering, relative to a manufacturing machine;   removing the air pressure and applying a vacuum to the underside of the textile structure to immobilize the textile structure; and   
       performing a manufacturing operation on the textile structure using the machine. 
     
     
         12 . The method as claimed in  claim 11  wherein the manufacturing operation is performed while the textile structure is hovering. 
     
     
         13 . The method as claimed in  claim 12  wherein the manufacturing operation is performed while the textile structure is also being horizontally displaced. 
     
     
         14 . The method as claimed in  claim 11  wherein performing the manufacturing operation comprises welding the textile using a welding machine having welding elements that are substantially vertically aligned with the textile while hovering. 
     
     
         15 . The method as claimed in  claim 11  further comprising inflating the textile structure using air pressure from a same air pressure source that causes the textile to hover. 
     
     
         16 . The method as claimed in  claim 11  further comprising:
 attaching a vacuum cup to the textile structure; and 
 lifting a portion of the textile structure using a lift mechanism connected to the vacuum cup. 
 
     
     
         17 . The method as claimed in  claim 11  further comprising:
 attaching a clamp to the textile structure; and 
 lifting a portion of the textile structure using a lift mechanism connected to the clamp. 
 
     
     
         18 . The method as claimed in  claim 11  further comprising suspending an operator from a gantry above the textile structure. 
     
     
         19 . The method as claimed in  claim 11  further comprising displacing the manufacturing machine. 
     
     
         20 . A manufacturing system comprising:
 an air pressure source for providing air pressure within a chamber having an upper surface that includes a plurality of air apertures for discharging air to cause a textile structure to hover above the upper surface; and   a manufacturing machine that is substantially vertically aligned with the surface to enable a manufacturing operation to be performed on the textile structure.   
     
     
         21 . The system as claimed in  claim 20  wherein the manufacturing machine is a welding machine suspended by a gantry. 
     
     
         22 . The system as claimed in  claim 20  wherein the manufacturing machine is a welding machine supported by a cantilevered crane. 
     
     
         23 . The system as claimed in  claim 20  further comprising a vacuum cup for attaching to the textile structure, the vacuum cup being connected to a lift mechanism for lifting a portion of the textile structure to which the vacuum cup is attached. 
     
     
         24 . The system as claimed in  claim 20  further comprising a clamp for attaching to the textile structure, the clamp being connected to a lift mechanism for lifting a portion of the textile structure to which the clamp is attached. 
     
     
         25 . The system as claimed in  claim 20  further comprising an air hose coupling connected to an air hose for inflating the textile structure. 
     
     
         26 . The system as claimed in  claim 20  wherein the air pressure source comprises a fan system having an intake fan for drawing air into the chamber. 
     
     
         27 . The system as claimed in  claim 26  wherein the fan system comprises an exhaust fan for evacuating air from the chamber to create a vacuum on the underside of the textile structure when the air pressure source is inoperative. 
     
     
         28 . The system as claimed in  claim 20  comprising a gantry connected to a suspended harness for suspending a worker above the textile structure. 
     
     
         29 . The system as claimed in  claim 20  comprising a gantry connected to a suspended seat for supporting a worker. 
     
     
         30 . The system as claimed in  claim 20  comprising a gantry connected to a suspended platform for accommodating a worker. 
     
     
         31 . A manufacturing system comprising:
 an air system for providing either air pressure within a chamber having an upper surface that includes a plurality of air apertures for discharging air to cause a textile structure to hover above the upper surface or for providing a vacuum to immobile the textile structure; and   a manufacturing machine that is substantially vertically aligned with the surface to enable a manufacturing operation to be performed on the textile structure.   
     
     
         32 . The system as claimed in  claim 31  wherein the manufacturing machine is a welding machine suspended by a gantry. 
     
     
         33 . The system as claimed in  claim 31  wherein the manufacturing machine is a welding machine supported by a cantilevered crane. 
     
     
         34 . The system as claimed in  claim 31  further comprising a vacuum cup for attaching to the textile structure, the vacuum cup being connected to a lift mechanism for lifting a portion of the textile structure to which the vacuum cup is attached. 
     
     
         35 . The system as claimed in  claim 31  further comprising a clamp for attaching to the textile structure, the clamp being connected to a lift mechanism for lifting a portion of the textile structure to which the clamp is attached. 
     
     
         36 . The system as claimed in  claim 31  further comprising an air hose coupling connected to an air hose for inflating the textile structure. 
     
     
         37 . The system as claimed in  claim 31  wherein the air system comprises a fan system having an intake fan for drawing air into the chamber. 
     
     
         38 . The system as claimed in  claim 37  wherein the air system comprises an exhaust fan for evacuating air from the chamber to create the vacuum on the underside of the textile structure when the air pressure source is inoperative. 
     
     
         39 . The system as claimed in  claim 31  comprising a gantry connected to a suspended harness for suspending a worker above the textile structure. 
     
     
         40 . The system as claimed in  claim 31  comprising a gantry connected to a suspended seat for supporting a worker. 
     
     
         41 . The system as claimed in  claim 31  comprising a gantry connected to a suspended platform for accommodating a worker.