System and method for automatic film removal

Abstract

To provide a backing film removal system.SOLUTION: The separation mechanism is configured such that the backing film removal system separates the first portion of the first backing film on the first side of the material fragment and the second portion of the second backing film on the second side of the material fragment from the material layer of the material fragment while the material fragment is held in a cantilevered position, and the second side is the opposite of the first side. The clamping mechanism is operable to apply a clamping force to secure the material layer and the second portion together. A separator assembly having a gripping mechanism is configured to grip the first portion. At least one of the gripping mechanism or end effector is movable to pull the first portion gripped by the gripping mechanism away from the material layer in order to remove the remaining portion of the first backing film from the material layer.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present subject matter relates generally to materials having a film backing, and more particularly to a system and method for automatic film removal. [Background technology]

[0002] Composite laminate parts generally include multiple layers or plies of composite material that are assembled together to provide the composite part with improved engineering properties. Composite parts are typically manufactured by stacking multiple plies on top of each other until a desired thickness and shape is achieved. For example, the manufacturing process typically includes cutting the composite plies to the desired shape, stacking the plies layer by layer, compressing the plies after each additional ply is laid on top of the previously stacked plies, and then curing the material. The composite plies can be fabricated with pre-impregnated resin, often referred to as "prepreg," and can be covered by a backing or protective film (e.g., poly film) that extends across one or more sides of the ply and facilitates handling of the material before or during layup. During the manufacture of the composite part, the backing film is removed from the composite plies. Summary of the Invention [Means for solving the problem]

[0003] A full and enabling disclosure of this disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in this specification, which makes reference to the accompanying figures. [Brief description of the drawings]

[0004] [Figure 1] 1 is a schematic diagram of an exemplary embodiment of a system for automatic film removal according to the present disclosure. [Diagram 2] 2 is a schematic diagram of other components of the exemplary system for automatic film removal of FIG. 1 in accordance with the present disclosure. [Diagram 3]3 is a schematic diagram of an exemplary system for automatic film removal of FIG. 1 according to the present disclosure, taken from line 3-3 of FIG. 1. [Figure 4] 2 is an expanded schematic diagram of an exemplary system for automatic film removal of FIG. 1 in accordance with the present disclosure. [Diagram 5] 5 is a schematic diagram of an exemplary system for automatic film removal of FIG. 1 according to the present disclosure, taken from line 5-5 of FIG. 1. [Figure 6] 2 is an expanded schematic diagram of an exemplary system for automatic film removal of FIG. 1 in accordance with the present disclosure. [Figure 7] 2 is an expanded schematic diagram of an exemplary system for automatic film removal of FIG. 1 in accordance with the present disclosure. [Figure 8] 2 is a schematic diagram of other components of the exemplary system for automatic film removal of FIG. 1 in accordance with the present disclosure. [Figure 9] 2 is an expanded schematic diagram of an exemplary system for automatic film removal of FIG. 1 in accordance with the present disclosure. [Figure 10] 2 is a schematic diagram of an example system for automatic film removal of FIG. 1 in accordance with the present disclosure. [Figure 11] 2 is a schematic diagram of an example system for automatic film removal of FIG. 1 in accordance with the present disclosure. [Figure 12] 2 is a schematic diagram of an example system for automatic film removal of FIG. 1 in accordance with the present disclosure. [Figure 13] FIG. 1 is a block diagram of a computing system according to various aspects of the present disclosure. [Figure 14] FIG. 1 is a block diagram illustrating an embodiment of a method for automatically removing a backing film from a composite piece according to various aspects of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0005] Corresponding reference characters indicate corresponding parts throughout the several views. The illustrations set forth herein depict example embodiments of the present disclosure, and such illustrations are not to be construed as limiting the scope of the present disclosure in any way.

[0006] Reference will now be made in detail to the present embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerals and letters to refer to features in the drawings. Like or similar designations in the drawings and description are used to refer to like or similar parts of the present disclosure.

[0007] The following description is provided to enable one of ordinary skill in the art to make and use the described embodiments contemplated for carrying out the present disclosure. However, various improvements, equivalents, modifications, and alternatives will remain readily apparent to those skilled in the art. Any and all such improvements, modifications, equivalents, and alternatives are intended to be within the scope of the present disclosure.

[0008] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, unless expressly specified otherwise, all embodiments described herein should be construed as exemplary.

[0009] For purposes of the following description, the terms "upper", "lower", "right", "left", "vertical", "horizontal", "upper", "lower", "lateral", "longitudinal", and their derivatives shall refer to the present disclosure as oriented in the figures of the drawings. However, it is understood that the present disclosure may assume various alternative modifications unless expressly specified otherwise. It is also understood that the specific devices illustrated in the accompanying drawings and described in the following description are merely exemplary embodiments of the present disclosure. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be construed as limiting.

[0010] As used herein, the terms "first" and "second" may be used interchangeably to distinguish one component from another, and are not intended to denote the location or importance of the individual components.

[0011] The singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0012] As used herein, the term "composite material" refers to a material fabricated from two or more constituent materials, at least one of which is non-metallic. Example composite materials include polymer matrix composites (PMCs), ceramic matrix composites (CMCs), chopped fiber composites, etc.

[0013] Traditionally, removing the backing film from the composite ply is a manual process performed by a person. Thus, manually separating and removing the backing film from the composite ply relies on the skill of the individual to ensure that the backing film is properly and quickly removed. Furthermore, sharp objects are often used in manual processes to release the backing film and subsequently remove it from the composite ply. Thereby, manually releasing and removing the backing film is tedious and may result in damage to the composite material. Furthermore, manual processes may not be time- and / or cost-efficient to release and / or remove the backing film from the composite material.

[0014] The present disclosure generally relates to systems and methods for automated film removal from composite materials. Embodiments of the present disclosure provide systems and methods for automated backing film removal from composite material pieces. The embodiments of the present disclosure enable backing film removal without relying on a user attempting to physically grip a portion of the backing film. In exemplary embodiments, the present disclosure applies a bending force to a free portion of the material piece to separate at least a portion of the backing film from the material layer, utilizing the differential stiffness between the backing film and the material layer of the material piece. The embodiments of the present disclosure also apply various clamping or gripping mechanisms to prevent unintentional or premature removal of the backing film from the other side of the material piece. By way of non-limiting example, the other side of the material piece can be the side of the material piece opposite the side that is laminated to the composite part. Also, in exemplary embodiments, portions of the backing film from both sides of the material piece can be at least partially separated from the material layer, so that the backing film from the opposite side can be easily removed before or after lamination of the material piece to the composite part. For example, in some instances, the backing film from the side of the material piece opposite the laminated side can remain on the material piece until after the material piece is laminated to a composite part. After being laminated to a composite part, the remaining backing film must be removed from the material piece without damaging, contaminating, or disturbing the material layers. Example embodiments of the present disclosure may be used to partially separate a portion of the backing ply opposite the laminated side of the material piece to facilitate easy removal of the backing ply from the non-laminated side of the material piece.

[0015] Referring now to the drawings, with like numerals indicating like elements throughout the views, specifically FIG. 1, which is a schematic diagram of an exemplary system 10 for automated film removal according to the present disclosure. In the illustrated embodiment, the system 10 comprises an end effector 12 coupled to a movable component 14 such that the end effector 12 can be moved to selected positions to perform various functions related to removing a backing film from a material section 16 of a composite material. In the illustrated embodiment, the end effector 12 comprises peripheral devices coupled to or mounted on the movable component 14 to perform the functions described herein (i.e., end-of-arm tooling (EOAT)). For example, the end effector 12 can be mechanical, electromechanical, magnetic, hydraulic, or pneumatic to steer or interact with an object. Exemplary end effectors may include electric, pneumatic, mechanical, hydraulic, or magnetic grippers or clamping mechanisms (e.g., motorized, pneumatically, or hydraulically controlled fingers, forks, or hooks, suction cups or vacuum plates, electromagnets) for pick-and-place operations, sensors, cameras, or other types of processing tools. In the illustrated embodiment, the end effector 12 includes a vacuum platen 30 and a clamping mechanism 40. As described further below, a vacuum source 132 that is fluidly coupled or connected to the end effector 12 may be actuated to apply a vacuum through the vacuum platen 30.

[0016] In an exemplary embodiment, the movable component 14 may comprise a six degree of freedom robotic arm or other type of structure to steer or move the end effector 12 to a desired position or orientation for a film removal operation, such as providing movement along three different axes and movement along three separate angles (about the three different axes). For example, the movable component 14 may be coupled to a base (not shown) that is fixedly coupled to a support structure, the movable component 14 may comprise one or more arms coupled together by one or more joints, where the one or more arms may be driven by one or more motors or actuators, and may comprise sensors for position monitoring and control. Thus, in an exemplary embodiment, as a non-limiting example, the movable component 14 may provide movement of the end effector 12 along axis X, axis Y, and axis Z, as well as rotation (or roll), rotation (or pitch), and rotation (or yaw) of the end effector 12 about axis X, axis Y, and axis Z, as directed via coordinate system 18. It should be understood that the moveable component 14 may be configured with fewer degrees of freedom of movement.

[0017] In the illustrated embodiment, the material piece 16 comprises a material layer 20 (e.g., a layer of composite material including unidirectional or woven fibers that are pre-impregnated or resin impregnated) with a backing film 22 disposed on or against a top or upper surface 24 of the material layer 20 and a backing film 26 disposed on a bottom or lower surface 28 of the material layer 20 opposite the top surface 24. The material piece 16 may comprise a section of a larger composite ply that has been cut to a desired size or shape from a larger strip or roll of composite material to provide the needs of a particular application of the material piece 16 to form a layer of a composite part.

[0018] In the illustrated embodiment, the system 10 also includes a support assembly 60. The support assembly 60 includes an upper surface 62 configured, by way of non-limiting example, in the form of a vacuum platen 64. As described further below, a vacuum source 130 fluidly coupled or connected to the support assembly 60 can be actuated to apply a vacuum through the vacuum platen 64. To facilitate backing ply removal from the piece of material 16 using the system 10, the piece of material 16 is placed or positioned on the vacuum platen 64 and the end effector 12 is positioned against the piece of material 16 such that the piece of material 16 is secured in a cantilevered position between the end effector 12 and the support assembly 60 (e.g., between the vacuum platens 30 and 64). In the illustrated embodiment, the vacuum platen 64 includes an edge 68 beyond which the piece of material 16 extends when the piece of material 16 is secured in a cantilevered position. Thus, in the cantilevered position, the piece of material 16 comprises an unsupported or free portion 70 (i.e., a portion of the piece of material 16 that extends past the edge 68 of the vacuum platen 64) and a fixed portion 72 (i.e., a portion of the piece of material 16 that is fixed between the end effector 12 and the support assembly 60). The piece of material 16 may be fixed between the end effector 12 and the support assembly 60 by a force or pressure applied by the end effector 12 towards the support assembly 60. It should also be appreciated that a vacuum may be applied via one or more of the vacuum platens 30 and 64 while the piece of material 16 is fixed in the cantilevered position.

[0019] In operation, the piece of material 16 is positioned between the end effector 12 and the support assembly 60 in a cantilevered position. In an exemplary embodiment, the system 10 is configured to first remove the backing film 26 from the piece of material 16 to accommodate the underside 28 of the material layer 20 that will be applied to the layup of the composite part. Thus, to accomplish the foregoing, the piece of material 16 is positioned between the end effector 12 and the support assembly 60 with the backing film 26 positioned against the support assembly 60. In an exemplary embodiment, the vacuum source 130 can be actuated to apply a vacuum through the vacuum platen 64 of the support assembly 60 and the piece of material 16 positioned on the vacuum platen 64 in the cantilevered position, or the piece of material 16 can be positioned on the vacuum platen 64 in the cantilevered position and then a vacuum is applied through the vacuum platen 64 of the support assembly 60 to hold the piece of material in a desired position. Alternatively, the vacuum source 132 can be actuated to apply a vacuum through the vacuum platen 30 of the end effector 12 and the piece of material 16 disposed on the vacuum platen 30 in a cantilevered position (e.g., with the backing film 22 disposed against the vacuum platen 30). The piece of material 16 may be disposed against any support surface and then the end effector 12 may be moved to a position to "pick up" the piece of material 16 from the support surface with vacuum applied through the vacuum platen 30 of the end effector 12. Thus, it should be understood that a variety of methods may be used to initially position the piece of material 16 relative to the end effector 12 or support assembly 60 in the system 10. As previously described, the end effector 12 is disposed against the support assembly 60 such that the piece of material 16 is disposed between the end effector 12 and the support assembly 60 in a cantilevered position (e.g., between the vacuum platens 30 and 64). It should be understood that when the end effector 12 is positioned against the support assembly 60 with the piece of material 16 disposed between the end effector 12 and the support assembly 60, the vacuum applied to one or more of the vacuum platens 30 or 64 may be discontinued or maintained.

[0020] In the illustrated embodiment, the system 10 further comprises one or more separation mechanisms 78 for at least partially separating at least a portion of the backing film 26 from the material layer 20 of the material fragment 16. For example, in the illustrated embodiment, one such separation mechanism 78 is a bending mechanism 80 configured to apply a bending force to the free portion 70 of the material fragment 16 for at least partially separating at least a portion of the backing film 26 from the material layer 20 of the material fragment 16. It should be understood that the bending force applied by the bending mechanism 80 can also at least partially separate at least a portion of the backing film 22 from the material layer 20 of the material fragment 16. In the illustrated embodiment, the bending mechanism 80 comprises a flipping mechanism 81 configured to flip the free portion 70 of the material fragment 16 when the material fragment 16 is secured between the end effector 12 and the support assembly 60 in the cantilevered position. For example, in the illustrated embodiment, the flipping mechanism 81 comprises a lever 82. A first end 84 of the lever 82 is coupled to a rotatable support element 86, and a second end 88 of the lever 82 distal to the first end 84 is unsupported and extends outwardly towards the piece of material 16 when the flipping mechanism 81 is positioned in a separation position relative to the piece of material 16 (i.e., when the flipping mechanism 81 is positioned such that the lever 82 is aligned with and can contact the free portion 70 of the piece of material 16). The flipping mechanism 81 includes an actuator 90 configured to cause a rotational movement of the support element 86 and thereby cause a corresponding rotational movement of the lever 82 such that the second end 88 follows an arcuate path 92 proximate the free portion 70. The actuator 90 is controlled to cause repeated reverse directional movement of the support element 86 such that the second end 88 of the lever 82 makes repeated contact with the free portion 70 from opposite sides of the free portion 70 (e.g., contacting the backing film 26 when moving upward and contacting the backing film 22 when moving downward).In the illustrated embodiment, the flip-up mechanism 81 may be movably coupled to a rail assembly 94 to facilitate translational movement of the flip-up mechanism 81 (e.g., along axis Y) relative to the support assembly 60 so that the lever 82 can be selectively positioned relative to the piece of material 16 (e.g., positioned in alignment with the piece of material 16 to contact the piece of material 16, or moved away from the piece of material 16 to facilitate placement of other system components in proximity to the piece of material 16).

[0021] Thus, embodiments of the present disclosure utilize the difference in stiffness between the backing film 26 and the material layer 20 to create a localized peeling or separation of the backing film 26 from the material layer 20 through bending. As described above, this difference in stiffness may also be applicable between the backing film 22 and the material layer 20 such that the bending force also causes a localized peeling or separation of at least a portion of the backing film 22 from the material layer 20. In the illustrated embodiment, the bending force is applied via the lever 82 of the flipping mechanism 81. However, it should be understood that the bending mechanism 80 may comprise other types of contact and non-contact mechanisms to apply the bending force to the free portion 70 of the material piece 16 (e.g., other types of mechanical mechanisms such as a pneumatic system that directs a pressurized fluid to one or more sides or surfaces of the free portion 70 of the material piece 16, a linear or rotary system that comprises one or more arms, pistons, cams, levers, plungers, etc. that contact the free portion 70 of the material piece 16).

[0022] In operation, the flipping mechanism 81 is positioned in alignment with the free portion 70 of the material fragment 16 and is actuated to cause the lever 82 to strike or flip the free portion 70 of the material fragment 16 one or more times (e.g., strike the material fragment 16 on the backing film 22 or backing film 26). Activation of the flipping mechanism 81 and contact of the lever 82 with the free portion 70 of the material fragment 16 is configured to cause separation or peeling of at least a portion 136 of the backing film 26 from the material layer 20 in the region of the free portion 70 of the material fragment 16. As described above, activation of the flipping mechanism 81 and contact of the lever 82 with the free portion 70 of the material fragment 16 can also cause separation or peeling of at least a portion 134 of the backing film 22 from the material layer 20 in the region of the free portion 70 of the material fragment 16.

[0023] Referring to FIG. 2, FIG. 2 is a schematic diagram of other components of the exemplary system 10 for automatic film removal of FIG. 1 according to the present disclosure. In the illustrated embodiment, the system 10 also includes another separation mechanism 78 in the form of a fluid ejection device 120 configured to eject fluid toward the free portion 70 of the material piece 16. For example, in the illustrated embodiment, the fluid ejection device 120 includes a nozzle 122 having an opening 124. The fluid ejection device 120 is coupled to a fluid source 126 such that pressurized fluid can be ejected from the nozzle 122 through the opening 124. In the illustrated embodiment, the fluid ejection device 120 can be positioned such that the opening 124 can direct the fluid toward the material piece 16. For example, in the illustrated embodiment, the fluid ejection device 120 can be positioned adjacent to the free portion 70 of the material piece 16 such that the opening 124 is positioned facing the free portion 70. In the illustrated embodiment, the fluid ejection device 120 is also coupled to the rail assembly 94 to permit translatable movement of the fluid ejection device 120 relative to the support assembly 60 to selectively position the fluid ejection device 120 adjacent to the free portion 70 of the piece of material 16. Thus, in the illustrated embodiment, the fluid ejection device 120 can be moved to a position adjacent to and facing the free portion 70, and can be moved away from the free portion 70. Thus, the flip mechanism 81 (FIG. 1) and the fluid ejection device 120 may be alternately positioned adjacent to the free portion 70 of the piece of material.

[0024] In an exemplary embodiment, following use of the bending mechanism 80 ( FIG. 1 ) to cause an initial at least partial separation of the backing film 26 from the layer of material 20, the bending mechanism 80 ( FIG. 1 ) may be replaced by a fluid ejection device 120. For example, in an exemplary embodiment, the bending mechanism 80 ( FIG. 1 ) may be moved away from the piece of material 16 (e.g., using the rail assembly 94 ( FIG. 1 )) and the fluid ejection device 120 may be moved into alignment with the piece of material 16 (e.g., using the rail assembly 94). During operation, a fluid (e.g., a pressurized air stream or other type of fluid) is ejected from the nozzle 122 toward the free portion 70 of the piece of material 16. The fluid ejected from the nozzle 122 is configured to further separate or ensure separation of the portion 136 of the backing film 26 from the layer of material 20 in the region of the free portion 70 of the piece of material 16. For example, in an exemplary embodiment, the fluid ejection device 120 may be used in conjunction with an imaging system 140 configured to capture one or more images of the material fragment 16 while fluid is being ejected from the nozzle 122 toward the free portion 70 of the material fragment 16. The captured images may be analyzed by a computing system, a user, or others to verify at least partial separation of the backing film 26 from the material layer 20 at the free portion 70. It should be understood that in an exemplary embodiment, the fluid ejection device 120 may be omitted from the system 10 such that separation of the backing film 26 from the material layer 20 is performed solely by the bending mechanism 80. It should also be understood that the imaging system 140 may be utilized during use of the bending mechanism 80 to verify separation of the backing film 26 from the material layer 20. In a manner similar to that described above in connection with the bending mechanism 80 (FIG. 1), the fluid ejection device 120 may cause separation of the portion 134 of the backing film 22 from the material layer 20 in the region of the free portion 70, or may further separate the portion 134. If desired, imaging system 140 may also be utilized to verify or ensure at least partial separation of backing film 22 from material layer 20.

[0025] Referring to Figure 3, Figure 3 is a schematic diagram of the support assembly 60 of Figure 1 according to the present disclosure, as viewed from line 3-3 of Figure 1. For ease of description and illustration, the end effector 12 (Figure 1) has been omitted from the view in Figure 3, and a portion of the piece of material 16 extending beyond or past the edge 68 has been depicted cut away to better show various features of the support assembly 60. In the illustrated embodiment, the support assembly 60 has an upper surface 62 configured in the form of a vacuum platen 64 having one or more vacuum ports 66. As will be described in more detail below, a vacuum may be applied through the vacuum platen 64 via the one or more vacuum ports 66 to hold the piece of material 16 against the upper surface 62 of the support assembly 60 (i.e., against the vacuum platen 64).

[0026] In the illustrated embodiment, the material piece 16 is positioned on the support assembly 60 such that the fiber direction 74 of the material piece 16 is oriented non-parallel to the edge 68 of the vacuum platen 64. For example, in the illustrated embodiment, the fiber direction 74 of the material piece 16 is oriented at an angle 76 between 45 degrees and 90 degrees (i.e., 45 degrees to perpendicular) relative to the edge 68 of the vacuum platen 64. In the illustrated embodiment, the fiber direction 74 of the material piece 16 is oriented with respect to the edge 68 of the vacuum platen 64, and the angle 76 is between 30 degrees and 90 degrees. It should be appreciated that the fiber direction 74 is oriented in a non-parallel manner relative to the edge 68 of the vacuum platen 64 to prevent undesired fiber delamination of the material piece 16 and to accentuate the stiffness mismatch between the material layer 20 and at least one of the backing films 22 or 26.

[0027] 3, the support assembly 60 includes an arm 100 rotatably coupled to the vacuum platen 64 proximate the edge 68 such that an upper surface 102 of the arm 100 is positionable adjacent to or in contact with the piece of material 16. For example, in the illustrated embodiment, the arm 100 is rotatably coupled to the vacuum platen 64 such that the arm 100 can be moved upwardly and downwardly relative to the edge 68. One or more linkages 106 are coupled to the arm 100 for selectively causing upward and downward movement of the arm 100 relative to the edge 68 via an actuator 108 coupled to the one or more linkages 106. The arm 100 is configured to have a length extending along a length of at least a portion of the edge 68 (e.g., in the direction of axis Y) and a width extending outwardly away from at least a portion of the edge 68 (e.g., in the direction of axis X) such that an upper surface 102 of the arm 100 is positionable selectively adjacent to or in contact with the free portion 70 of the piece of material 16. Actuation of the actuator 108 may also cause the upper surface 102 of the arm to retract downwardly, away from the free portion 70. In the illustrated embodiment, the arm 100 includes at least one vacuum port 110 positioned on the upper surface 102 of the arm 100, through which a vacuum pressure may be selectively applied (e.g., via actuation of a vacuum source 130 (FIG. 1) that is fluidly coupled to the vacuum port 110). Although a single vacuum port 110 is illustrated, it should be understood that multiple vacuum ports 110 may be used.

[0028] 4, which is an enlarged schematic diagram of the exemplary system 10 for automated film removal of FIGS. 1-3 according to the present disclosure at a particular stage of the backing film removal process. In the exemplary embodiment, after at least a portion 136 of the backing film 26 is separated from the material layer 20 (e.g., using the bending mechanism 80 (FIG. 1) (alone or in combination with the fluid ejection device 120 (FIG. 2))), the arm 100 is actuated upward in the direction indicated by the arrow 150 toward the free portion 70 of the material piece 16 until the upper surface 102 of the arm 100 is disposed against or adjacent to the backing film 26. The vacuum source 130 (FIG. 1) may be selectively controlled (e.g., by a control valve or otherwise) or actuated to apply a vacuum to the upper surface 102 of the arm 100 through the vacuum port 110 (FIG. 3). A vacuum may be applied through vacuum port 110 (FIG. 3) prior to movement of arm 100 toward backing film 26 while arm 100 is moving upwardly toward backing film 26 or when arm 100 reaches a designated position proximate to backing film 26 (e.g., near or in contact with backing film 26). The vacuum applied through vacuum port 110 (FIG. 3) is configured to adhere portion 136 of backing film 26 to upper surface 102 of arm 100. After movement of arm 100 upward toward piece of material 16 and application of vacuum through vacuum port 110 (FIG. 3), arm 100 is moved downwardly away from layer of material 20 in the direction indicated by arrow 152 such that portion 136 of backing film 26 is pulled by arm 100 away from layer of material 20. For example, vacuum applied through vacuum port 110 (FIG. 3) holds portion 136 of backing film 26 against upper surface 102 of arm 100. Thus, support assembly 60 is configured to pull portion 136 of backing film 26 away from layer of material 20 such that portion 136 of backing film 26 is held in a spaced apart position from layer of material 20.

[0029] In an exemplary embodiment, the system 10 is configured to verify that the portion 136 of the backing film 26 has been separated from the layer of material 20. For example, in an exemplary embodiment, the imaging system 140 (FIG. 2) can be used to verify that the portion 136 of the backing film 26 has been separated from the layer of material 20 and attached to the top surface 102 of the arm 100 (e.g., via a processing device that performs image analysis on one or more images captured by the imaging system 140 (FIG. 2)). Additionally or alternatively, the system 10 may be configured to verify that the portion 136 of the backing film 26 has been separated from the layer of material 20 and attached to the top surface 102 of the arm 100 based on an increased vacuum pressure detected through the vacuum port 110 (FIG. 3) (e.g., via a processing device that measures or analyzes the vacuum pressure being pulled through the vacuum port 110 (FIG. 3) compared to a known, predetermined, or expected vacuum pressure without the backing film 26 attached to the top surface 102 of the arm 100). In an exemplary embodiment, an optical proximity sensor 156 may be used to detect the location of the portion 136 relative to the arm 100 to verify that the portion 136 of the backing film 26 has been separated from the material layer 20 and attached to the top surface 102 of the arm 100.

[0030] Referring to Figure 5, Figure 5 is a schematic diagram of the end effector 12 of Figure 1 according to the present disclosure, as viewed from line 5-5 of Figure 1. In the illustrated embodiment, the end effector 12 includes a vacuum platen 30 with one or more vacuum ports 32 disposed at an end 34 of the end effector 12 that faces the piece of material 16 (e.g., on a downward-facing end face 36 of the vacuum platen 30). As previously described, a vacuum may be applied through the vacuum platen 30 via the one or more vacuum ports 32 (e.g., via a vacuum source 132 (Figure 1)) to hold the piece of material 16 against the end face 36 of the end effector 12 (i.e., against the vacuum platen 30).

[0031] In the illustrated embodiment, the end effector 12 also includes a clamping mechanism 40. In the illustrated embodiment, the clamping mechanism 40 includes a clamping device 42 in the form of a finger gripper 44. In the illustrated embodiment, the finger gripper 44 includes an L-shaped finger gripper 44 having a vertical leg 46 and a horizontal leg 48 extending outwardly from the vertical leg 46. In the illustrated embodiment, the finger gripper 44 is movable with at least two degrees of freedom such that the finger gripper 44 can be moved to various positions relative to the piece of material 16. For example, in the illustrated embodiment, the clamping mechanism 40 also includes a clamping bar 50 defining a clamping surface 52 that faces downward (e.g., faces in the same direction as the end face 36). The end effector 12 includes an actuator 54 configured to provide rotational and translational movement of the finger gripper 44 relative to the clamping bar 50. For example, in the illustrated embodiment, the actuator 54 is configured to translate the finger gripper 44 in a vertical direction (e.g., a direction corresponding to the longitudinal axis of the vertical leg 46, which also corresponds to the Z-axis of the coordinate system 18) and rotate the finger gripper 44 about the longitudinal axis of the vertical leg 46. Thus, in the illustrated embodiment, rotation of the finger gripper 44 about the longitudinal axis of the vertical leg 46 causes rotation of the horizontal leg 48 in a horizontal plane (e.g., in a plane parallel to the end surface 36 of the vacuum platen 30 (e.g., about a plane formed by the X-axis and Y-axis of the coordinate system 18)). Such movement of the horizontal leg 48 resulting from the rotational movement of the finger gripper 44 can selectively position the horizontal leg 48 opposite the clamping surface 52. With the horizontal leg 48 disposed opposite the clamping surface 52, vertical or upward movement of the finger gripper 44 in a direction corresponding to the longitudinal axis of the vertical leg 46 correspondingly moves the horizontal leg 48 toward the clamping surface to facilitate clamping of an object (e.g., a piece of material 16) between the horizontal leg 48 and the clamping surface 52. The finger gripper 44 may be rotated and moved vertically to position the horizontal leg 48 above the end surface 36 to avoid interference of the finger gripper 44 with other components of the system 10.In the illustrated embodiment, the clamping surface 52 may include at least one vacuum port 58 through which a vacuum may be applied (e.g., via actuation of a vacuum source 132 ( FIG. 1 ) fluidly coupled to the vacuum port 58) to further secure the object (e.g., the piece of material 16) to the clamping surface 52. It should be understood that the illustrated embodiment of the end effector 12 may include a finger gripper 44 without a vacuum port 58, a finger gripper 44 with a vacuum port 58, or a vacuum port 58 without a finger gripper 44.

[0032] 6 and 7, which are enlarged schematic views of the exemplary system 10 for automated film removal of FIGS. 1-5 according to the present disclosure, depicting the use or operation of the end effector 12 and support assembly 60 during further stages of the backing film removal process. For example, after a portion 136 of the backing film 26 has been separated from the layer of material 20 and attached to the upper surface 102 of the arm 100 as depicted in FIG. 4, the end effector 12 is raised upward (e.g., in the direction of axis Z) away from the piece of material 16, rotated 90 degrees clockwise about axis Z from the position depicted in FIG. 1 to the position depicted in FIG. 6, and lowered (e.g., in the direction of axis Z) toward the support assembly 60 to return the end effector 12 to a position against the piece of material 16 (only the return position of the end effector depicted in FIG. 6). This raising, rotating, and downward movement of the end effector 12 moves the clamping mechanism 40 into position adjacent to the free portion 70 of the piece of material 16. In an exemplary embodiment, if a vacuum is currently active through the vacuum platen 30, such vacuum may be discontinued before the end effector 12 is raised upwardly away from the piece of material 16. Correspondingly, if a vacuum is not active through the vacuum platen 64, such vacuum may be applied to hold the piece of material 16 in its current position against the support assembly 60 while the end effector 12 is repositioned relative to the piece of material 16. In an exemplary embodiment, the vacuum may be reapplied through the vacuum platen 30 after the end effector 12 is repositioned as depicted in FIGS. 6 and 7 to reposition the piece of material 16 between the end effector 12 and the support assembly 60.

[0033] In operation, with the clamping mechanism 40 positioned proximate the free portion 70 of the piece of material 16, the actuator 54 causes vertical downward movement of the finger grip 44 (e.g., in the direction of axis Z or the longitudinal axis of the vertical leg 46) to position the horizontal leg 48 vertically between the layer of material 20 and the portion 136 of the backing film 26 (as best depicted in FIG. 6 ). The actuator 54 then causes rotational movement of the finger grip 44 about the longitudinal axis of the vertical leg 46 to dispose the horizontal leg 48 between the layer of material 20 and the portion 136 of the backing film 26 (as best depicted in FIG. 7 ). The actuator 54 then causes vertical upward movement of the finger grip 44 (e.g., in the direction of axis Z or the longitudinal axis of the vertical leg 46) to retract the finger grip 44 toward the layer of material 20. Retraction of the finger grip 44 causes the horizontal leg 48 of the finger grip 44 to apply a clamping force against the exposed portion 59 of the material layer 20 (e.g., the portion of the material layer 20 that is no longer covered by the backing film 26). The clamping force applied by the finger grip 44 clamps the material layer 20 and the backing film 22 (including the portion 134 of the backing film 22) against the clamping surface 52 of the clamping bar 50. In the illustrated embodiment, at least the horizontal leg 48 of the finger grip 44 is configured to have a minimum cross-sectional area along its width (as opposed to the longitudinal length along the axis of the horizontal leg 48) to minimize the area of ​​contact with the exposed portion 59 of the material layer 20. For example, in the illustrated embodiment, the lateral width of the horizontal leg 48 may be less than 5 millimeters. However, it should be understood that the horizontal leg 48 may be configured to have a different lateral width. Also, in the illustrated embodiment, the positioning of horizontal leg 48 between exposed portion 59 of material layer 20 and portion 136 of backing film 26 maintains separation of portion 136 from layer 20 of material.After the layer of material 20 and backing film 22 are clamped against the clamping surface 52 of the clamping bar 50, the vacuum applied through the vacuum port 110 of the arm 100 (FIGS. 3 and 4) may be discontinued (thereby releasing the backing film 26 from the top surface 102 of the arm 100 (FIG. 4)) and the arm 100 (FIG. 4) may be retracted away from the piece of material 16 (e.g., retracted to the initial position). Any vacuum applied through the vacuum platen 64 may also be discontinued as the vacuum applied through the vacuum platen 30 holds the piece of material 16 against the end surface 36 (FIG. 5) of the end effector 12.

[0034] Referring to FIG. 8, FIG. 8 is an enlarged schematic diagram of the exemplary system 10 for automated film removal of FIGS. 1-7 according to the present disclosure during the next stage of the backing ply removal process. As depicted in FIG. 8, the end effector 12 is vertically raised (e.g., in the direction of axis Z) away from the support assembly 60 (FIGS. 1-4, 6, and 7) and rotated clockwise about axis Y through approximately 90 degrees with the material piece 16 attached to the end face 36 of the end effector 12 via vacuum applied through the vacuum platen 30. Additionally, the finger gripper 44 maintains a clamping force against the exposed portion 59 of the material layer 20 to secure the material layer 20 and backing film 22 against the clamping bar 50. In the illustrated embodiment, the system 10 includes a separator assembly 160. Separator assembly 160 includes a frame assembly 162 that supports rollers 164 that are rotatably coupled to frame assembly 162. Rollers 164 extend transversely (e.g., along axis Y) to the widthwise extent of frame assembly 162 and define axes 166 about which rollers 164 rotate. Separator assembly 160 also includes a sled assembly 170 that is translatably coupled to frame assembly 162 to permit translational movement of sled assembly 170 relative to frame assembly 162 in the direction indicated by arrow 172.

[0035] In the illustrated embodiment, the sled assembly 170 includes a plate 174 that is rotatably coupled to the sled assembly 170. For example, in the illustrated embodiment, the sled assembly includes a carrier 176. The plate 174 is rotatably coupled to the carrier 176 via a pin 180 or to allow rotation of the plate 174 relative to the carrier 176. In the illustrated embodiment, the plate 174 includes an end surface 186 that is disposed in a predetermined position to face the piece of material 16 when the end effector 12 is positioned as depicted in FIG. 8 . As such, the end effector 12 is moved in the direction indicated by arrow 154 (e.g., along axis X) toward the separator assembly 160 to position the end effector 12 and the piece of material 16 proximate to the separator assembly 160, as will be further described below. It should be understood that alternatively or additionally, the separator assembly 160 may be moved toward the end effector 12 in a direction opposite to that indicated by arrow 154 (e.g., along axis X) to position the end effector 12 and material pieces 16 in proximity to the separator assembly 160.

[0036] 9, which is an enlarged schematic isometric view of a separator assembly 160 according to the present disclosure. In the illustrated embodiment, the separator assembly 160 comprises a frame assembly 162 supporting rollers 164 rotatably coupled thereto. The rollers 164 extend transversely (e.g., along axis Y) to the widthwise extent of the frame assembly and define axes 166 about which the rollers 164 rotate, as indicated by arrow 168. In the illustrated embodiment, the sled assembly 170 comprises a plate 174 rotatably coupled to a carrier 176 of the sled assembly 170. For example, in the illustrated embodiment, the carrier 176 has a pair of spaced apart arms 178 (only one shown in FIG. 9) with each arm 178 extending toward opposite sides of the plate 174. Plate 174 is rotatably coupled to arm 178 via pin 180 or as indicated by arrow 184 to permit rotation of plate 174 about axis 182 defined by pin 180. In the illustrated embodiment, carrier 176 includes one or more linkages 185 movably coupled to plate 174 such that linkages 185 can be utilized (e.g., via an actuator (not shown) or otherwise) to cause rotational movement of plate 174 about axis 182. In the illustrated embodiment, end surface 186 includes at least one vacuum port 188.

[0037] In the illustrated embodiment, the sled assembly 170 also includes a gripping mechanism 190. In the illustrated embodiment, the gripping mechanism 190 is configured in the form of a finger gripper 194. In the illustrated embodiment, the finger gripper 194 includes an L-shaped finger gripper 194 having a horizontal leg 196 and a vertical leg 198 extending outwardly from the horizontal leg 196. In the illustrated embodiment, the finger gripper 194 is movable with at least two degrees of freedom such that the finger gripper 194 can be moved to various positions relative to the end surface 186. For example, in the illustrated embodiment, the horizontal leg 196 is extendable or translatable through the plate 174 in a direction corresponding to a longitudinal axis of the horizontal leg 196 (e.g., along axis X), and the finger gripper 194 is rotatable about the longitudinal axis of the horizontal leg 196. The sled assembly 170 may include an actuator 200 configured to provide rotational and translational movement of the finger gripper 194 relative to the end surface 186. Thus, in the illustrated embodiment, rotation of the finger gripper 194 about the longitudinal axis of the horizontal leg 196 causes rotation of the vertical leg 198 in a vertical plane (e.g., in a plane parallel to the end surface 186 of the plate 174 (e.g., about the plane formed by the Y and Z axes of the coordinate system 18 when the sled assembly 170 is positioned as depicted in FIG. 9 )) as indicated by arrow 201. Such movement of the vertical leg 198 resulting from the rotational movement of the finger gripper 194 may selectively position or position the vertical leg 198 opposite the end surface 186. In the illustrated embodiment, plate 174 also includes a recess 202 disposed in end face 186 to allow finger grip 194 to be retracted (e.g., translated inwardly toward end face 186 along the longitudinal axis of horizontal leg 196) to a position below end face 186 (e.g., so that vertical leg 198 does not extend outwardly beyond end face 186). In the illustrated embodiment, separator assembly 160 also includes a tensioner 210 configured to cause translational movement of sled assembly 170 relative to frame assembly 162 in the direction indicated by arrow 172.

[0038] 10, which is a schematic diagram of a separator assembly 160 and end effector 12 of system 10 depicting a further example stage of film removal according to the present disclosure. In FIG. 10, the separator assembly 160 and end effector 12 are positioned proximate one another with an end face 186 of the plate 174 facing the end face 36 of the end effector 12. In the example embodiment, the end effector 12 is positioned such that the roller 164 of the sled assembly 170 is positioned in contact with the backing film 26 and such that a portion 136 of the backing film 26 is positioned proximate a vacuum port 188 ( FIG. 9 ) located on the end face 186 of the plate 174. In operation, a vacuum source 212 fluidly coupled to the vacuum port 188 (FIG. 9) is selectively activated to apply a vacuum through the vacuum port 188 (FIG. 9) thereby drawing the portion 136 of the backing film 26 against the edge surface 186 of the plate 174. As indicated in FIG. 10, the clamping mechanism 40 of the end effector 12 holds the layer of material 20 and the backing film 22 in a clamped position against the clamping bar 50 (e.g., via the finger grippers 44 which apply a clamping force against the exposed portion 59 of the layer of material 20). As previously described, vacuum applied through the vacuum platen 30 holds the piece of material 16 against the end effector 12.

[0039] 11, which is a schematic diagram of the separator assembly 160 and end effector 12 of the system 10 depicting a further exemplary stage of film removal according to the present disclosure. In FIG. 11, after the portion 136 of the backing film 26 has been adhered against the end surface 186 of the plate 174, the linkage 175 (FIG. 10) can be actuated to rotate the plate 174 about the axis 182 away from the end effector 12, thereby further separating the portion 136 of the backing film 26 from the material layer 20. In an exemplary embodiment, with the plate 174 rotated away from the end effector 12 as depicted in FIG. 11, the gripping mechanism 190 can be actuated to grip or otherwise clamp the portion 136 of the backing film 26 against the end surface 186 of the plate 174. For example, in the illustrated embodiment, the finger grip 194 can be extended outwardly from the recess 202 (FIG. 9) away from the end face 186 (e.g., by causing translational movement of the finger grip 194 in a direction corresponding to the longitudinal axis of the horizontal leg 196 by an actuator 200 (FIG. 9)) to position the vertical leg 198 away from the end face 186 or above the end face 186 (depicted in dashed lines in FIG. 11). The actuator 200 (FIG. 9) then positions the vertical leg 198 above and adjacent to the portion 136 of the backing film 26, and then retracts the finger gripper 194 toward the end surface 186 and rotates the finger gripper 194 about the longitudinal axis of the horizontal leg 196 to grip or otherwise secure the portion 136 of the backing film 26 against the end surface 186. For example, after extending the finger gripper 194 outwardly from the end surface 186, the finger gripper 194 can be rotated approximately 90 degrees counterclockwise in the direction indicated by arrow 201 (FIG. 9) and then retracted inwardly toward the end surface 186.

[0040] 12, which is a schematic diagram of a separator assembly 160 and end effector 12 of system 10 depicting a further example stage of film removal according to the present disclosure. In FIG. 12, after a portion 136 of backing film 26 is gripped by finger grippers 194 of separator assembly 160, at least one of end effector 12 or sled assembly 170 is moved in a different direction relative to one another to remove remaining portion 224 of backing film 26 away from layer of material 20 for the remainder of material section 16. For example, vacuum applied via vacuum platen 30 of end effector 12 and clamping mechanism 40 hold layer of material 20 and backing film 22 against end effector 12. In the illustrated embodiment, the end effector 12 is simultaneously moved vertically upward (e.g., in the direction of axis Z indicated by arrow 220) while the sled assembly 170 is translated away from the end effector 12 in the direction indicated by arrow 222. Movement of the sled assembly 170 (e.g., via tensioner 210 (FIG. 9)) in the direction indicated by arrow 222 provides a relatively constant force at an acute angle indicated by arrow 226 to the plane defined by the backing film 26 in the direction indicated by arrow 222. The simultaneous movement of the end effector 12 and sled assembly 170 separates the backing film 26 from the layer of material 20 for the remainder of the material section 16 until it is completely removed from the material section 16. In the embodiment shown in FIG. 12, the sled assembly 170 is translated away from the end effector 12 at an angle of approximately 45 degrees relative to the vertical axis Z. It should be understood, however, that other angular orientations may be used. Additionally, while the backing film 26 is being removed from the piece of material 16, the roller 164 maintains contact with at least a portion of the remaining portion 224 to ensure that the layer of material 20 and the backing film 22 remain secured against the end effector 12. For example, the roller 164 may track slightly behind the removed portion of the backing film 26 and press against and apply pressure to the layer of material 20 where the backing film 26 is still intact.Thus, the rollers 164 also prevent premature separation of the material layer 20 and backing film 22 from the end surface 36 of the end effector 12. Also, after complete removal of the backing film 26 from the material piece 16, the vacuum applied through the vacuum platen 30 may be stopped and the clamping mechanism actuated to release the material layer 20 and backing film 22 from their clamped position against the clamping bar 50. The material piece 16, including the material layer 20 and backing film 22, may then be removed from the end effector 12 and applied to a component stack. As indicated above, it should also be understood that in the illustrated embodiment, the end effector 12 can move in the direction 220 while the sled assembly 170 remains stationary, or the sled assembly 170 can move in the direction 222 while the end effector 12 remains stationary, to remove the remaining portion 224 of the backing film 26 from the material layer 20.

[0041] Also, because the portion 134 of the backing film 22 has previously been at least partially separated from the material layer 20 (e.g., by the bending mechanism 80 (FIG. 1) alone or by the bending mechanism 80 (FIG. 1) in combination with the fluid ejection device 120 (FIG. 2)), the portion 134 of the backing film 22 can be easily grasped to facilitate removal of the backing film 22 from the material section 16. For example, the end effector 12 can be used to grasp the portion 134 (e.g., using vacuum applied through the vacuum port 58 (FIG. 4), the finger grippers 44 (FIG. 4), each alone or in combination with one another) to remove the backing film 22 from the material layer 20, such as after lamination, although a different end effector may be used, or the user may manually remove the backing film 22.

[0042] 13, an example computing system 300 is depicted in accordance with an example embodiment of the present disclosure. The computing system 300 may be used to control various operations associated with the system 10, such as, for example, but not limited to, controlling the movement or operation aspects of the end effector 12, controlling the movement or operation aspects of the bending mechanism 80, controlling the movement or operation aspects of the fluid ejection device 120, controlling the movement or operation aspects of the separator assembly 160, controlling the operation or actuation of one or more of the vacuum sources 130, 132, or 212, for use as (or with) the imaging system 140 or for use with the proximity sensor 156. For example, the computing system 300 may be used as or with the imaging system 140 to analyze one or more images captured by the imaging system 140 to verify separation of the backing ply from the material layer (e.g., analyzing pixel data of one or more captured images). The computing system 300 may also be used with the proximity sensor 156 to determine the position of the backing ply (e.g., with respect to the top surface 102 of the arm 100 (FIG. 4)). The computing system 300 may comprise one or more computing devices 310. The computing device 310 may comprise one or more processing units 310A and one or more memory devices 310B. The one or more processing units 310A may comprise any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, a logic device, and / or other suitable processing device. The one or more memory devices 310B may include one or more computer readable media, including but not limited to non-transitory computer readable media, RAM, ROM, hard drives, flash devices, and / or other memory devices.

[0043] The one or more memory devices 310B may store information accessible by the one or more processing devices 310A, including computer-readable instructions 310C that may be executed by the one or more processing devices 310A. The instructions 310C may be any set of instructions that, when executed by the one or more processing devices 310A, cause the one or more processing devices 310A to perform operations. In some embodiments, the instructions 310C may be executed by the one or more processing devices 310A to cause the one or more processing devices 310A to perform operations, such as any of the operations and functions for which the computing system 300 and / or computing device 310 are configured, operations for operating the system 10 as described herein, and / or any other operations or functions of the one or more computing devices 310. Thus, the operations performed by the system 10 may be computer-implemented processes. The instructions 310C may be software written in any suitable programming language or may be implemented in hardware. Additionally and / or alternatively, the instructions 310C may be executed in separate threads, logically and / or virtually, in the processing device 310A. The memory device 310B may further store data 310D that may be accessed by the processing unit 310A. For example, the data 310D may include data indicating vacuum pressure, image data, position data, position speed change data, or data indicating operating parameters of the system 10.

[0044] Computing device 310 may also include a network interface 310E, for example, used to communicate with other components of system 300 (e.g., over a network). Network interface 310E may include any suitable components for interfacing with one or more networks, including, for example, transmitters, receivers, ports, controllers, antennas, and / or other suitable components. One or more external display devices (not depicted) may be configured to receive one or more instructions from computing device 310, to display one or more images captured by imaging system 140 (e.g., to allow a user to visually verify separation of the backing ply from the material layer), or otherwise.

[0045] 14 provides a flow diagram of an example method (500) for automated film removal from a composite piece according to an example embodiment of the present disclosure. For example, the example method (500) may be utilized to automatically remove at least one backing film (e.g., backing film 26) from a composite piece 16 as described herein. It should be understood that the method (500) is discussed herein only to illustrate example aspects of the present subject matter and is not intended to be limiting.

[0046] At (502), the method (500) includes fixing the piece of material 16 in a cantilevered position. At (504), the method (500) includes applying a bending force to the piece of material 16 to at least partially separate at least a portion of the backing film 26 from the layer of material 20 of the piece of material 16. At (506), the method (500) includes verifying at least partial separation of at least a portion 136 of the backing film 26 from the layer of material 20 of the piece of material 16.

[0047] At (508), the method (500) includes gripping a portion 136 of the backing film 26. At (510), the method (500) includes securing the layer of material 20 spaced from the separated portion 136 of the backing film 26. At (512), the method (500) includes moving at least one of the gripped portion 136 of the backing film or the secured layer of material 20 in different directions to remove the backing film 26 from the layer of material 20 for the remainder of the material section 16.

[0048] Thus, embodiments of the present disclosure provide a system and method for automated backing film removal from a composite piece. The embodiments of the present disclosure enable backing film removal without relying on a user attempting to physically grip a portion of the backing film. In an exemplary embodiment, the present disclosure applies a bending force to a free portion of the material piece to separate at least a portion of the backing film from the material layer, utilizing the differential stiffness between the backing film and the material layer of the material piece. The embodiments of the present disclosure also apply various clamping or gripping mechanisms to prevent unintentional removal of the backing film from a particular side of the material piece (e.g., the side of the material piece opposite the side that is laminated to the composite part). Also, in an exemplary embodiment, portions of the backing film from both sides of the material piece are at least partially separated from the material layer so that the backing film from the opposite side can be easily removed before or after lamination of the material piece to the composite part. For example, composite pre-impregnated materials generally include a backing film on each side of the resin impregnated material such that the backing film needs to be removed before lamination, or in some cases after lamination. The backing film is generally very thin, and the tackiness of the resin serves to hold the backing film against the material layer. Therefore, due to the tackiness of the pre-impregnated material layer, removal of the backing film is difficult and may result in damage or contamination of the material layer if performed manually, especially for smaller unidirectional materials with complex shapes. Therefore, the automatic backing film removal system and method of the present disclosure facilitates backing film removal while preventing undesired damage to the material layer during such removal.

[0049] Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only, and in accordance with the principles of the present disclosure, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0050] Further aspects of the invention are provided by the subject matter of the following clauses.

[0051] A backing film removal system comprising: a separation mechanism configured to separate a first portion of a first backing film on a first side of the material fragment and a second portion of a second backing film on a second side of the material fragment from a layer of material of the material fragment while the material fragment is held in a cantilevered position, the second side being opposite the first side; a clamping mechanism operable to apply a clamping force to secure the layer of material and the second portion together; and a separator assembly having a gripping mechanism configured to grip the first portion, at least one of the gripping mechanism or the clamping mechanism being movable to pull the first portion gripped by the gripping mechanism away from the layer of material to remove a remaining portion of the first backing film from the layer of material.

[0052] The backing film removal system of the preceding clause, further comprising a support assembly configured to pull and hold the first portion of the first backing film after separation.

[0053] 20. The backing film removal system of any preceding clause, wherein the support assembly includes an arm having at least one support assembly vacuum port fluidly coupled to a vacuum source, where a vacuum is selectively applied to the at least one support assembly vacuum port to secure the first portion spaced apart from the layer of material.

[0054] 2. The backing film removal system of any preceding clause, wherein the separator assembly includes at least one separator assembly vacuum port fluidly coupled to a vacuum source, the vacuum source operable to selectively apply vacuum through the at least one separator assembly vacuum port to adhere the first portion to the separator assembly.

[0055] The backing film removal system of any preceding clause, wherein the separation mechanism includes at least one of a bending mechanism configured to apply a bending force to the piece of material or a nozzle configured to eject a fluid toward the piece of material.

[0056] The backing film removal system of any preceding clause, further comprising an imaging system configured to capture one or more images of the piece of material, the imaging system comprising at least one processing device configured to analyze the one or more images to verify separation of the first portion from the layer of material.

[0057] The backing film removal system of any preceding clause, wherein the clamping mechanism is coupled to the end effector, the end effector configured to secure the material piece in a cantilevered position during separation.

[0058] 2. The backing film removal system of any preceding clause, wherein the separator assembly includes a roller, the separator assembly configured to position the roller against the first backing film while a remaining portion of the first backing film is removed from the material layer.

[0059] The backing film removal system of any preceding clause, wherein the separator assembly comprises a frame assembly, a carrier movably coupled to the frame assembly for selective translatable movement relative to the frame assembly, and a plate rotatably coupled to the carrier, the plate to which the gripping mechanism is retractably coupled.

[0060] The backing film removal system of the preceding clause, further comprising an end effector configured to press the piece of material against a support assembly to secure it in a cantilevered position, the support assembly configured to pull and hold the first portion away from the layer of material.

[0061] The backing film removal system of any preceding clause, wherein the clamping mechanism comprises a clamping device and a clamping surface, the clamping device being movable to position the clamping device against the layer of material to apply a clamping force to secure the layer of material and the second portion together.

[0062] The backing film removal system of any preceding clause, further comprising an arm having a vacuum port fluidly connected to a vacuum source, the arm being movable towards the piece of material, the vacuum source being operable to draw a vacuum through the vacuum port to secure the first portion to the arm.

[0063] The backing film removal system of any preceding clause, wherein the end effector comprises a vacuum platen to further secure the material fragment to the end effector during removal of the remaining portion of the first backing film from the layer of material.

[0064] The backing film removal system of any preceding clause, wherein the end effector comprises a vacuum platen having one or more vacuum ports.

[0065] The backing film removal system of any preceding clause, wherein the support assembly includes a vacuum platen, and the end effector secures the section of material in a cantilevered position between the end effector and the vacuum platen of the support assembly.

[0066] The backing film removal system of any preceding clause, wherein the vacuum platen of the support assembly comprises one or more vacuum ports.

[0067] 2. The backing film removal system of any preceding clause, wherein the separator assembly moves in a first direction and the end effector moves in a second direction different from the first direction to pull the first portion gripped by the gripping mechanism away from the layer of material.

[0068] 13. The backing film removal system of any preceding clause, wherein the gripping mechanism and the end effector move simultaneously to pull the first portion gripped by the gripping mechanism away from the layer of material.

[0069] The backing film removal system of any preceding clause, wherein when the piece of material is secured in the cantilevered position, a free end of the piece of material extends past an edge of the vacuum platen of the support assembly.

[0070] The backing film removal system of any preceding clause, wherein the piece of material has a fiber direction, the piece of material being fixed in a cantilevered position, the fiber direction being non-parallel to an edge of the vacuum platen.

[0071] 13. The backing film removal system of any preceding clause, wherein the material piece is secured in a cantilevered position with the fiber direction being between 45 degrees and 90 degrees relative to the edge of the vacuum platen.

[0072] 13. The backing film removal system of any preceding clause, further comprising an imaging device, the imaging device configured to capture an image of a free end of the piece of material to enable verification of separation of the first portion from the layer of material.

[0073] 2. The backing film removal system of any preceding clause, wherein the end effector is configured to secure the section of material between the end effector and the support assembly, and the end effector is configured to transfer the section of material from the support assembly to a position adjacent the separator assembly.

[0074] 13. The backing film removal system of any preceding clause, wherein the clamping mechanism is configured to clamp the layer of material and the second portion to the end effector during removal of the remaining portion of the first backing film from the layer of material.

[0075] The backing film removal system of any preceding clause, wherein the end effector is disposed at a first position to secure the piece of material in a cantilevered position, and the end effector is movable from the first position to a second position to clamp the layer of material and the second portion to the end effector.

[0076] 20. The backing film removal system of any preceding clause, wherein a vacuum is applied through at least one vacuum port in the vacuum platen to hold the piece of material against the vacuum platen while the end effector moves from the first position to the second position.

[0077] The backing film removal system of any preceding clause, wherein the bending mechanism comprises a flip mechanism comprising a lever operable to contact the free portion of the piece of material.

[0078] The backing film removal system of any preceding clause, wherein the separator assembly comprises a frame assembly, a conveyor translatably connected to the frame assembly, and a plate rotatably connected to the conveyor, the plate to which the gripping mechanism is retractably connected.

[0079] 13. The backing film removal system of any preceding clause, wherein the plate includes at least one vacuum port through which a vacuum is selectively applied to draw the first portion into the plate.

[0080] The backing film removal system of any preceding clause, further comprising an optical proximity sensor configured to verify separation of the first portion from the layer of material.

[0081] A method for removing a backing film from a piece of material, the method comprising: fixing the piece of material in a cantilevered position with an end effector, the piece of material comprising a layer of material having a first backing film on a first side thereof and a second backing film on a second side thereof, the second side being opposite the first side; separating a first portion of the first backing film and a second portion of the second backing film from the layer of material with a separation mechanism; gripping the first portion with a gripping mechanism; applying a clamping force to the exposed portion of the layer of material to clamp the layer of material and the second portion to the end effector; and removing a remaining portion of the first backing film from the layer of material by moving at least one of the gripping mechanism or the end effector to pull the first portion gripped by the gripping mechanism away from the layer of material.

[0082] The method of the preceding clause, wherein the separating step further comprises ejecting a fluid toward the piece of material to cause separation of the first and second portions from the layer of material.

[0083] The method of any preceding clause, further comprising positioning an arm having at least one arm vacuum port proximate to the first portion and spaced apart from the layer of material; and drawing a vacuum through the at least one arm vacuum port to secure the first portion to the arm.

[0084] The method of any preceding clause, further comprising verifying that the first part is secured to the arm based on at least one of: comparing a vacuum pressure drawn through at least one arm vacuum port to a predetermined vacuum pressure, analyzing at least one image captured by the imaging system via a processing device, or determining a location of the first part relative to the arm via a proximity sensor.

[0085] The method of any preceding clause, further comprising applying a roller against the first backing film while a remaining portion of the first backing film is being removed from the layer of material.

[0086] The method of any preceding clause, wherein the end effector includes a clamping device configured to apply a clamping force to the exposed portion of the material layer, the method further including the steps of selectively disposing the clamping device between the first portion and the exposed portion of the material layer, and retracting the clamping device against the exposed portion of the material layer to apply a clamping force to the exposed portion of the material layer.

[0087] The method of any preceding clause, further comprising ejecting a fluid toward the piece of material to cause separation of the first and second portions from the layer of material.

[0088] The method of any preceding clause, further comprising positioning an arm having a vacuum port proximate to the first portion and applying a vacuum through the vacuum port to secure the first portion to the arm spaced apart from the layer of material.

[0089] The method of any preceding clause, further comprising verifying separation of the first portion from the layer of material based on at least one of the vacuum pressure or the captured image.

[0090] The method of any preceding clause, wherein the piece of material is secured between the end effector and the vacuum platen, the method further comprising positioning the piece of material such that a free end of the piece of material extends past an edge of the vacuum platen when the piece of material is secured in the cantilevered position.

[0091] The method of any preceding clause, wherein the piece of material has a fiber direction, the method further comprising fixing the piece of material in a cantilevered position, the fiber direction being non-parallel to an edge of the vacuum platen.

[0092] The method of any preceding clause, further comprising the step of fixing the piece of material in a cantilevered position, the fiber direction being between 45 degrees and 90 degrees relative to an edge of the vacuum platen.

[0093] The method of any preceding clause, further comprising simultaneously moving the gripping mechanism and the end effector to pull the first portion away from the layer of material.

[0094] 1. A backing film removal system comprising: an end effector configured to secure a piece of material in a cantilevered position, the piece of material comprising a layer of material having a first backing film on a first side of the layer of material, the end effector comprising a clamping mechanism operable to secure the layer of material to the end effector; at least one separation mechanism configured to separate a first portion of the first backing film from the layer of material; and a separator assembly having at least one separator assembly vacuum port, the separator assembly configured to pull a vacuum through the at least one separator assembly vacuum port to pull the first portion away from the layer of material, the separator assembly further comprising a gripping mechanism configured to hold the first portion, and at least one of the gripping mechanism or the end effector is movable to pull the first portion gripped by the gripping mechanism away from the layer of material.

[0095] 2. The backing film removal system of any preceding clause, wherein the separator assembly includes a roller, the separator assembly configured to position the roller against the first backing film while a remaining portion of the first backing film is removed from the material layer.

[0096] 2. The backing film removal system of any preceding clause, wherein the end effector is configured to press the piece of material against the support assembly to secure it in a cantilevered position, the support assembly being configured to pull the first portion away from the layer of material.

[0097] The backing film removal system of any preceding clause, wherein the clamping mechanism is selectively movable to clamp against the exposed portion of the layer of material to clamp the exposed portion of the layer of material against the end effector.

[0098] The backing film removal system of any preceding clause, further comprising an imaging system configured to capture one or more images of the piece of material, the imaging system comprising at least one processing device configured to analyze the one or more images to verify separation of the first portion from the layer of material.

[0099] 1. A backing film removal system comprising: an end effector configured to secure a piece of material in a cantilevered position, the piece of material comprising a layer of material having a first backing film on a first side of the layer of material, the end effector comprising a clamping mechanism; at least one separation mechanism configured to separate a first portion of the first backing film from the layer of material, the clamping mechanism being operable to apply a clamping force to the exposed portion of the layer of material to secure the layer of material to the end effector; and a separator assembly having a gripping mechanism configured to grip the first portion, the gripping mechanism and the end effector being movable in different directions to pull the first portion gripped by the gripping mechanism away from the layer of material to remove a remaining portion of the first backing film from the layer of material.

[0100] 2. The backing film removal system of any preceding clause, wherein the separator assembly is configured to apply pressure to the remaining portion while the remaining portion is being removed from the layer of material.

[0101] 2. The backing film removal system of any preceding clause, wherein the end effector is configured to press the piece of material against the support assembly to secure it in a cantilevered position, the support assembly being configured to pull the first portion away from the layer of material.

[0102] 20. The backing film removal system of any preceding clause, wherein the end effector is configured to selectively position the clamping mechanism between the first portion and the layer of material and retract the clamping mechanism against the exposed portion of the layer of material to clamp the layer of material against the end effector.

[0103] The backing film removal system of any preceding clause, further comprising at least one of an imaging system or an optical sensor configured to verify separation of the first portion from the layer of material.

[0104] A non-transitory computer-readable medium comprising computer-executable instructions that, when executed by one or more processing devices of a computing system, cause the one or more processing devices to: fix a piece of material in a cantilevered position with an end effector, where the piece of material has a fixed portion and a free portion, the piece of material comprising a layer of material having a first backing film on a first side thereof and a second backing film on a second side thereof opposite the first side; apply a bending force to the free portion to separate a first portion of the first backing film from the layer of material; grip the first portion with a sled assembly; grip the layer of material and the second backing film with the end effector; and move at least one of the sled assembly or the end effector to pull the first portion gripped by the separator assembly away from the layer of material to remove a remaining portion of the first backing film from the layer of material.

[0105] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to eject a fluid toward the free portion after applying a bending force to the free portion to cause separation of the first portion and the second portion from the layer of material.

[0106] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to move an arm having a vacuum port toward the free portion and apply a vacuum through the vacuum port to secure the first portion to the arm.

[0107] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to verify that the first portion is secured to the arm based on at least one of vacuum pressure or a captured image.

[0108] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to apply a vacuum through at least one vacuum port of the end effector to secure the piece of material to the end effector and move the end effector towards a separator assembly.

[0109] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to apply pressure via a roller to the first backing film while a remaining portion of the first backing film is removed from the material layer.

[0110] The non-transitory computer-readable medium of any preceding clause, wherein the piece of material is secured between the end effector and the vacuum platen, and the computer-executable instructions, when executed by one or more processing devices of the computing system, cause the one or more processing devices to apply a vacuum through at least one vacuum port of the vacuum platen to hold the piece of material against the vacuum platen.

[0111] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to, after verifying that the first portion has been separated from the layer of material, move the end effector from the first position to a second position where the piece of material is secured at the cantilever position, and clamp the layer of material and the second portion to the end effector with the end effector at the second position.

[0112] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to, after moving the end effector to a second position, activate a vacuum at the end effector to secure the piece of material to the end effector, and move the end effector from the second position to a third position adjacent the sled assembly.

[0113] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to apply a vacuum through a vacuum port disposed in the sled assembly to secure the first portion to the sled assembly.

[0114] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to move the sled assembly in a first direction and move the end effector in a second direction different from the first direction to detach the first portion from the layer of material.

[0115] The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed by one or more processors of a computing system, cause the one or more processors to simultaneously move the sled assembly and the end effector to detach the first portion from the layer of material.

[0116] This written description uses examples to disclose the disclosure, including the best mode, and to enable any person skilled in the art to practice the disclosure, including making and using any device or system, and practicing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

[0117] While the present disclosure has been described as having an exemplary design, it is possible to further modify it within the scope of the present disclosure. As such, this application is intended to cover any variations, uses, or adaptations of the present disclosure using its broad principles. Moreover, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and fall within the limits of the appended claims.

[0118] Further aspects of the invention are provided by the subject matter of the following clauses.

[0119] 1. A separation mechanism configured to separate a first portion of a first backing film on a first side of the piece of material and a second portion of a second backing film on a second side of the piece of material from a layer of material of the piece of material while the piece of material is held in a cantilevered position, the second side being opposite the first side; a clamping mechanism operable to apply a clamping force to secure the layer of material and the second portion together; a separator assembly having a gripping mechanism configured to grip a first portion, wherein at least one of the gripping mechanism or the clamping mechanism is movable to pull the first portion gripped by the gripping mechanism away from the layer of material to remove a remaining portion of the first backing film from the layer of material; A backing film removal system comprising:

[0120] 2. The backing film removal system of any preceding clause, further comprising a support assembly configured to pull and hold the first portion of the first backing film after separation.

[0121] 3. The backing film removal system of any preceding clause, wherein the support assembly includes an arm having at least one support assembly vacuum port fluidly connected to a vacuum source, whereby a vacuum is selectively applied to the at least one support assembly vacuum port to secure the first portion spaced apart from the layer of material.

[0122] 4. The backing film removal system of any preceding clause, wherein the separator assembly includes at least one separator assembly vacuum port fluidly coupled to a vacuum source, the vacuum source being operable to selectively apply vacuum through the at least one separator assembly vacuum port to adhere the first portion to the separator assembly.

[0123] 5. The separation mechanism is a bending mechanism configured to apply a bending force to the piece of material; or a nozzle configured to eject a fluid toward the piece of material; A backing film removal system according to any preceding clause, comprising at least one of the following:

[0124] 6. The backing film removal system of any preceding clause, further comprising an imaging system configured to capture one or more images of the piece of material, the imaging system comprising at least one processing device configured to analyze the one or more images to verify separation of the first portion from the layer of material.

[0125] 7. The backing film removal system of any preceding clause, wherein the clamping mechanism is coupled to the end effector, the end effector configured to secure the material piece in a cantilevered position during separation.

[0126] 8. The backing film removal system of any preceding clause, wherein the separator assembly includes a roller, the separator assembly configured to position the roller against the first backing film while a remaining portion of the first backing film is being removed from the material layer.

[0127] 9. The separator assembly comprises: A frame assembly; a carriage movably coupled to the frame assembly for selective translatable movement relative to the frame assembly; a plate rotatably coupled to the carrier, the plate having the gripping mechanism retractably coupled thereto; 2. The backing film removal system of any preceding clause, comprising:

[0128] 10. A method for removing a backing film from a piece of material, comprising: Fixing a piece of material in a cantilevered position with an end effector, the piece of material comprising a layer of material having a first backing film on a first side thereof and a second backing film on a second side thereof, the second side being opposite the first side; separating a first portion of the first backing film and a second portion of the second backing film from the layer of material with a separation mechanism; gripping the first portion with a gripping mechanism; applying a clamping force to the exposed portion of the layer of material to clamp the layer of material and the second portion to the end effector; removing a remaining portion of the first backing film from the layer of material by moving at least one of the gripping mechanism or the end effector to pull a first portion gripped by the gripping mechanism away from the layer of material; The method includes:

[0129] 11. The method of any preceding clause, wherein the separating step further comprises ejecting a fluid toward the piece of material to cause separation of the first and second portions from the layer of material.

[0130] 12. Positioning an arm having at least one arm vacuum port proximate to the first portion and spaced apart from the bed of material; drawing a vacuum through at least one arm vacuum port to secure the first portion to the arm; The method of any of the preceding clauses, including the following:

[0131] 13. Verify that the first portion is secured to the arm. comparing a vacuum pressure drawn through the at least one arm vacuum port to a predetermined vacuum pressure; Analysing, via a processing device, at least one image captured by the imaging system; or determining a location of the first portion relative to the arm via a proximity sensor; The method of any preceding clause, further comprising the step of verifying based on at least one of:

[0132] 14. The method of any preceding clause, further comprising applying a roller against the first backing film while a remaining portion of the first backing film is being removed from the layer of material.

[0133] 15. The end effector includes a clamping device configured to apply a clamping force to an exposed portion of the layer of material, and the method includes: selectively disposing a fastening device between the first portion and the exposed portion of the layer of material; pressing a clamping device against and retracting the exposed portion of the layer of material to apply a clamping force to the exposed portion of the layer of material; The method of any of the preceding clauses, including the following:

[0134] 16. An end effector configured to secure a section of material in a cantilevered position, the section of material comprising a layer of material having a first backing film on a first side of the layer of material, the end effector comprising a clamping mechanism operable to secure the layer of material to the end effector; at least one separation mechanism configured to separate a first portion of the first backing film from the material layer; a separator assembly having at least one separator assembly vacuum port, the separator assembly configured to pull a vacuum through the at least one separator assembly vacuum port to separate a first portion from the bed of material, the separator assembly further comprising a gripping mechanism configured to grip the first portion, at least one of the gripping mechanism or the end effector being movable to pull the first portion gripped by the gripping mechanism away from the bed of material; A backing film removal system comprising:

[0135] 17. The backing film removal system of any preceding clause, wherein the separator assembly includes a roller, the separator assembly configured to position the roller against the first backing film while a remaining portion of the first backing film is being removed from the material layer.

[0136] 18. The separator assembly comprises: A frame assembly; a carriage movably coupled to the frame assembly for selective translatable movement relative to the frame assembly; a plate rotatably coupled to the carrier, the plate having the gripping mechanism retractably coupled thereto; 2. The backing film removal system of any preceding clause, comprising:

[0137] 19. The backing film removal system of any preceding clause, wherein the clamping mechanism is selectively movable to clamp against the exposed portion of the layer of material to clamp the exposed portion of the layer of material against the end effector.

[0138] 20. The backing film removal system of any preceding clause, further comprising an imaging system configured to capture one or more images of the piece of material, the imaging system comprising at least one processing device configured to analyze the one or more images to verify separation of the first portion from the layer of material. [Explanation of symbols]

[0139] 10. System 12 End effector 14 Movable components 16 Composite material fragments 18 Coordinate Systems 20 material layers 22 Backing film 24 Top surface, top side 26 Backing film 28 Lower surface, lower surface 30 Vacuum Platen 32 Vacuum port 34 edge 36 End face 40 Tightening mechanism 42 Tightening Device 44 Finger grip part 46 Vertical leg 48 Horizontal leg 50 Clamping bar 52 Clamping Surface 54 Actuator 58 Vacuum Port 59 Exposed part 60 Support assembly 62 Top surface 64 Vacuum Platen 66 Vacuum Port 68 En 70 Unsupported and free parts 72 Fixed part 74 Fiber Orientation 76 angle 78 Separation mechanism 80 Bending mechanism 81 Snapping mechanism 82 Lever 84 First End 86 Rotatable support element 88 Second End 90 Actuator 92 Arcuate Path 94 Rail Assembly 100 Arm 102 Top surface 106 Link mechanism 108 Actuator 110 Vacuum Port 120 Fluid discharge device 122 Nozzle 124 Aperture 126 Fluid Source 130, 132 Vacuum source 134 A portion of the backing film 22 136 A part of the backing film 26 140 Imaging System 150 Arrow 152 Arrow 154 Arrow 156 Optical Proximity Sensor 160 Separator assembly 162 Frame Assembly 164 Lola 166 Axis 168 Arrow 170 Sled Assembly 172 Arrow 174 board 175 Link mechanism 176 Transport Section 178 Arm 180 pins 182 Axis 184 Arrow 185 Link mechanism 186 End face 188 Vacuum Port 190 Gripping mechanism 194 Finger grip part 196 Horizontal leg 198 Vertical leg 200 Actuator 201 Arrow 202 Recess 210 Tensioner 212 Vacuum source 220 Arrow 222 Arrow 224 Remaining 226 Arrow 300 Computing Systems 310 Computing Devices 310A Processing Equipment 310B Memory Device 310C Computer Readable Instructions 310D Data 310E Network Interface

Claims

1. a separation mechanism (78) configured to separate a first portion (136) of a first backing film (26) at a first side (28) of the piece of material (16) and a second portion (134) of a second backing film (22) at a second side (24) of the piece of material (16) from a layer of material (20) of the piece of material (16) while the piece of material (16) is held in a cantilevered position, the second side (24) being opposite the first side (28); a clamping mechanism (40) operable to apply a clamping force to secure the layer of material (20) and the second portion (134) together; a separator assembly (160) having a gripping mechanism (190) configured to grip the first portion (136), wherein at least one of the gripping mechanism (190) or an end effector (12) is movable to pull the first portion (136) gripped by the gripping mechanism (190) away from the layer of material (20) to remove a remaining portion (224) of the first backing film (26) from the layer of material (20); A backing film removal system (10) comprising:

2. 2. The backing film removal system (10) of claim 1, further comprising a support assembly (60) configured to tension and hold the first portion (136) of the first backing film (26) after separation.

3. 3. The backing film removal system (10) of claim 2, wherein the support assembly (60) comprises an arm (100) having at least one support assembly vacuum port (110) fluidly connected to a vacuum source (130) through which a vacuum is selectively applied to the at least one support assembly vacuum port (110) to secure the first portion (136) away from the layer of material (20).

4. 4. The backing film removal system (10) of any one of claims 1 to 3, wherein the separator assembly (160) comprises at least one separator assembly vacuum port (188) fluidly connected to a vacuum source (212), the vacuum source (212) being operable to selectively apply a vacuum through the at least one separator assembly vacuum port (188) to adhere the first portion (136) to the separator assembly (160).

5. The separation mechanism (78) a bending mechanism (80) configured to apply a bending force to the piece of material (16); or a nozzle (122) configured to eject a fluid toward the piece of material (16); The backing film removal system (10) of claim 1, comprising at least one of:

6. 6. The backing film removal system (10) of claim 5, further comprising an imaging system (140) configured to capture one or more images of the piece of material (16), the imaging system (140) comprising at least one processing device (310A) configured to analyze the one or more images to verify separation of the first portion (136) from the layer of material (20).

7. 7. The backing film removal system (10) of claim 1, wherein the clamping mechanism (40) is coupled to an end effector (12) configured to secure the material piece (16) in the cantilevered position during the separation.

8. 8. The backing film removal system (10) of claim 1, wherein the separator assembly (160) comprises a roller (164), and the separator assembly (160) is configured to position the roller (164) against the first backing film (26) while the remaining portion (224) of the first backing film (26) is being removed from the material layer (20).

9. The separator assembly (160) comprises: A frame assembly (162); a carriage (176) movably coupled to said frame assembly (162) for selective translatable movement relative to said frame assembly (162); a plate (174) rotatably coupled to the carrier (176), the plate (174) having the gripping mechanism (190) retractably coupled thereto; The backing film removal system (10) of any one of claims 1 to 8, comprising:

10. A method for removing a backing film from a piece of material (16), comprising the steps of: fixing the piece of material (16) in a cantilevered position with an end effector (12), the piece of material (16) comprising a layer of material (20) having a first backing film (26) on a first side (28) of the piece of material (16) and a second backing film (22) on a second side (24) of the piece of material (20), the second side (24) being opposite the first side (28); separating a first portion (136) of the first backing film (26) and a second portion (134) of the second backing film (22) from the layer of material (20) with a separation mechanism (78); gripping the first portion (136) with a gripping mechanism (190); applying a clamping force to the exposed portion (59) of the layer of material (20) to clamp the layer of material (20) and the second portion (134) to the end effector (12); removing a remaining portion (224) of the first backing film (26) from the layer of material (20) by moving at least one of the gripping mechanism (190) or the end effector (12) to pull the first portion (136) gripped by the gripping mechanism (190) away from the layer of material (20); The method includes:

11. 11. The method of claim 10, wherein the separating step further comprises ejecting a fluid toward the piece of material (16) to cause separation of the first portion (136) and the second portion (134) from the layer of material (20).

12. positioning an arm (100) having at least one arm vacuum port (110) adjacent to the first portion (136) and spaced apart from the layer of material (20); drawing a vacuum through the at least one arm vacuum port (110) to secure the first portion (136) to the arm (100); 12. The method of claim 10 or 11, further comprising:

13. The first portion (136) is fixed to the arm (100), comparing the vacuum pressure drawn through the at least one arm vacuum port (110) to a predetermined vacuum pressure; Analyzing, via a processing device (310A), at least one image captured by the imaging system (140); or determining a location of the first portion (136) relative to the arm (100) via a proximity sensor (156); The method of claim 12 , further comprising verifying based on at least one of:

14. 14. The method of any one of claims 10 to 13, further comprising applying a roller (160) against the first backing film (26) while the remaining portion (224) of the first backing film (136) is being removed from the layer of material (20).

15. The end effector (12) comprises a clamping device (42) configured to apply the clamping force to the exposed portion (59) of the layer of material (20), and the method comprises: selectively disposing the fastening device (42) between the first portion (136) and the exposed portion (59) of the layer of material (20); retracting the clamping device (42) against the exposed portion (59) of the layer of material (20) to apply the clamping force to the exposed portion (59) of the layer of material (20); 15. The method of any one of claims 10 to 14, further comprising:

Images