Tape laying head

Abstract

To provide a tape laying head configured to lay a tow material into a mold in building a composite structure.SOLUTION: There is provided a tape laying head, comprising: a shearing mechanism configured to receive a tow material from a tow supply and to steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism, the shearing mechanism being further configured to apply a driving force to the tow material, the driving force having a longitudinal component and a transverse component with respect to the tow material during steering of the tow material; and a tension control system configured to control the transverse component of the driving force acting on the tow material to be equal to or less than a maximum transverse frictional force associated with the shearing mechanism by varying a tensioning force applied to the tow material by the tension control system and monitoring the driving force.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] Embodiments of the present invention relate to a tape laying head configured to lay tow material on a mold in the construction of a composite structure, a controller for use in a tension control system of a tape laying system, related control methods, and related computer-readable media.

Background Art

[0002] Composite materials having a matrix material (e.g., a thermosetting resin) that forms a matrix for holding elongated reinforcing elements (e.g., carbon fibers) are commonly used to provide strong and lightweight structures. Such materials are now used in a wide range of different applications, from sporting goods to the aerospace industry.

[0003] Composite structures can be formed using substantially parallel carbon fiber tapes or tows (a tape may include multiple tows, but herein the terms "tape" and "tow" are used synonymously). The tows can be pre-impregnated with the matrix material, or the matrix material can be added at a later time during the manufacturing process. The tows are laid down in layers on a mold structure. The laid mold structure is then heated under pressure, e.g., in an autoclave, to polymerize the matrix material and form a composite structure (which is later removed from the mold).

[0004] Laying the tows on the mold structure may require the tows to be advanced through one or more bends or curves. This can affect the parallel arrangement of the carbon fibers in the tows because the fiber path length can vary depending on the position of the tow relative to the width of the tow (e.g., inside or outside of the bend or curve). The results can include structural defects such as, for example, buckling of the carbon fibers, or movement to a non-parallel arrangement, or misalignment with the intended tow laying path. These problems can detrimentally affect the properties of the resulting composite structure.

[0005] Also, generally, there is a requirement to improve the acceleration and deceleration times for the tow laying process, as this can have a significant impact on the overall speed of the tow laying operation (which typically includes multiple stop - start processes that require deceleration and acceleration).

[0006] Patent Document 1 discloses an apparatus used to form a corrugated pre - impregnated tow material. However, the document does not provide teachings regarding the laying of the resulting tow onto a mold structure. Thus, the teachings are unrelated to the apparatus and techniques for laying the resulting tow, and the disclosed apparatus is not suitable for such purposes. Additionally, as a result of changing the rotational speed requirements of the rollers, complex apparatus is required to mitigate problems related to the loosening of the reinforcing elements. Furthermore, the fixed width of the combination roller and pinch roller limits the degree of corrugation that can be achieved in the pre - impregnated material manufactured using this apparatus. In addition, there is no disclosed means to enable each tow path within the structure to have a different angular change with respect to the reference axis.

[0007] Patent Document 2 relates to a machine for coating a surface with a strip - shaped fiber / resin composite material. According to this document, the head for laying the strip onto the surface is pivotally attached to its support, and its central vertical plane always remains perpendicular to the contact line between the surface and the strip, regardless of the surface irregularities. This machine is said to be used for manufacturing various structures in the field of aircraft structures.

[0008] Patent Document 3 discloses an automatic tape head assembly for a multi-axis tape laying machine, including a tape supply reel and a tape compression roller. The tape from the supply reel passes through the space between two independent structures of the supply reel and the compression roller, which define a tape path that substantially maintains the zero-gauss curvature of the tape. The tape path is a curved path referred to as a compliance loop, which is said to result in a curved path that is substantially or partially unconstrained between the supply reel and the compression roller. This structure allows the compression roller to shift laterally and vertically relative to the supply reel, while the supply reel is generally said to be in a fixed position relative to the tape head assembly. This structure is also said to allow the compression roller to roll, steer, and follow the natural path of the fiber tape completely independently of the supply reel.

[0009] Patent Document 4 teaches a method that includes using a processing element to press a strip and limit the torsional portion at the end. The strip is torsionally twisted eccentrically within the torsional portion such that the strip obtains a lateral curvature at the processing element. The direction and degree of torsion are said to be selected such that the longitudinal difference of the torsional portion is compensated.

[0010] Patent Document 5 teaches a reinforcing strip that is laid on a rotation receiving surface during the manufacture of a tire. The strip passes through a guide that is alternately moved laterally relative to the running path of the strip, whereby the strip is laid in a wavy pattern on the receiving surface. The amplitude of the alternating lateral movement is varied as a function of (a) the speed of the portion of the strip approaching the guide and (b) the ratio of the speed of the receiving surface. Between the guide and the receiving surface, the strip is rotated 90 degrees about the longitudinal axis of the strip such that it is laid tangentially on the receiving surface.

[0011] Patent Document 6 discloses a tow placement head member for laying a tow tape including reinforcing fibers and a matrix or binding material. The tow placement head member is used for forming a variable angle tow composite structure and includes a pinch device. The pinch device is configured to receive the tow tape and allow the tow tape to pass therethrough. The pinch device includes a tow supply roller configured to guide the tow tape toward a compression shoe, and a tow supply shoe. The compression shoe is configured to receive the tow tape from the pinch device and press the tow tape against the surface on which the tow tape is to be laid. The pinch device is configured to apply shear deformation to a portion of the tow tape between the compression shoe and the pinch device.

[0012] Patent Document 7 discloses a fiber coating apparatus including a fiber coating head having a coating roller for manufacturing a component made of a composite material. The fiber coating head further includes a guiding system for guiding the fibers onto the coating roller and / or means for applying a resin to each fiber when the fiber leaves the guiding system. The fiber coating apparatus may also include a fiber storage system and conveying means for conveying the fibers from the fiber storage system to the coating head. The conveying means may include flexible tubes each capable of receiving the fibers within its internal channel. The conveying means may further include a tension limiting system disposed between the coating head and the storage system. The fiber coating apparatus may further include a system for moving the coating head.

[0013] Patent Document 8 teaches a method for removing a backing film from a roll of tape used for laying the tape or arranging fibers. This method includes rewinding the tape from the spool while the backing film is still attached to the tape, extending a part of the tape with the backing film still attached around the winding roller, partially removing the backing film from the tape and attaching the backing film to the winding roller, extending a part of the tape from which the backing film has been removed from the winding roller to the dancer roller, and continuously winding the backing film around the winding roller by the movement of the tape around the winding roller when the tape is moved from the spool to the dancer roller, and when the winding roller is driven. The winding roller includes a rotatable winding roller that is driven only by the movement of the tape around the winding roller.

[0014] Patent Document 9 discloses a fiber tension applying device for use with a spool of fibers from which the fibers are drawn. The device includes a support, and a hub rotatably attached to the support. The hub is adapted on the support to have a fiber spool attached to the hub for rotation together with the hub. The hub is rotatably attached for rotation around an axis, and the axis is stationary with respect to the rotation of the hub around the axis. The hub and means for applying resistance to the fibers drawn from the spool. The means for applying resistance is disposed on the hub and includes biasing means, and a part of the biasing means is fixed to the axis.

Prior Art Documents

Patent Documents

[0015]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

[0016] In a system that can use a shearing mechanism, there is a need to achieve a high shearing angle with a low risk of breakage of the tow material and to enable easy adjustment for different laying operations.

[0017] The higher the shear stiffness of the tow material, the more difficult it is to implement an effective shearing mechanism and the higher the risk of defects.

[0018] Embodiments seek to mitigate one or more problems associated with the prior art. [Means for Solving the Problems]

[0019] Accordingly, one aspect of the present invention provides a tape laying head configured to lay a tow material on a mold in the construction of a composite structure, the tape laying head comprising a shearing mechanism configured to receive the tow material from a tow supply and to steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism, the shearing mechanism further being configured to apply a driving force to the tow material, the driving force having a longitudinal component and a lateral component with respect to the tow material during steering of the tow material, and a tension control system configured to vary the tension applied to the tow material by the tension control system and to monitor the driving force so as to control the lateral component of the driving force acting on the tow material to be below the maximum lateral frictional force associated with the shearing mechanism.

[0020] The tension control system may further include a first load sensor configured to generate a first load sensor signal representative of the tension of the tow material between the tow supply and the shearing mechanism, and the first load sensor signal may be used to monitor the driving force.

[0021] The tow material may comprise a backing material, the shearing mechanism may be configured to separate the tow material from the backing material, and the tension control system may further include a second load sensor configured to generate a second load sensor signal representative of the tension of the backing material between the shearing mechanism and the backing material recovery section, and the second load sensor signal may be used to monitor the driving force.

[0022] The shearing mechanism may further include a tow guide roller and a gripping shoe or roller, and the tension control system may further include a first motor configured to drive the rotation of the tow guide roller, and the tension may be applied at least in part by the first motor.

[0023] The tension control system may further include a second motor configured to drive the operation of the backing material recovery section, and the tension may be applied at least in part by the second motor.

[0024] The tension control system may further include a brake associated with the tape supply unit and configured to brake the feeding of the tow material from the tape supply unit to the shearing mechanism, and the tension may be at least partially applied by the brake.

[0025] The tension control system may further be configured to maintain the driving force above a minimum threshold value by changing the tension.

[0026] The tow material may be a pre-impregnated tow material.

[0027] The shearing mechanism may include a compression roller and a gripping shoe or roller. The first shearing boundary of the pair of shearing boundaries is defined by the contact point between the compression roller and the mold in normal operation, and the second shearing boundary of the pair of shearing boundaries is defined by the contact point between the compression roller and the gripping shoe or roller.

[0028] The tape laying head further includes a web mechanism. The tow material is provided with a web before the shearing deformation of the tow material, and the web mechanism may be configured to remove the web from the tow material after the tow material is laid on the mold.

[0029] The web mechanism may further be configured to apply the web to the tow material prior to the shearing deformation of the tow material.

[0030] The web mechanism may include a web material supply unit and a web material recovery unit associated with a motor. The motor is configured to operate the web material recovery unit to pull the web from the web material supply unit.

[0031] The tape laying head may further include a tow material supply unit and / or a backing material recovery unit, and a slip compensation mechanism configured to move the shearing mechanism laterally with respect to the tow material supply unit and / or the backing material recovery unit so that the lateral slip of the tow material is compensated. As a result, the lateral slip of the tow material is compensated.

[0032] The slip compensation mechanism may include one or more rails configured to enable movement of the shearing mechanism, or one or more of the ear guide rollers and the gripping shoes, relative to a part of the head, and a driving device for driving the movement of the shearing mechanism, or the ear guide rollers and the gripping shoes.

[0033] The slip compensation mechanism may further include a sensor configured to sense lateral slip of the ear material.

[0034] Another aspect provides a tape laying system including a plurality of tape laying heads as described above.

[0035] Another aspect provides a controller for use in a tension control system of a tape laying system, the tape laying system receiving ear material from an ear supply and including a shearing mechanism configured to direct the ear material by applying shear deformation to the ear material between a pair of shear boundaries defined by the shearing mechanism, the shearing mechanism further configured to apply a driving force to the ear material, the driving force having a longitudinal component and a lateral component relative to the ear material during the directing of the ear material, and the controller configured to control the lateral component of the driving force acting on the ear material to be equal to or less than a maximum lateral frictional force associated with the shearing mechanism by causing a change in the tension applied to the ear material and monitoring the driving force.

[0036] The controller may further be configured to receive a first load sensor signal representative of the tension of the ear material between the ear supply and the shearing mechanism, and the first load sensor signal may be used by the controller to monitor the driving force.

[0037] The ear material may include a backing material, the shearing mechanism may be configured to separate the ear material from the backing material, and the controller may further be configured to receive a second load sensor signal representative of the tension of the backing material between the shearing mechanism and the backing material recovery section, and the second load sensor signal may be used by the controller to monitor the driving force.

[0038] The controller may further be configured to output a first motor signal, the shearing mechanism may further include a silk guiding roller and a gripping shoe or roller, the first motor may drive the rotation of the silk guiding roller, the first motor signal may control the operation of the first motor, and the tension may be at least partially applied by the first motor.

[0039] The controller may further be configured to output a second motor signal, the second motor may drive the operation of the backing material recovery unit, the second motor signal may control the operation of the second motor, and the tension may be at least partially applied by the second motor.

[0040] The brake may be associated with the tape supply unit and may be configured to brake the feeding of the silk material from the tape supply unit to the shearing mechanism. The controller may be configured to generate a brake signal for controlling the brake, and the tension may be at least partially applied by the brake.

[0041] The controller may further be configured to maintain the driving force above a minimum threshold value by changing the tension.

[0042] The tape laying system may further include a web mechanism. The silk material is provided with a web before the shearing deformation of the silk material. The controller may further be configured to operate the web mechanism after the silk material is laid on the mold and remove the web from the silk material.

[0043] The controller may further be configured to operate the web mechanism and apply the web to the silk material prior to the shearing deformation of the silk material.

[0044] The web mechanism may include a web material supply unit and a web material recovery unit associated with a motor. The controller may further be configured to operate the motor to pull the web from the web material supply unit.

[0045] The tape laying system may further include a supply section for the tow material and / or a backing material recovery section, and a slip compensation mechanism. The controller may further be configured to operate the slip compensation mechanism to move the shearing mechanism laterally relative to the supply section for the tow material and / or the backing material recovery section, so that the lateral slip of the tow material is compensated for.

[0046] The slip compensation mechanism includes one or more rails configured to enable movement of one or more of the shearing mechanism, or the tow guide roller and the gripping shoe, relative to a part of the system, and a drive device. The controller is configured to operate the drive device to drive the movement of the shearing mechanism, or the tow guide roller and the gripping shoe.

[0047] The controller may further be configured to receive a signal indicating the lateral slip of the tow material from a sensor.

[0048] Another aspect provides a control method for use in a tension control system of a tape laying system. The tape laying system includes a shearing mechanism configured to receive tow material from a tow supply section and steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism. The shearing mechanism is further configured to apply a driving force to the tow material. During the steering of the tow material, the driving force has a longitudinal component and a lateral component with respect to the tow material. The method includes causing a variation in the tension applied to the tow material and controlling, by monitoring the driving force, the lateral component of the driving force acting on the tow material to be equal to or less than the maximum lateral frictional force associated with the shearing mechanism.

[0049] The control method may further include receiving a first load sensor signal representing the tension of the tow material between the tow supply section and the shearing mechanism and using the first load sensor signal for monitoring the driving force.

[0050] The ear material may include a backing material, the shearing mechanism may be configured to separate the ear material from the backing material, and the control method may further include receiving a second load sensor signal representing the tension of the backing material between the shearing mechanism and the backing material recovery unit, and using the second load sensor signal for monitoring the driving force.

[0051] The control method may further include outputting a first motor signal. The shearing mechanism may further include an ear guide roller and a gripping shoe or roller. The first motor may drive the rotation of the ear guide roller, the first motor signal may control the operation of the first motor, and the tension may be at least partially applied by the first motor.

[0052] The control method may further include outputting a second motor signal. The second motor may drive the operation of the backing material recovery unit, the second motor signal may control the operation of the second motor, and the tension may be at least partially applied by the second motor.

[0053] The brake may be associated with the tape supply unit and may be configured to brake the feeding of the ear material from the tape supply unit to the shearing mechanism. The control method may further include generating a brake signal for controlling the brake, and the tension may be at least partially applied by the brake.

[0054] The control method may further include maintaining the driving force above a minimum threshold value by changing the tension.

[0055] The tape laying system may further include a web mechanism. The ear material may be provided with a web before the shearing deformation of the ear material. The method may further include operating the web mechanism to remove the web from the ear material after the ear material is laid on the mold.

[0056] The method may further include operating the web mechanism to apply the web to the ear material prior to the shearing deformation of the ear material.

[0057] The web mechanism may include a supply section of web material and a web material recovery section associated with a motor, and the method may further include operating the motor to pull the web from the supply section of web material.

[0058] The tape laying system may further include a supply section of tow material and / or a backing material recovery section, and a slip compensation mechanism, and the method may further include operating the slip compensation mechanism to move the shearing mechanism laterally relative to the supply section of tow material and / or the backing material recovery section, such that lateral slippage of the tow material is compensated for.

[0059] The slip compensation mechanism may include one or more rails configured to enable movement of one or more of the shearing mechanism, or the tow guide rollers and gripping shoes, relative to a part of the system, and a drive device, and the method may further include operating the drive device to drive the movement of the shearing mechanism, or the tow guide rollers and gripping shoes.

[0060] The method may further include receiving, from a sensor, a signal indicative of lateral slippage of the tow material.

[0061] Another aspect provides a computer-readable medium having instructions stored thereon which, when executed, cause the operation of the control method described above.

[0062] Another aspect provides a tape laying head configured to lay a tow material onto a mold in the construction of a composite structure. The tape laying head includes a shearing mechanism that receives the tow material from a tow supply and is configured to steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism. The shearing mechanism is further configured to apply a driving force to the tow material, the driving force having a longitudinal component and a transverse component with respect to the tow material during steering of the tow material. The shearing mechanism includes a compression roller and a gripping shoe or roller. A first shear boundary of the pair of shear boundaries is defined by a contact point of the compression roller with the mold during normal operation, and a second shear boundary of the pair of shear boundaries is defined by a contact point of the compression roller with the gripping shoe or roller.

[0063] Another aspect provides a tape laying head configured to lay a tow material onto a mold in the construction of a composite structure. The tape laying head includes a shearing mechanism that receives the tow material from a tow supply and is configured to steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism. The shearing mechanism is further configured to apply a driving force to the tow material, the driving force having a longitudinal component and a transverse component with respect to the tow material during steering of the tow material, and a web mechanism. The tow material includes a web prior to shear deformation of the tow material, and the web mechanism is configured to remove the web from the tow material after the tow material is laid onto the mold.

[0064] The web mechanism may further be configured to apply the web to the tow material prior to shear deformation of the tow material.

[0065] The web mechanism includes a web material supply and a web material recovery associated with a motor. The motor is configured to operate the web material recovery to pull the web from the web material supply.

[0066] Another aspect provides a tape laying head configured to lay a tow material in a mold in constructing a composite structure. The tape laying head includes a shearing mechanism that receives the tow material from a tow supply section and is configured to steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism. The shearing mechanism is further configured to apply a driving force to the tow material, and the driving force has a longitudinal component and a lateral component with respect to the tow material during steering of the tow material. The tape laying head includes the shearing mechanism, a supply section of the tow material, and / or a backing material recovery section, and a slip compensation mechanism configured to laterally move the shearing mechanism with respect to the supply section of the tow material and / or the backing material recovery section, whereby lateral slip of the tow material is compensated for.

[0067] The slip compensation mechanism may include one or more rails configured to enable movement of one or more of the shearing mechanism, or a tow guide roller and a gripping shoe, with respect to a part of the head, and a driving device for driving the movement of the shearing mechanism, or the tow guide roller and the gripping shoe.

[0068] The slip compensation mechanism may further include a sensor configured to sense lateral slip of the tow material.

[0069] Another aspect provides a tape laying system including a plurality of tape laying heads as described above.

[0070] Another aspect provides a controller for use in a tension control system of a tape laying system, the tape laying system including a shearing mechanism configured to receive tow material from a tow supply and to direct the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism, the shearing mechanism further configured to apply a driving force to the tow material, the driving force having a longitudinal component and a lateral component with respect to the tow material during the directing of the tow material, a web mechanism, the tow material comprising a web prior to shearing deformation of the tow material, the controller configured to operate the web mechanism to remove the web from the tow material after the tow material has been laid in a mold.

[0071] The controller may further be configured to operate the web mechanism to apply the web to the tow material prior to shearing deformation of the tow material.

[0072] The web mechanism may include a supply of web material and a web material take-up associated with a motor, the controller further configured to operate the motor to pull the web from the supply of web material.

[0073] Another aspect provides a controller for use in a tension control system of a tape laying system, the tape laying system including a shearing mechanism configured to receive tow material from a tow supply and to direct the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism, the shearing mechanism further configured to apply a driving force to the tow material, the driving force having a longitudinal component and a lateral component with respect to the tow material during the directing of the tow material, a tow material supply and / or a backing material take-up, and a slip compensation mechanism, the controller configured to operate the slip compensation mechanism to move the shearing mechanism laterally with respect to the tow material supply and / or the backing material take-up, such that lateral slip of the tow material is compensated for.

[0074] The slip compensation mechanism includes one or more rails configured to enable movement of a part of the tape laying system, which is either a shearing mechanism or one or more of the ear guiding rollers and gripping shoes, and a driving device. The controller is configured to operate the driving device to drive the movement of the shearing mechanism or the ear guiding rollers and gripping shoes.

[0075] The controller may further be configured to receive from the sensor a signal representing the lateral slip of the ear material.

[0076] Another aspect provides a control method for use in a tension control system of a tape laying system. The tape laying system includes a shearing mechanism that receives ear material from an ear supply unit and is configured to steer the ear material by applying shear deformation to the ear material between a pair of shear boundaries defined by the shearing mechanism. The shearing mechanism is further configured to apply a driving force to the ear material, and the driving force has a longitudinal component and a lateral component with respect to the ear material during the steering of the ear material. The tape laying system further includes a web mechanism, and the ear material is provided with a web before the shear deformation of the ear material. The method includes operating the web mechanism to remove the web from the ear material after the ear material is laid in the mold.

[0077] The method may further include operating the web mechanism to apply the web to the ear material prior to the shear deformation of the ear material.

[0078] The web mechanism may include a web material supply unit and a web material recovery unit associated with a motor, and the method may further include operating the motor to pull the web from the web material supply unit.

[0079] Another aspect provides a control method for use in a tension control system of a tape laying system, the tape laying system including a shearing mechanism that receives a tow material from a tow supply and is configured to steer the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism, the shearing mechanism further being configured to apply a driving force to the tow material, the driving force having a longitudinal component and a lateral component with respect to the tow material during steering of the tow material, the tape laying system further including a web mechanism, a supply of the tow material, and / or a backing material recovery section, and a slip compensation mechanism, the method including operating the slip compensation mechanism to move the shearing mechanism laterally with respect to the supply of the tow material and / or the backing material recovery section, whereby lateral slip of the tow material is compensated for.

[0080] The slip compensation mechanism can include one or more rails configured to enable movement of a part of the tape laying system, such as the shearing mechanism or one or more of the tow guide rollers and gripping shoes, and a drive device, the method further including operating the drive device to drive movement of the shearing mechanism or the tow guide rollers and gripping shoes.

[0081] The method can further include receiving a signal representative of lateral slip of the tow material from a sensor.

[0082] Another aspect provides a computer-readable medium having instructions stored thereon that, when executed, cause operation of the control method described above.

[0083] Embodiments are described by way of example only with reference to the accompanying drawings.

Brief Description of the Drawings

[0084]

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Mode for Carrying Out the Invention

[0085] The embodiment includes a tape laying head 1 (see, for example, FIGS. 2 and 3). The tape laying head 1 is configured to lay a tape 2 on a mold 3. The tape laying head 1 can be a part of a tape laying system 100, and some embodiments can include a tape laying system 100 that can include, for example, a plurality of tape laying heads 1 as described herein.

[0086] The tape laying head 1 can be configured to lay the tape 2 on the mold 3, for example, as part of the construction of a composite structure.

[0087] The tape laying system 100 is configured to move the tape laying head 1, or each tape laying head 1, across the mold 3, for example, using a robotic arm or a gantry. The tape laying head 1, or each tape laying head 1, is configured to lay the tape 2 on the mold 3 when the mold 3 is traversed by the tape laying head 1, or each tape laying head 1. In some embodiments, the tape laying system 100 is configured to move the tape laying head 1, or each tape laying head 1, across a substantially stationary mold 3, but equally, the tape laying system 100 can be configured to move the mold 3 (or move both the mold 3 and the tape laying head 1, or each tape laying head 1) relative to a substantially stationary tape laying head 1, or each tape laying head 1. In either case, the tape laying system 100 can be configured to move the tape laying head 1, or each tape laying head 1, relative to the mold 3, and this can be achieved.

[0088] The tape laying head 1 is configured to receive the tape 2 from the tape supply unit 4 for laying on the mold 3. The tape supply unit 4 can form, for example, a part of the tape laying head 1 and can also be a part of a wide tape laying system 100.

[0089] The tape 2 from the tape supply unit 4 is configured to be fed by the tape laying head 1 to the shearing mechanism 5. The shearing mechanism 5 receives the tape 2 from the tape supply unit 4 and is configured to lay the tape 2 on the mold 3.

[0090] In some embodiments, the tape 2 provided by the tape supply unit can have a backing material 21 and a tow material 22, and the backing material 21 supports the tow material 22 (e.g., when the tape 2 is fed from the tape supply unit 4 to the shearing mechanism 5 or towards the shearing mechanism 5). For example, the tow material 22 is to be laid on the mold 3, and the backing material 21 can be for discarding. The tow material 22 can include one or more reinforcing fibers and will be described in more detail herein. In some embodiments, the backing material 21 can provide a binding material or a resin material that is bound to one or more reinforcing fibers to form the tow material 22. The binding material or the resin material can be provided, for example, as a layer on the backing material 21.

[0091] In the region of or within the shearing mechanism 5, the backing material 21 can be removed from the tow material 22. This can occur before the tow material is laid on the mold 3 or when the tow material is being laid on the mold 3. A heater (not shown) can be provided to heat the tow material 22 and, in particular, the binding material or the resin material. The heater can be provided, for example, in the path of the tow material 22 upstream of the shearing mechanism 5.

[0092] When the tape laying head 1 is separated from the tow material 22, the backing material 21 can be configured to be fed to the backing material recovery unit 6. The backing material recovery unit 6 can be configured to recover the backing material 21 for later disposal (which may include recycling, for example). The backing material recovery unit 6 can form part of, for example, the tape laying head 1 or can be part of a wide tape laying system 100.

[0093] Accordingly, during operation, the tape 2 can pass from the tape supply unit 4 to the shearing mechanism 5 (see the solid arrows in FIG. 1 indicating the direction of travel of the tape 2 and / or the backing material 21). In or within the region of the shearing mechanism 5, the backing material 21 of the tape 2 can be separated from the tow material 22. The shearing mechanism 5 can carry the tow material 22 to the mold 3 (the dashed arrow in FIG. 3 indicates the direction of travel of the shearing mechanism 5 relative to the mold 3), and the backing material 21 can be fed to the backing material recovery unit 6 for recovery. All or some of these operations can be performed as part of the operation of the tape laying head 1, but as described, some parts (such as the tape supply unit 4 and / or the backing material recovery unit 6) can be part of a wide tape laying system 100, so the feeding and / or recovery operations can be performed by the wide tape laying system 100 as appropriate.

[0094] The embodiment includes a tension control system 7 (see, for example, FIGS. 1 and 3). The tension control system 7 is configured to control the tension of the tow material 22 at a stage immediately before the laying of the tow material into the mold 3. In other words, the tension control system 7 can be configured to control the tension of the tow material 22 in the shearing mechanism 5.

[0095] Tape The tape 2 as described includes a backing material 21 and a tow material 22. The backing material 21 can be, for example, a paper-based backing material 21. The backing material 21 can be configured, for example, to support the tow material 22 before laying the tow material 22 on the mold 3. The backing material 21 can also be configured to assist in the storage of the tape 2, and as a result, the tape 2 can be wound around a bobbin 41 (such as, for example, in a tape supply unit 4 with reference to FIG. 10).

[0096] The tow material 22 can take a number of different forms, but includes, for example, one or more reinforcing fibers 22a (see, for example, FIG. 4) that can be carbon fibers or glass fibers. The reinforcing fibers 22a can be elongated fibers and can be in a woven or non-woven configuration within the tow material 22. When a plurality of reinforcing fibers 22a are provided, they can be provided in one or more bundles known as tows 22b.

[0097] The tow material 22 can include a binding material. The binding material can be configured, for example, to assist in holding the relative arrangement of the reinforcing fibers 22a with respect to each other and / or to assist in adhering the tow material 22 to the mold 3 (or another layer of the tow material 22 already laid on the mold 3). The binding material may be insufficient as a resin material for use in forming a composite structure from the tow material 22. Thus, the tow material 22 can be impregnated, for example, with a thermosetting resin material after laying the tow material 22 on the mold 3 and / or can be intended to be impregnated. Such a tow material 22 can be described as a dry tow material 22 due to the absence of a suitable resin material in its supplied form.

[0098] The tow material 22 can be a pre-impregnated tow material 22. The pre-impregnated tow material 22 includes a suitable resin material (i.e., a thermosetting resin material) in its supplied form and forms a composite structure from the tow material 22. Thus, for example, there is no need to apply additional thermosetting resin material. Thus, the pre-impregnated tow material 22 includes one or more reinforcing fibers 22a and a resin material. The resin material can also be referred to as a matrix material and can take other forms.

[0099] The pre-impregnated tow material 22 tends to have a higher shear rigidity than the dry tow material 22.

[0100] In some embodiments, the tow material 22 is provided in two parts, one or more reinforcing fibers and a binder material or resin material. The two parts can be combined, for example, within the tape laying head 1 or within a wide tape laying system 100. The binder material or resin material can be provided, for example, on the backing material 21.

[0101] In some embodiments, an endless backing material 21 can be provided (as part of the tape laying head 1), which serves the same purpose as the backing material 21 described herein with respect to supporting the tow material 22 (however, it is not related to the storage of the tow material 22 or the provision of the binder material or resin material). Thus, in such embodiments, the tow material 22 can be provided from the tape supply unit 4 to the endless backing material 21 within the tape laying head 1. In these embodiments, the reference to the tape 2 with respect to the tape supply unit 4 is a reference to the tow material 22 (for example, the tow material 22 can be provided on the bobbin 41, etc.).

[0102] Embodiments are described with respect to the tape 2 including the backing material 21 in its supplied form, but the same applies in embodiments where the backing material 21 is in the form of an endless backing material 21 provided within the tape laying head 1, or in embodiments where the tow material 22 is added to the resin material within the tape laying head 1 or within the wide tape laying system 100.

[0103] Generally, as used herein, a reference to the tape 2 can be interpreted as a reference to one or more tows, each of which can include one or more reinforcing fibers 22a. Thus, a reference to the tape 2 can be a reference to a tow, and the term is not used herein with any particular meaning unless otherwise explained.

[0104] Tape supply The tape supply unit 4 may include a bobbin 41 around which the tape 2 is wound. The tape supply unit 4 may include a creel 42 (see, for example, FIG. 10) configured to receive and support the bobbin 41. In some embodiments, there are a plurality of bobbins 41, and each bobbin 41 is received and supported by the creel 42.

[0105] As described, the tape supply unit 4 may form part of the tape laying head 1 or part of a wide tape laying system 100.

[0106] The tape supply unit 4 may be configured to supply the tape 2 to the shearing mechanism 5, and as such, a tape path may be defined between the tape supply unit and the shearing mechanism 5. This tape path may be at least partially formed by the tape laying head 1. One or more portions of this tape path may be defined by a tube, for example, through which the tape 2 can pass.

[0107] In some embodiments, the tape supply unit 4 is configured to supply the tape 2 to a plurality of tape laying heads 1 of the tape laying system 100 (for example, in embodiments where there are a plurality of tape laying heads 1 as part of the tape laying system 100). Thus, the tape supply unit 4 may include at least one bobbin 41 for each tape laying head 1, such that separate tapes (or tows) 2 can be supplied to each tape laying head 1. In some embodiments, one or more tapes (or tows) 2 are supplied in parallel to a single (i.e., only one and one only) tape laying head 1 (and there may be a plurality of such tape laying heads 1 each receiving a plurality of tapes 2 in parallel from the tape supply unit 4).

[0108] The bobbin 41 or each bobbin 41 may be removable, and the tape supply unit 4 may include a creel 42 configured to receive one or more bobbins 41. The tape supply unit 4 may at least partially define one or more tape paths configured such that the tape 2 passes toward the shearing mechanism 5 (or, optionally, a plurality of mechanisms 5).

[0109] The tape 2 supplied by the tape supply unit 4 can be any tape 2 described herein. Thus, in some embodiments, this tape 2 can include the tow material 22 and the backing material 21. In some embodiments, the tape 2 supplied by the tape supply unit 4 includes the tow material 22, but the backing material 21 is provided separately, for example, as an endless loop. The tow supply unit 4 can be configured to deliver the tow material 22 to the backing material 21 (e.g., an endless loop) in some such embodiments. In some embodiments, the endless loop can be considered part of the tape supply unit 4. In some embodiments, the endless loop can be part of, for example, the tape laying head 1.

[0110] Shearing mechanism The shearing mechanism 5 can generally be a mechanism as described in Patent Document 6.

[0111] The shearing mechanism 5 can include a compression shoe 51 configured to press the tow material 22 onto the mold 3 (herein, reference to the laying of materials such as the tow material 22 onto the mold 3 is understood to include the indirect laying of materials onto the mold 3 (e.g., the laying of materials onto a layer of materials already laid on the mold 3)).

[0112] The compression shoe 51 may have a first side portion 51a that faces a second side portion 51b across the width of the compression shoe 51. The first side portion 51a may generally be flat, or may have a planar surface, or may have surfaces of different configurations, as illustrated. At the base of the first side portion 51a (and which may be the base of the compression shoe 51), there may be a substantially straight trailing edge of the compression shoe 51. The trailing edge bounds the first side portion 51a of the compression shoe 51 and the compression side 51c of the compression shoe 51. The compression side 51c includes a compression surface 51c, and the terms are used synonymously herein.

[0113] The compression surface 51c is configured to press the tow material 22 against the mold 3. The compression surface 51c may be configured to allow the tow material 22 to pass between the compression shoe 51 and the mold 3 when the compression shoe 51 (and, for example, the tape laying head 1) moves across the mold 3 to lay the tow material 22. The compression surface 51c may be a substantially smooth surface and may have a relatively low coefficient of friction to allow the compression shoe 51 to slide over the laid tow material 22.

[0114] The trailing edge of the compression shoe 51 represents the final portion of the compression shoe 51 that presses the tow material 22 against the mold 3 as the compression shoe 51 moves relative to the mold 3 during normal laying operations. Thus, this may also be referred to as the trailing edge of the compression shoe 51, more specifically, the trailing edge of the compression surface 51c (wherein rearward (and forward) is defined by the direction of movement of the compression shoe 51 relative to the mold 3).

[0115] The compression shoe 51 may also include a leading edge. The leading edge may face the trailing edge across the width of the compression shoe 51 (and the width thereof may be at the base of the compression shoe 51). The leading edge may bound between the second side portion 51b of the compression shoe 51 and the compression side 51c of the compression shoe 51.

[0116] The leading edge of the compression shoe 51 represents the first part of the compression shoe 51 that presses the ear material 22 against the mold 3 when the compression shoe 51 moves relative to the mold 3 during normal laying operations (this can be the shear boundary described herein). Thus, this will be referred to as the leading edge of the compression shoe 51, more specifically, the leading edge of the compression surface 51c (again, forward (and backward) is defined by the direction of movement of the compression shoe 51 relative to the mold 3).

[0117] In some embodiments, the trailing edge can be a relatively sharp edge in that the first side 51a can intersect the compression side 51c along a thin edge (i.e., having a relatively small radius). In some embodiments, the leading edge can be a relatively rounded edge in that the second side 51b can intersect the compression side 51c along a curved edge (in cross-section) having a relatively large radius (compared to the above-mentioned thin part).

[0118] Both the trailing edge and the leading edge can be substantially straight edges. In other words, the two edges can each extend along a substantially straight axis. The leading edge and the trailing edge can be substantially parallel to each other (i.e., the substantially straight axes can be substantially parallel to each other).

[0119] The second side 51b can have, for example, a curved surface as shown, or can have a surface of a different form. In some embodiments, the second side 51b can have both a generally flat portion and a generally curved portion, for example, as shown.

[0120] The second side 51b can be configured (e.g., formed and sized) to at least partially receive the ear guide roller 52. Thus, the ear guide roller 52 can be part of the shearing mechanism 51 and can be disposed adjacent to the compression shoe 51. In particular, the ear guide roller 52 can be disposed adjacent to the second side 51b of the compression shoe 51.

[0121] The corn guide roller 52 can be arranged such that the corn material 22 can pass through the portion of the corn guide roller 52 adjacent to the compression shoe 51 before the corn material 22 reaches the compression shoe 51. In other words, the corn guide roller 52 can be arranged upstream of the compression shoe 51 with respect to the path of the corn material 22 through the shearing mechanism 5.

[0122] The corn material 22 has a movement path from the tape supply unit 4 to the shearing mechanism 5, and it should be understood that this path is formed from various portions passing through the tape laying head 1. The corn material path can be the same as the tape path in some places, and the terms can be synonymous. However, typically, the tape path refers to the path of the tape 2 (i.e., the path of the corn material 22 and, if provided, the path of the backing material 21), while the corn material path can also be the path for the backing material or may not be the path for the backing material. The path (corn material or tape) has upstream and downstream directions defined, in some cases, by the normal advancing direction of the corn material 22 or the tape 2 during the laying operation, that is, generally from the tape supply unit 4 towards the shearing mechanism 5 (especially towards the compression shoe 51).

[0123] The corn guide roller 52 can be configured to rotate about an axis that is generally parallel to the leading edge of the compression shoe 51. The corn guide roller 52 can have an outer surface made of silicone in some embodiments.

[0124] The shearing mechanism 5 can include a gripping shoe 53 (which can also be referred to as, for example, a corn supply shoe). The gripping shoe 53 can be arranged adjacent to the corn guide roller 52, and the corn material can pass between the gripping shoe 53 and the corn guide roller 52. In other words, at least a part of the corn material path (and, in some cases, the tape path) can be defined between the corn guide roller 52 and the gripping shoe 53.

[0125] The gripping shoe 53 can be formed from a generally elongated member that is rotatably attached to the ear guide roller 52. The distance between at least a portion of the gripping shoe 53 and at least a portion of the ear guide roller 52 can be varied by rotation of the gripping shoe 53 about its rotatable mount 53a (the rotatable mount 53a can form part of the shearing mechanism 5). As shown, for example, the gripping shoe 53 can have a distal end adjacent to the ear guide roller 52 and a proximal end (opposite the distal end). The rotatable mount 53a can be disposed between the proximal and distal ends of the gripping shoe 53.

[0126] The distal end of the gripping shoe 53 can be shaped to increase the surface area between the ear guide roller 52 and the gripping shoe 53 such that ear material 22 (or tape 2) can be sandwiched therebetween. Accordingly, the distal end of the gripping shoe 53 can be curved, and the degree of curvature can generally match the circumferential shape of at least a portion of the ear guide roller 52.

[0127] The rotational movement of the gripping shoe 53 about the rotatable mount 53a can vary the distance between at least a portion of the gripping shoe 53 (e.g., a portion of its distal end) and the ear guide roller 52. The rotational movement of the gripping shoe 53 about the rotatable mount 53a can vary the force applied to the ear material 22 or tape 2 between at least a portion of the gripping shoe 53 (e.g., a portion of its distal end) and the ear guide roller 52 (this force can be a compressive force and, in other words, can be a gripping or clamping force).

[0128] The gripping shoe 53 can include an elastic biasing device 54, such as a spring, which can be, for example, a helical spring configured to bias the distal end of the gripping shoe 53 toward the guide roller 52. In some embodiments, the elastic biasing device 54 includes a pneumatic or hydraulic ram.

[0129] Thus, the ear material 22 can follow the ear material path (in the gripping area) between the ear guide roller 52 and the gripping shoe 53 before passing into the compression shoe 51, and the compression shoe 51 can press the ear material 22 onto the mold 3 in the compression area (i.e., can lay the ear material 22 on the mold 3).

[0130] In some embodiments, the ear material 22 can be accompanied by the backing material 21 through the path between the ear guide roller 52 and the gripping shoe 53 (i.e., in the gripping area). As such, this portion of the path can similarly be described as a tape path. When the tape 2 leaves the path defined between the ear guide roller 52 and the gripping shoe 53, the backing material 21 can be removed from the ear material 22. In other words, when the tape 2 leaves the gripping area, the backing material 21 can be separated from the ear material 22. In some embodiments (such as those shown), the backing material 21 can pass around the distal most end of the gripping shoe 53.

[0131] The distal most end of the gripping shoe 53 can be the outermost end portion of its distal end. The distal most end of the gripping shoe 53 can be sized and / or shaped (e.g., can have an appropriate radius) to assist in the separation of the backing material 21 from the ear material 22.

[0132] Thus, the backing material 21 can follow the backing material path from the gripping shoe 53. This path can extend to or towards the backing material recovery section 6, which can be downstream (with respect to the path of movement of the backing material 21 and the normal direction) of the shearing mechanism 5.

[0133] The last portion of the gripping shoe 53 that the ear material 22 contacts (along its path towards the compression shoe 51) can, in some embodiments, be referred to as a gripping edge and can be a straight portion of the gripping shoe 53 that extends parallel to the leading edge of the compression shoe 51, and this edge can be a shearing boundary as described herein.

[0134] As can be understood, the shearing mechanism 5 can be configured to move in a first direction with respect to the mold 3. The first direction can be, for example, the laying direction, and in the illustrated example of FIG. 3, it is generally from left to right.

[0135] The shearing mechanism 5 can further be configured to move in a second direction with respect to the mold 3. The second direction is generally perpendicular to the first direction (for example, in the illustrated example of FIG. 3, the direction of entering and exiting the page). This second direction can be the shearing direction and is intended to subject the tow material 22 to shear deformation. As can be understood, this second direction can be parallel to the trailing edge, the leading edge, and / or the axis of rotation of the tow guide roller 52.

[0136] The movement of the shearing mechanism 5 in the first direction can be driven by the tape laying head 1 that moves in the first direction with respect to the mold 3. The movement of the tape laying head 1 in the first direction with respect to the mold 3 can be driven by the movement (with respect to the mold 3) of a part of the tape laying system 100 to which the tape laying head 1 is attached. For this purpose, the tape laying system 100 can include a gantry to which the tape laying head 1 is attached (the same gantry can have a plurality of tape laying heads 1 attached thereto).

[0137] The movement of the shearing mechanism 5 in the second direction can be driven by the tape laying head 1 that moves in the second direction with respect to the mold 3. The movement of the tape laying head 1 in the second direction with respect to the mold 3 can be driven by the movement (with respect to the mold 3) of a part (such as a gantry) of the tape laying system 100 to which the tape laying head 1 is attached. In some embodiments, the movement of the shearing mechanism 5 in the second direction can be the driven movement of the shearing mechanism 5 with respect to the tape laying head 1 in the second direction.

[0138] Accordingly, the shearing mechanism 5 can be configured to provide shear deformation of the tow material 22, for example, referred to as tow steering or shear tow steering. In some embodiments, the shearing mechanism 5 can take different forms. For example, the compression shoe 51 can be in the form of a roller. Similarly, the gripping shoe 53 can also be, for example, in the form of a roller. In any case, the shearing mechanism 5 can provide a pair of shear boundaries.

[0139] Backing material recovery part The backing material recovery part 6 can include, for example, referring to FIG. 11, a bobbin 61 (to distinguish this bobbin 61 from the bobbin 41, the bobbin 61 can be referred to as the recovery bobbin 61, and the other bobbin 41 can be referred to as the supply bobbin 41, for example). The recovery bobbin 61 can be configured to receive and recover the backing material 21 following separation from the tow material 22. In other words, during operation of the tape laying head 1 and / or the system 100, the used backing material 21 can be wound around the recovery bobbin 61.

[0140] The backing material recovery part 6 can include a creel 62 that can be configured to receive and support the recovery bobbin 61. In some embodiments, there are a plurality of recovery bobbins 61, and each recovery bobbin 61 is received and supported by the creel 62. The creel 62 can be a separate creel 62 from that of the tape supply part 4, and thus, it can be referred to as the recovery creel 62 (the other creel 42 is referred to as the supply creel 42). However, in some embodiments, the creel is shared such that the supply creel 42 and the recovery creel 62 are the same creel (i.e., the same creel structure).

[0141] As described, the backing material recovery part 6 can form part of the tape laying head 1 or part of the wide tape laying system 100.

[0142] The backing material recovery unit 6 may be configured to receive the backing material 21 from the shearing mechanism 5. As such, a path for the backing material may be defined between the shearing mechanism 5 and the backing material recovery unit 6. This path for the backing material may be at least partially formed by the tape laying head. One or more portions of this path for the backing material may be defined, for example, by a tube through which the backing material 21 can pass.

[0143] In some embodiments, the backing material recovery unit 6 is configured to receive the backing material 21 from a plurality of tape laying heads 1 of the tape laying system 100 (for example, in embodiments where there are a plurality of tape laying heads 1 as part of the tape laying system 100). Accordingly, the backing material recovery unit 6 may include at least one bobbin 61 for each tape laying head 1, and the separated backing material 21 may be received from each tape laying head 1. In some embodiments, one or more strips of the backing material 21 are received in parallel from a single (i.e., only one and only one) tape laying head 1 (and there may be a plurality of such tape laying heads 1 each providing a plurality of strips of the backing material 21 to the backing material recovery unit 6 in parallel).

[0144] The bobbin or each bobbin 61 may be removable, and the backing material recovery unit 6 may include a creel 62 configured to receive one or more bobbins 61. The backing material recovery unit 6 may at least partially define one or more paths for the backing material such that the backing material 21 passes toward the backing material recovery unit 6 (or, in some cases, a plurality of recovery units 6).

[0145] In embodiments where the backing material 21 is an endless loop, the path of the backing material may pass from the shearing mechanism 5 to the backing material recovery unit 6 and then back to the shearing mechanism 5 (at the shearing mechanism 5, the backing material 21 is part of the tape 2 and, as described for embodiments where it is not an endless loop, its path may pass between the guide roller 52 and the gripping shoe 53).

[0146] Tension control system It has been found that the control of the tension of the tow material 22 in the cutting mechanism 5 is important to promote more ideal cutting deformation of the tow material 22. In particular, the control of the tension of the tow material 22 between the gripping region and the pressing region (which can be between the gripping edge of the gripping shoe 53 and the front edge of the compression shoe 51, i.e., between the cutting boundaries) is important.

[0147] As described, the tow material 22 may include one or more reinforcing fibers 22a. For purposes of illustration, embodiments are contemplated in which the tow material 22 includes a plurality of reinforcing fibers 22a, and at least some of these fibers are arranged parallel to each other along, for example, the length of the tow material 22 (the length of which generally follows the path of the tow material).

[0148] Ideally, the cutting deformation imparted by the use of the cutting mechanism 5 results in cutting deformation - in-tow cutting deformation in all of the reinforcing fibers 22a across the width of the tow material 22 (see FIG. 4). This cutting deformation would ideally be substantially uniform. This requires sliding of the reinforcing fibers 22a within the tow material 22 relative to each other.

[0149] However, in practice, such sliding does not occur easily and uniformly between the reinforcing fibers of the tow material 22, and inter-tow cutting occurs (see FIG. 4). This results in localized buckling or wrinkling (or other defects). These defects will typically occur adjacent to the boundaries of the cutting deformation (which are defined by the gripping region and the pressing region, i.e., the cutting boundaries, described herein).

[0150] In addition, the sliding results in the laid tow material 22 being misaligned with the intended laid tow material path on the mold 3.

[0151] It has been found that controlling the tension of the corn material 22 between the compression region and the gripping region (i.e., between the shear boundaries) can reduce the risk of such defects occurring. In particular, applying tension while shearing the corn material 22 forces the corn material 22 to deform by in-corn shearing, which is the preferred mode of shear deformation (the mode for providing optimal quality).

[0152] Accordingly, an embodiment includes a tension control system 7 configured to control this tension during operation of the tape laying head 1.

[0153] The tension control system 7 may include a first load sensor 71 and a second load sensor 72 (see FIGS. 1 and 3). The first and second load sensors 71, 72 are communicably connected to a controller 73 of the tension control system 7.

[0154] The controller 73 may include one or more processors 73a, a memory 73b, a computer-readable medium 73c, and an input / output interface 73d, all of which may be communicably connected together to form the controller 73.

[0155] The first and second load sensors 71 may be communicably connected to the input / output interface 73d of the controller 73. Accordingly, the controller 73 may be configured to receive a first load sensor signal from the first load sensor 71 and a second load sensor signal from the second load sensor 72. These signals may be received, for example, at the input / output interface 73d.

[0156] The first load sensor signal may be a signal indicating the load detected by the first load sensor 71. The second load sensor signal may be a signal indicating the load detected by the second load sensor 72.

[0157] The first load sensor 71 may be configured to sense the tension of the ear material 22 upstream of the ear material path of the shearing mechanism 5. Accordingly, the first load sensor signal may be a signal indicating the tension of the ear material 22 between the tape supply unit 4 and the shearing mechanism 5. As can be understood from the description herein, this tension of the ear material 22 may be the tension of the tape 2 (including, for example, the ear material 22 and the backing material 21).

[0158] The second load sensor 72 may be configured to sense the tension of the backing material 71 downstream of the shearing mechanism 5 in the backing material path. Accordingly, the second load sensor signal may be a signal indicating the tension of the backing material 21 between the shearing mechanism 5 and the backing material recovery unit 6.

[0159] In other words, the first and second load sensor signals indicate the tensions on both sides of the shearing mechanism 51 with respect to the paths of these materials in the ear material 22 and the backing material 21, respectively. These may similarly be regarded as the input tension (related to the tension indicated by the first load sensor signal) and the output tension (related to the tension indicated by the second load sensor signal).

[0160] The first and second load sensors 71, 72 may take a number of different forms. In some embodiments, each of the first and second load sensors 71, 72 includes a respective pair of follower rollers 71a, 72a. Accordingly, there may be a first pair of follower rollers 71a of the first load sensor 71. There may be a second pair of follower rollers 72a of the second load sensor 72.

[0161] Each follower roller of the first pair of follower rollers 71a may be substantially parallel to each other and may be configured to rotate about respective axes that may be perpendicular to the advancing direction of the ear material 22.

[0162] Each follower roller of the second pair of follower rollers 72a may be substantially parallel to each other and may be configured to rotate about respective axes that may be perpendicular to the advancing direction of the backing material 21.

[0163] The first secondary roller pair 71a can be arranged on one side of the ear material 22 (which can be the tape 2). The first load sensor 71 can be offset from the first secondary roller pair 71a and can include a first load cell 71b arranged on the other side of the ear material 22 with respect to the first secondary roller pair 71a. The ear material path can pass at least partially around one of the rollers of the first secondary roller pair 71a, around the first load cell 71b, and then at least partially around the other of the rollers of the first secondary roller pair 71a.

[0164] The first load cell 71b can be in the form of a roller attached to a shaft, and the load cell member is associated with the shaft, for example, to measure the force on the shaft.

[0165] The second secondary roller pair 72a can be arranged on one side of the backing material 21. The second load sensor 72 can be offset from the second secondary roller pair 72a and can include a second load cell 72b arranged on the other side of the backing material 21 with respect to the second secondary roller pair 72a. The backing material path can pass at least partially around one of the rollers of the second secondary roller pair 72a, around the second load cell 72b, and then at least partially around the other of the rollers of the second secondary roller pair 72a.

[0166] The second load cell 72b can be in the form of a roller attached to a shaft, and the load cell member is associated with the shaft, for example, to measure the force on the shaft.

[0167] The tension control system 7 can include a first motor 74 associated with the backing material recovery section 6, a second motor 75 associated with the shearing mechanism 5, and a brake 76 associated with the tape supply section 4.

[0168] The first motor 74 can be configured to drive the rotation of the recovery bobbin 61. This can be achieved, for example, by driving (directly or indirectly) the rotation of at least a part of the creel 62 to which the recovery bobbin 61 can be attached or is attached. Indirect drive can include, for example, one or more gears.

[0169] The first motor 74 can be communicably connected to the controller 73, and thus can be communicably connected to the input / output interface 73d. The first motor 74 can be configured to receive a first motor control signal from the controller 73 via a communicable connection. The first motor control signal can control the operation of the first motor 74.

[0170] The second motor 75 can be configured to drive the rotation of the ear guide roller 52. This can be achieved, for example, by driving (directly or indirectly) the rotation of the spindle (the spindle that is part of the shearing mechanism 5) to which the ear guide roller 52 is attached. Indirect drive can include, for example, one or more gears.

[0171] The second motor 75 can be communicably connected to the controller 73, and thus can be communicably connected to the input / output interface 73d. The second motor 75 can be configured to receive a second motor control signal from the controller 73 via a communicable connection. The second motor control signal can control the operation of the second motor 75.

[0172] In some embodiments, there is no motor associated with the tape supply unit 4 (or there is no motor configured to drive the rotation of the tape supply unit 4 in the feeding of the ear material 22 or the tape 2). Since the tape 2 or the ear material 22 can be pulled out from the tape supply unit 4 by other parts of the tape laying head 1 (such as via the operation of the first and / or second motors 74, 75, etc.), in such embodiments, it can be regarded as being operated passively.

[0173] The brake 76 can be configured to apply a braking force such as braking torque to the tape supply unit 4, that is, to apply braking to the supply of the tow material 22 or the tape 2 from the tape supply unit 4, or otherwise to decelerate the supply. For example, the brake 76 can be configured to apply a braking force to the supply bobbin 41 in order to change the rotational speed of the supply bobbin 41. To achieve this, the brake 76 can be associated with the supply bobbin 41 and / or the creel 42 to which the supply bobbin 41 is attached and / or can be attached.

[0174] The brake 76 can take a number of different forms. The brake 76 can be electronically actuated and thus can be communicatively coupled to the controller 73 and configured to receive a brake signal from the controller 73. The brake 76 can thus be communicatively connected to the input / output interface 73d.

[0175] The brake 76 can be configured to apply a varying braking force under the control of the brake signal. Thus, the braking torque applied to the tape supply unit 4 (e.g., the creel 42 and / or the bobbin 41) can vary in response to the brake signal.

[0176] In some embodiments, the brake 76 is in the form of a magnetic brake. Thus, a part of the tape supply unit 4 (for example, a part of the bobbin 41 or the creel 42) that rotates when the tape 2 is fed therefrom may carry at least one first magnet, which may be a permanent magnet. The first magnet may form part of the brake 76. The brake 76 may include a second magnet, which may be an electromagnet. The second magnet may be disposed within and associated with the magnetic field of the first magnet. The second magnet may be fixed relative to the movement with the first magnet. In other words, the second magnet may be a substantially fixed magnet. The brake signal may be configured to change the magnetic field generated by the second magnet with respect to the first magnet to apply or release the braking force. The brake 76 may be, for example, a motor (this motor is only configured to provide the braking force, but may be configured not to drive the supply of the tow material 22 from the tape supply unit 4). As will be appreciated, different configurations of magnetic brakes are possible, including embodiments in which the second magnet and the first magnet move physically relative to each other depending on the brake signal to change the braking force. Other forms of brakes are possible, for example, a mechanical brake in which a brake disc connected to rotate with the bobbin 41 or the creel 42 is selectively gripped between brake pads to apply a braking force (a gripping force that varies depending on the brake signal). Other forms of friction brakes are also contemplated as the brake 76.

[0177] Accordingly, the controller 73 may be configured to receive the first and second load sensor signals. The controller 73 may be configured to output the first and second motor control signals and the brake signal.

[0178] The processor or each processor 73a may be configured to execute instructions, which may be stored on a computer-readable medium 73c. Execution of these instructions may result in the execution of one or more tension control operations in connection with the tape laying head, as described herein. These tension control operations may include controlling the operation of the first motor 74, the second motor 75, and / or the brake 76.

[0179] The processor or each processor 73a may be communicatively connected to a memory 73b, and the processor or each processor 73a may use the memory 73b in the execution of instructions. The memory 73b may be, for example, a volatile memory.

[0180] The controller 73 may also be a shared controller configured to control the tape laying head 1 and / or one or more other operations of the wide tape laying system 100. This may include, for example, the movement of the shearing mechanism 5 relative to the mold 3 (which may include, for example, the movement of the tape laying head 1 relative to the mold 3).

[0181] The controller 73 may be configured to receive one or more operating parameters. The operating parameter or each operating parameter may be received from other parts of the tape laying head 1 and / or from the tape laying system 100.

[0182] One or more operating parameters may include, for example, a setpoint for the tension of the tow material 22 (i.e., the desired tow material tension 22 in the shearing mechanism 51 (such as between the compression shoe 51 and the gripping shoe 53)) that represents a characteristic of the operation of the tape laying head 1, and / or a shear angle for the tow material 22 (i.e., the shear angle for the tow material 22 laid on the mold 3 as described herein), and / or the moving speed of the tape laying head 1 relative to the mold 3.

[0183] One or more operating parameters may be received via the input / output interface 73d, provided to the processor or each processor 73a, and / or stored in the memory 73b and / or stored in the computer-readable medium 73c.

[0184] The controller 73 may be configured to use the received operating parameter or each received operating parameter in performing the tension control operation or each tension control operation.

[0185] Tension control Assume that the tow material 22 is laid on the mold 3 in a straight line using a conventional tape laying device. When the tow material passes through the conventional tape laying head, the device resistance force T, which is the sum of all the forces (e.g., frictional forces) acting on the tow material l exists. These forces may include, for example, friction associated with the bobbin in the supply mechanism of the tow material, friction associated with all the rollers through which the tow material passes, and friction associated with all the surfaces within the head through which the tow material passes.

[0186] During the laying of the tow material 22 in a conventional device, the head is moved relative to the mold 3, which provides the driving force P.

[0187] Referring to FIG. 5, the device resistance force T l and the driving force P are opposed to each other and parallel to each other (i.e., they are aligned). The driving force P also represents the tension of the tow material being laid.

[0188] Device resistance force T l If it is equal to the driving force P, then in that case, a constant laying speed (the laying speed of the tow material 22 on the mold 3) is achieved, which is also the supply speed of the tow material 22.

[0189] In other words, if it is as shown in Equation 1 below, a constant laying speed is achieved in the straight laying of the tow material 22 (also refer to FIG. 5, in which the dashed arrow indicates the moving direction of the tow material 22).

[0190]

Number

[0191] In a tape laying device in which a shearing mechanism (for example, a shearing mechanism similar to the shearing mechanism 5 described in this specification) is provided and used, in that case, the driving force P is no longer aligned with the device resistance force T. In particular, the driving force P is angled with respect to the device resistance force T. The angle at which the driving force P acts with respect to the device resistance force T is determined by the shearing angle. The shearing angle is the angle of the tow material 22 laid with respect to the main traveling direction (i.e., the longitudinal direction) of the head with respect to the mold 3. As can be understood, the shearing mechanism operates by moving the head in the lateral direction (a direction perpendicular to the longitudinal direction) with respect to the mold 3. l and is not aligned. In particular, the driving force P is angled with respect to the device resistance force T. l The driving force P is angled with respect to the device resistance force T. l The angle at which the driving force P acts with respect to the device resistance force T is determined by the shearing angle. The shearing angle is the angle of the tow material 22 laid with respect to the main traveling direction (i.e., the longitudinal direction) of the head with respect to the mold 3. As can be understood, the shearing mechanism operates by moving the head in the lateral direction (a direction perpendicular to the longitudinal direction) with respect to the mold 3.

[0192] Therefore, in such a case, the driving force P is considered to have a longitudinal component P l and a lateral component P t Typically, regardless of the shearing angle, the device resistance force T l remains substantially constant.

[0193] As such, at a constant laying speed, it becomes as shown in Equation 2 below.

[0194]

Number

[0195] Therefore, as the shearing angle increases, the magnitude of the driving force P increases, and thus the lateral component of this force also increases as shown in Equation 3 below, where θ is the shearing angle (for example, see Figure 6, in Figure 6, the dashed arrow indicates the moving direction of the tow material 22).

[0196]

Number

[0197] In a shearing mechanism provided with a gripping shoe and an ear guide roller (such as the shearing mechanism 5 described in this specification, which includes the gripping shoe 53 and the ear guide roller 52), the action of the gripping shoe and the ear guide roller on the ear material 22 serves to resist the lateral movement of the ear material across the gripping shoe. In other words, as the shearing angle increases, the action serves to suppress the slippage of the ear material 22 across the gripping shoe. Therefore, the gripping shoe and the ear guide roller provide a lateral frictional force T t to be provided.

[0198] If the lateral component P t of the driving force P is less than the maximum lateral frictional force T t,max , then there is no lateral slippage of the ear material 22 across the gripping shoe.

[0199] Therefore, if it is as shown in Equation 4 below, then there is no lateral slippage of the ear material 22 across the gripping shoe.

[0200]

Equation

[0201] When slippage occurs, at that time, the ear material 22 does not follow the desired ear path determined by the movement of the head relative to the mold 3, which is a desired ear path where it is natural to think that no slippage occurs. In fact, ultimately, the ear material 22 reaches the edge of the gripping shoe 53 and / or the ear guide roller 52, is crushed at that edge, and / or interferes with the operation of the head.

[0202] Therefore, in a conventional device provided with a shearing mechanism, there is a limit to the achievable shearing angle, and this limit is determined by the maximum lateral frictional force T t,max . The maximum lateral frictional force can be affected by parameters such as the coefficient of friction of the surface of the ear guide roller 52 and the pressure applied by the gripping shoe 53.

[0203] In many conventional devices, there is a design focus on minimizing the tension in the tow material 22 at the time when the tow material 22 is laid (i.e., at the time of deposition). This can be achieved in conventional devices by actively driving the supply of the tow material 22 (e.g., by overfeeding the tow material 22 to a shearing mechanism if there is a shearing mechanism). Additionally or alternatively, in conventional devices, this can be achieved by minimizing the total frictional force on the tow material 22 passing through the device, particularly the device resistance force T l by minimizing it.

[0204] In the device described herein (i.e., the shearing mechanism 5), or in a device having a shearing mechanism similar to that of Patent Document 6, most of the device resistance force T l is the result of the action of the gripping shoe 53 on the tow material 22 and the tow guide roller 52. This is required to provide the lateral frictional force T t to provide.

[0205] In the device of Patent Document 6, for example, the supply speed of the tow material 22 is synchronized (e.g., mechanically) with the recovery speed of the backing material 21. This synchronization aims to minimize the tension in the tow material 22. When the bobbin runs out of the tow material 22 or accumulates the backing material 21, electronic synchronization can be implemented to vary the lengths of feeding and recovery of the materials 21 and 22. However, such electronic synchronization has proven to be difficult to implement reliably in some cases, which can lead to laying defects, head stops, and defects in the laid tow material 22. These problems can be exacerbated, for example, by the increased speed of the laying operation and the increased frequency of start-stop cycles in the laying operation. Such a system also provides no mechanism by which the tension in the tow material 22 can be varied during the laying operation (particularly a laying operation involving shearing of the tow material 22).

[0206] Therefore, the tension control system 7 of some embodiments applies an additional force P mis required to introduce into the operation of the head 1 (this additional force may also be referred to as a tensile force or an additional tensile force). This additional force P m may be a force acting to pull the web material 22 and / or the backing material 21, and thus assist in the supply of the web material 22.

[0207] Therefore, during the linear laying of the web material, the force according to the operation of the tension control system 7 can be expressed by the following Equation 5 (for a constant laying speed).

[0208]

Equation

[0209] In other words, the device resistance T l is, referring to FIG. 7, equal to the driving force P and the combined (i.e., additional) force P m (in FIG. 7, the dashed arrow indicates the moving direction of the web material 22).

[0210] During the shearing operation (i.e., during the steering of the web material 22 by the shearing action using the shearing mechanism 5), the force can be expressed by the following Equation 6.

[0211]

Equation

[0212] In other words, the device resistance T l is, referring to FIG. 8, equal to the longitudinal component P l of the driving force and the combined (i.e., additional) force P m (in FIG. 8, the dashed arrow indicates the moving direction of the web material 22).

[0213] The tension control system 7 may be required to control the additional force P m through active control as described herein. Therefore, the tension control system 7 controls this additional force P mIt is possible to seek to increase the maximum shear angle, which can be achieved by adjusting to eliminate substantial lateral slippage of the ear material 22 across the gripping shoe 53.

[0214]

Number

[0215] The tension control system 7 can also, as described herein, by active control, seek to control the device resistance force T l (thus, the device resistance force T l is considered to be a tension that can be varied by the controller 73 in addition to the additional force P m ).

[0216] In other words, the lateral component P t of the driving force can be controlled to maintain a non-slip state as defined by Equation 8 below.

[0217]

Number

[0218] By adjusting the additional force P m , the tension control system 7 can also adjust the tension of the ear material 22 in the shearing mechanism 5 (e.g., the tension between the compression shoe 51 and the gripping shoe 53).

[0219] Therefore, the tension control system 7 is configured to adjust the additional force P t in order to prevent the lateral component of the driving force P t,max from exceeding the maximum lateral frictional force T m .

[0220] In addition, the tension control system 7 adjusts the additional force P mcan be configured to adjust. This predetermined minimum value can be, for example, one of one or more operating parameters (i.e., the setpoint of the tension of the tow material 22).

[0221] The minimum tension of the tow material 22 in the shearing mechanism 5 may be required to reduce defects in the laid tow material 22. This may include, for example, ensuring that the reinforcing fibers 22a of the tow material 22 slide relative to each other.

[0222] As will be understood, the minimum tension of the tow material 22 in the shearing mechanism 5 depends on factors such as the shear stiffness of the tow material 22, the resistance to sliding of the reinforcing fibers 22a relative to each other (which can be a property of the fibers 22a and / or the binding material or resin material), the width of the tow material 22 (i.e., the depth across the shearing mechanism 5 perpendicular to the longitudinal axis of the tow material 22), the distance between the compression shoe 51 and the gripping shoe 53, and / or similar factors.

[0223] Additional force P m In some embodiments, can be adjusted by the tension control system 7 to provide a predetermined tension profile of the tow material 22. This tension profile may depend on parameters such as the tow material 22, the moving speed of the head relative to the mold 3, the shearing angle, or other characteristics of the tow material 22 or the laying process.

[0224] Referring to FIG. 9, the tension control system 7 can be configured to use a predetermined tension (i.e., the desired tension) of the tow material 22 in the shearing mechanism 5 and the shearing angle, both of which can be examples of the operating parameters discussed herein.

[0225] The predetermined tension of the tow material 22 in the cutting mechanism 5 can be in the range of tension from the minimum tension discussed herein to a maximum tension that can be below the tension required to maintain a non-slip state. Although it is ideal for there to be no slippage of the tow material 22 across the gripping shoe 53, as will be understood, in certain applications (e.g., applications where resulting defects may be tolerated), it may be acceptable to allow some slippage. In some applications, non-slippage is important, and as such, the maximum tension can be lower than the theoretical tension where a safety margin (which can be 1% or more of the theoretical tension, 5% or more of the theoretical tension, 10% or more of the theoretical tension, or 20% or more of the theoretical tension) is required to maintain a non-slip state.

[0226] To determine the maximum tension (whether it be the predetermined tension itself or as used in setting the predetermined tension, which can be a range), it may be necessary to determine one or more characteristics of the operation of the tow laying head 1 and / or the tow laying system 100.

[0227] For example, it may be necessary to determine one or more components of the maximum lateral frictional force T t,max , and / or the device resistance force T l .

[0228] For example, the characteristic or each characteristic can be determined through experiments, such as using the tow laying head 1 and / or the system 100 to lay the tow material 22 and then inspecting the laid tow material 22 for defects. In some embodiments, the maximum lateral frictional force T t,max can be determined through the provision of one or more tape end detectors.

[0229] The tape end detector or each tape end detector (there may be two tape end detectors) can be positioned relative to the gripping shoe 53 (and / or the compression shoe 51 and / or the ear guide roller 52), for example, to detect the collision between the detector(s) and the ear material at the point where the ear material 22 enters or exits the gripping area, or, alternatively (e.g., after the backing material 21 is removed from the tape material 22), to detect the backing material 21.

[0230] Accordingly, the tape end detector is arranged at or towards one end of the gripping shoe 53 (or other component) and is configured to detect the slippage of the ear material 22, such that the ear material 22 collides with the detector. A pair of tape end detectors can be arranged, for example, at or towards opposite ends of the gripping shoe 53 (or other component).

[0231] In some embodiments, in terms of the characteristics or each characteristic (and thus the maximum tension), some embodiments may include a test device including an anchor 501 and a load cell 502 (see FIG. 17). The ear material 22 can be connected to the anchor 501 and can pass through the load cell 502 between the anchor 501 and the compression mechanism 5. This can be used to determine the tape tension (i.e., the tension of the ear material 22) for various different operating conditions (e.g., different moving speeds of the compression mechanism 5 relative to the anchor 501). In other embodiments, the test device may include a motor-driven creel instead of the anchor 501, in which case the movement of the compression mechanism 5 relative to the creel is not required since the creel can be rotated to apply tension to the ear material 22.

[0232] Accordingly, during the use of the system 100 and / or the head 1, slippage can be detected, which can be used to confirm the lateral frictional force at which the slippage occurs, and thus the maximum lateral frictional force T t,max This can be used, for example, to enable the maximum lateral frictional force T t,max to be modeled in relation to the operating parameters of the system 100 and / or the head 1 (such as the speed of the head relative to the mold 3).

[0233] One or more of these characteristics can be received as an input to the tension control system 7 (e.g., to a controller 73 (e.g., to a processor or each processor 73a via an input / output interface 73d)), and can be manually input from a user interface device 8 that can be communicatively connected to the tension control system 7 (e.g., via a wired or wireless communication link).

[0234] The characteristic or each characteristic can be stored in a computer-readable medium 73c, for example, for later retrieval and use by the processor(s) 73a.

[0235] Similarly, to determine a predetermined tension (e.g., a minimum tension of a range or the predetermined tension itself), the tension control system 7 (e.g., a controller 73 (e.g., a processor or each processor 73a via an input / output interface 73d)) may need to receive one or more characteristics of the tow material 22, such as its shear stiffness. One or more of these characteristics can enable the control system 7 (e.g., a controller 73 using a processor or each processor 73a) to determine a predetermined tension, or can be the predetermined tension itself (which can be, for example, a minimum tension of a range).

[0236] Again, one or more of these characteristics can be manually input via the user interface device 8 and can be stored in a computer-readable medium 73c, for example, for later retrieval and use by the processor 73a.

[0237] For example, each of these characteristics or these characteristics can be determined through experimentation, such as by laying the tow material 22 using the tow laying head 1 and / or the system 100 and then inspecting the laid tow material 22 for defects. Other options include the use of test rigs and / or models generated from experimental results.

[0238] Furthermore, some versions of the system 100 or the tension control system 7 may include a backing material recovery unit 6 driven at a fixed torque, or a backing material recovery unit 6 coupled to the creel 62 via a clutch mechanism (not shown), which may be a friction clutch. In such cases, the resistance force and driving force of the backing material recovery unit 6 can be experimentally measured to calibrate the system 100.

[0239] These and other such systems 100, 7 may include one or more sensors (e.g., ultrasonic and / or contact sensors) that can detect changes in the diameter of the creel (when material is being released or recovered) and adjust the operation of the systems 100, 7, thus achieving the required tension of the tow material 22.

[0240] The shear angle used as an input to the tension control system 7 can be a constant shear angle for a particular operation of the tow laying head 1, or it can be changed during the operation of the tow laying head 1. Thus, this shear angle can be the maximum shear angle required for a particular operation of the tow laying head 1, or it can be changed substantially in real time during the operation of the tow laying head 1.

[0241] These inputs can be received by the controller 73 of the tension control system 7 and passed to the processor(s) 73a. Thus, it will be understood that the operation of the controller 73 is due to the operation of the processor(s) 73a, and their operation can be the result of the execution of instructions stored in the computer-readable medium 73c.

[0242] The controller 73 can also be configured to receive the first and second load sensor signals, as described. These can be used, for example, as feedback to the controller 73.

[0243] Using one or more of these inputs, the controller 73 can be configured to generate the first and second motor control signals and the brake signal to control the tension of the tow material 22 in the shearing mechanism 5, as described.

[0244] In the cutting mechanism 5, the actual tension of the tow material 22 cannot be directly measured because the measurement would interfere with the cutting operation. However, the tension can be estimated or determined using Equation 9 below.

[0245]

Equation

[0246] In particular, the device resistance T l can be known (for example, as an experimentally determined characteristic of the tape laying head 1 and as a result of the tension of the tow material 22 upstream of the cutting mechanism 5 determined using (for example) the first load sensor 71). The device resistance can be stored in a look-up table, and different resistances can exist for different respective operating parameters of the system 100 and / or the head 1 (for example, for different speeds of movement of the head relative to the mold). Instead of a look-up table, the device resistance can be determined using a model of the resistance under different operating parameters. Similarly, the cutting angle (θ) can be a parameter provided to the controller 73 as described. The additional force P m is the force provided by the operation of the tension control system 7 and can be represented by the tension of the backing material downstream of the cutting mechanism 5.

[0247] The tension of the tow material 22 between the cutting boundaries can be represented by the driving force P Accordingly, the controller 73 can be configured to control the first and / or second motor control signals and / or the brake signal to adjust (i.e., change) the tension of the tow material 22 between the cutting boundaries. The controller 73 can monitor this tension in the tow material 22 (i.e., by monitoring the driving force P). The control of the first and / or second motor control signals and / or the brake signal is based on the device resistance T l and / or the additional force P mcan be adjusted (i.e., changed), and thus, the tension of the tow material 22 between the shear boundaries can be adjusted. This adjustment can be an active adjustment during the operation of the tape laying head 1.

[0248] The effect of the adjustment can be determined by the use of the first and second load sensor signals, which provide feedback in relation to the device resistance force T l , and / or the additional force P m . This feedback can be used as an indirect measurement of the tension of the tow material 22 between the shear boundaries (represented by the driving force P), and thus, it can be monitored.

[0249] This feedback can cause further variations in the first and / or second motor control signals, and / or the brake signal by the controller 73. In some embodiments, the controller 73 can be configured to make such variations with respect to the first and / or second motor control signals based on the second load sensor signal.

[0250] In some embodiments, the controller 73 can be configured to make such variations with respect to the brake signal based on the first load sensor signal. In some embodiments, the controller 73 is configured to make such variations at least partially based on the diameters of the backing material recovery section 6 and / or the tape supply section 4 (and / or the associated reels 42 / 62).

[0251] As already described, the tension control system 7 can be used with the tape 2 that does not include the backing material 21 in some embodiments (in other words, the tape laying system 100 may not include the backing material recovery section 6). In such embodiments, the tow material 22 can be attached to the surface of the mold, for example, by using an adhesive material.

[0252] Tension region isolation According to some embodiments, the tensions of the tow material 22 and the backing material 21 can be isolated and substantially independently controlled in different regions within the tow laying head 1.

[0253] In particular, these regions can include a first region from the tape supply unit 4 to the shearing mechanism 5 (in particular, up to the gripping region), a second region within the shearing mechanism 5 (in particular, between the shearing boundaries), and a third region between the shearing mechanism 5 and the backing material recovery unit 6 (in particular, from the compression shoe 51). This can be achieved, for example, in relation to the first region, by applying an appropriate force to the tow material 22 by the tow guide roller 52 and the gripping shoe 53 to effect isolation.

[0254] Thus, in some embodiments, the tension of the tow material 22 and the tension of the backing material 21 can be controlled substantially independently of the tension of the tow material 22 between the shearing boundaries. In other words, the tension of the tow material 22 in the second region can be controlled substantially independently of the tension of the tow material 22 or the backing material 21 in the first and third regions.

[0255] This can, for example, allow for higher acceleration and deceleration of the movement of the compression shoe 51 relative to the mold 3 that does not substantially affect the laying operation (i.e., without excessive tension in the second region).

[0256] Thus, some embodiments can include pressing the gripping shoe 53 against the tow guide roller 52 with a force sufficient to separate the tension in the second region from the tension in the first region and / or the third region. Thereby, the tension in the first region and / or the third region can be increased and higher acceleration and / or deceleration can be achieved without substantially affecting the shearing operation.

[0257] Web mechanism As described herein, the tow material 22 may include a binder material or a resin material, which tends to make the tow material sticky and thus prone to adhering to the compression shoe 51. This may mean that, in turn, the material of the compression shoe 51 needs to be such that the risk of this unintended adhesion is reduced. Further, during the laying and shearing of the tow material 22, the thickness of the material 22 increases and its width decreases, which subjects the tow material 22 to a lateral compressive stress (by the shear deformation of the tow material 22). This can cause buckling or the occurrence of such defects (e.g., wrinkles).

[0258] Accordingly, some embodiments may include a web mechanism 200. The web mechanism 200 is configured to apply a web 201 of material to one side of the tow material 22 that contacts the compression shoe 51. This application can be performed by the web mechanism 200 before the tow material reaches the compression shoe 51 and / or the tow guide roller 52 and / or the gripping shoe 53.

[0259] The web 201 can increase the lateral buckling resistance of the tow material 22 and / or provide a surface that contacts the compression shoe 51 and is unlikely to adhere to the compression shoe 51 (the web 201 may not include a binder material).

[0260] The web mechanism 200 is shown, for example, in FIG. 12. As can be understood, FIG. 12 is a variant of the embodiment described with reference to FIG. 3 and will not be described again for the sake of brevity (further, for the sake of simplification, many of the reference numerals are omitted from FIG. 12). Accordingly, reference should be made to FIG. 3 and the relevant parts of the description.

[0261] The web mechanism 200 may include a web material supply section 202 and a web material recovery section 203. The web material supply section 202 may be associated with a brake 202a configured to brake the release of the web 201 from the supply section 202. The web material supply section 202 may be, for example, in the form of a creel around which a supply body of the web 201 is wound. The web material supply section 202 may generally be arranged upstream (with respect to the movement of the tow material 22) of the shearing mechanism 5. The web material supply section 202 may generally be arranged behind the shearing mechanism 5 with respect to the advancing direction of the web material towards the mold 3.

[0262] The web material recovery section 203 may be associated with a motor 203a configured to draw the web 201 from the supply section 202. The web material recovery section 203 may be, for example, in the form of a creel around which the used web 201 is wound. The web material recovery section 203 may generally be arranged in front of the shearing mechanism 5 with respect to the advancing direction of the web material towards the mold 3.

[0263] The web 201 may travel from the web material supply section 202 (along the relevant path) and contact the tow material 22 prior to its tow material 22 entering the gripping region (for example, the path between the tow guide roller 52 and the gripping shoe 53). The web 201 may be pressed against the tow material 22 by the action of the tow guide roller 52 and the gripping shoe 53. The web 201 may be positioned such that it is between the tow material 22 and the tow guide roller 52.

[0264] The path of the web 201 can pass through the compression shoe 51 following the path of the ear material 22. After the ear material 22 is laid in the mold 3 by the compression shoe 51, the web 201 can be removed from the ear material 22 and advanced to the web material recovery section 203. This can be achieved by positioning the web material recovery section 203 relative to the compression shoe 51 such that the web 201 is lifted from the ear material 22 when the ear material 22 (and the web 201) leaves the compression shoe 51. As such, the web material recovery section 203 can be disposed further away from the mold 3 than the compression shoe 51 is from the mold 3.

[0265] The operation of the brake 202a and the motor 203a of the web mechanism 200 can be controlled by the controller 73 (alternatively, a separate controller can be provided).

[0266] As understood, the web 201 is positioned between the ear material 22 and the compression shoe 51. As such, there is a reduced risk of unintended adhesion of the ear material 22 to the compression shoe 51. Further, the web 201 provides structural support to the ear material 22. This can be particularly useful in relation to delicate (e.g., thin) ear material 22.

[0267] The ideal properties of the web 201 are - having a low shear stiffness and exhibiting good shear quality (i.e., having few or substantially no wrinkles or other defects during shearing), - exhibiting high lateral compression buckling resistance (e.g., by having fibers or reinforcing members in a direction perpendicular to the path of the ear material 22) (e.g., the lateral compression buckling resistance can be the same as or higher than that of the ear material 22), - adhering to the ear material 22 and being releasably bonded as necessary, - having an upper surface with a low coefficient of friction, and - exhibiting a shear locking limit higher than that of the ear material 22, or the maximum shear angle of the path (whichever is the highest).

[0268] The shear locking limit can be defined as the shear angle at which the fibers can no longer be repositioned during deformation (i.e., the fibers are locked). Thus, further shear deformation (increasing the shear angle further) will lead to the formation of defects such as wrinkles. Intra-tooth shear is not possible beyond the locking limit (i.e., the fibers cannot slip / reposition).

[0269] Web 201 can be a peel tape. Web 201 can be a woven material and can be formed from low-friction fibers. Web 201 can be formed, for example, from polytetrafluoroethylene (PTFE) (such as Teflon®). Web 201 can have longitudinal and transverse fibers that can be substantially perpendicular to each other.

[0270] Web 201 can include an adhesive on one of its surfaces, and that side can be the side that contacts the tooth material 22 during use.

[0271] Compression roller Embodiments herein are described generally with reference to the compression shoe 51. However, in some embodiments, reference is made to the compression roller 300. In this regard, refer to FIGS. 13 - 15. In some embodiments, the compression roller 300 replaces the compression shoe 51 and the tooth guide roller 52 may not be present. Instead, the gripping shoe 53 can engage the compression roller 300, or in other words, the compression roller 300 can perform the roles of both the compression shoe 51 and the tooth guide roller 52. Such embodiments can be implemented by other embodiments described herein, for example, controlling the tension in the tooth material 22 and / or in the isolation of the tension regions as described.

[0272] As can be seen in FIGS. 13 and 14, in particular, the radius of the cross-section through the compression roller 300 can be greater than the distance between the contact point of the gripping shoe 53 (e.g., at its distal end) and the compression roller 300. This contact point can be below the midpoint of the compression roller 300 (the midpoint can be the central axis passing through it, which can be the axis of rotation of the compression roller 300). The compression roller 300 is configured to rotate about an axis generally perpendicular to the path of the ear material 22. The compression roller 300 can be configured to contact the mold 3 and press the ear material 22 against the mold 3.

[0273] As will be appreciated, in such embodiments, shearing of the ear material 22 can occur between the contact point of the gripping shoe 53 and the compression roller 300 and the contact point between the compression roller 300 and the mold 3 (such points are, of course, lines in some embodiments).

[0274] According to some embodiments, the radius of the cross-section through the compression roller 300 can be reduced to provide a minimum shear gap (i.e., the distance between two shear boundaries). This minimizes the effective length of contact between adjacent fibers (referring to the portion of the ear material 22 being sheared), thereby promoting in-ear shearing, reducing the associated friction, and allowing fiber slippage or repositioning.

[0275] As described herein, the compression roller 300 can be configured to rotate with respect to the gripping shoe 53 and the mold 3. This rotation can be driven by the movement of the compression roller 300 on the mold 3 and / or directly driven by a motor. However, in some embodiments, the compression roller 300 is fixed against rotation with respect to the gripping shoe 53 and the mold 3, in which case the compression roller 300 can slide on the mold 3.

[0276] The compression roller 300 can be formed of (or coated with), for example, PTFE. The compression roller 300 can be formed of a relatively low friction material. The compression roller 300 can have a substantially rigid outer surface and can also have a relatively soft outer surface. In some embodiments, the compression roller 300 can be formed of a silicone roller having a PTFE sleeve. In some embodiments, the compression roller 300 is soft enough to deform to conform to surface variations of the mold 3, thereby enabling the compression roller 300 to conform to a non-flat and non-uniform surface.

[0277] Advantages of such embodiments can include applying a membrane stress to the portion of the tow material 22 that is being sheared, which counteracts the transverse compressive stress that the tow material can experience due to shearing of the tow material (when the tow material is pulled around the surface of the compression roller 300 during shearing). The stress depends on the radius of the compression roller 300 (a smaller radius leads to higher stress), the shear gap (i.e., the distance between the shear boundaries), and the tow material tension.

[0278] The absence or reduction of out-of-plane shear stress (e.g., the stress imposed on the tow material 22 due to minimization of the sliding motion of the compression roller 300 as compared to embodiments of the compression shoe 51) can reduce the risk of defects due to fiber separation (especially in sticky tow materials). The compression roller 300 may only need to slide to generate the lateral movement required to enable shearing (i.e., movement parallel to the axis of rotation of the compression roller 300). The compression roller 300 can rotate about its axis of rotation in some embodiments (i.e., different from embodiments of the compression shoe 51).

[0279] In some embodiments (see FIG. 15), the compression roller 300 may be flexible along its length such that the compression roller 300 can form a curve. The gripping shoe 53 may similarly be correspondingly flexible along its length such that it can form a curve. In this case, an elastic biasing member may be provided along the length of the flexible gripping shoe 53 to maintain contact with the compression roller 300, and each elastic biasing member may include a spring-loaded piston. This may, for example, enable laying the tow material on the single, or double-curved mold 3. In other words, such embodiments enable use in connection with more complex molds 3.

[0280] These embodiments may be used with or without the web mechanism 200.

[0281] Furthermore, although the gripping shoe 53 is described, these embodiments may use a gripping roller.

[0282] Slip compensation mechanism Some embodiments may include a slip compensation mechanism 400 (see FIG. 16). The slip compensation mechanism 400 may be configured to provide some compensation for lateral slip of the tow material 22 relative to the gripping shoe 53, and may be used in embodiments having either the compression shoe 51 or the compression roller 300 (with or without the web mechanism 200), and may be implemented in combination with other described embodiments such as, for example, tension control and / or tension zone isolation techniques. In fact, in some embodiments, the slip compensation mechanism 400 may be applied to other tow material laying devices, including those taught in Patent Document 6.

[0283] The slip compensation mechanism 400 may be configured to receive a signal indicative of slip of the tow material 22 relative to the gripping shoe 53, and in particular, may receive a signal indicative of slip greater than a threshold distance. This slip will be, as understood, lateral slip along the gripping shoe 53.

[0284] In some embodiments, the slip compensation mechanism 400 includes a sensor 401 that senses the slip of the ear material 22 and generates a signal. However, in some embodiments, the sensor 401 is provided remotely. Two possible sensor positions are schematically shown in FIG. 16.

[0285] The sensor 401 can be a tape or web edge sensor.

[0286] The sensor 401 can include an optical sensor. The optical sensor can be configured to sense, for example, the interruption of light (e.g., infrared light) from a light source (which can be part of the sensor) by the ear material 22. Thus, the sensor 401 can be disposed upstream of the gripping shoe 53 with respect to the direction of travel of the ear material 22 and offset to one side of the normal path of the ear material 22. When the ear material 22 triggers the sensor 401, this can indicate the slip of the ear material 22 depending on the position of the sensor 401. Similarly, the sensor 401 can be configured to sense the lateral movement of the backing material 21 downstream of the gripping shoe 53 in a similar manner but in place of the ear material 22. Of course, when sensing the lateral movement of the ear material 22, this can be the combined ear material 22 and backing material 21 in some embodiments.

[0287] The sensor 401 can include sub-sensors for detecting lateral slip in the first and second directions (each sub-sensor being configured to detect slip in one of the two directions).

[0288] The sensor 401 can take several different forms, and another possible type of optical sensor is a camera that can capture and analyze an image of the ear material 22. Non-optical sensors can be used, and these can include, for example, ultrasonic sensors.

[0289] The slip compensation mechanism 400 may be configured to move the shearing mechanism 5 (and, in particular, the shearing boundary) in a lateral direction with respect to the tape supply unit 4 and / or the backing material recovery unit 6, and correct the detected slip (detected using the signal from the sensor 401). Therefore, the slip compensation mechanism 400 may be configured to move the shearing mechanism 5 (in particular, the shearing boundary) in a direction perpendicular to the advancing direction of the compression shoe 51 (or the compression roller 300) with respect to the mold 3. The tape supply unit 4 and / or the backing material recovery unit 6 may be referred to as, for example, a creel unit 600 (see FIG. 18). The creel unit 600 may include first and second load sensors 71, 72. Therefore, the slip compensation mechanism 400 may be configured to move the shearing mechanism 5 with respect to the creel unit 600.

[0290] The shearing boundary generated by the pressing of the compression shoe 51 or the compression roller 300 (depending on the case) may be referred to as the first shearing boundary. The first shearing boundary may slide laterally on the surface of the laid tow material 22. The tow material 22 may be considered to be fixed (with respect to the mold) at this position when the tow material 22 is attached to the surface of the mold 3. Therefore, by displacing the shearing mechanism 51, the tow material 22 can be moved at the second shearing boundary (i.e., the boundary generated (depending on the case) by the pressing of the gripping shoe 53 and the tow guide roller 52, or the pressing of the gripping shoe 53 against the compression roller 300). However, in some embodiments, only the second shearing boundary is moved.

[0291] The shearing boundary (the first shearing boundary), which is generated by the pressing of the compression shoe or the compression roller (depending on which shearing mechanism is used), may slide laterally on the surface of the tape material. The tape material is also considered to be fixed at this position when the tape is attached to the surface of the mold. Thus, in fact, by displacing the shearing mechanism, the tape is moved at the shearing boundary (the second shearing boundary), which is generated by the pressing of the gripping shoe against the tow guide roller or the pressing of the gripping shoe against the compression roller (depending on which shearing mechanism is used) and is the starting point of the misalignment.

[0292] In another example of the mechanism, only the second shear boundary can be actuated. However, this creates some complexity in terms of packaging all the necessary components within the tape laying system.

[0293] The slip compensation mechanism 400 may include one or more rails 402 to which the shearing mechanism 5 is attached for movement therealong. The rail or each rail 402 may be carried by a mounting device of the head 1 or another part of the system 100 (e.g., one or more members, not shown, that receive the rail or each rail 402), and the rail or each rail 402 may be movable relative to the mounting device during its lateral movement as described above. Thus, the shearing mechanism 5 may be movable relative to the mounting device (i.e., relative to the head 1 or another part of the system 100). The movement of the shearing mechanism 5 relative to the mounting device can be driven in several different ways. For example, the slip compensation mechanism 400 may include a belt or chain drive, a pneumatic or hydraulic ram, or a rack and pinion drive to drive the lateral movement of the shearing mechanism 5. In some embodiments, the rail or each rail 402 is part of the head 1 or the system 100, and the mounting device is attached to the shearing mechanism 5.

[0294] In some embodiments, the slip occurs in the gripping area, and thus the movement of the shearing mechanism 5 relative to the tape supply section 4 and / or the backing material recovery section 6 can be used to correct this slip. In some embodiments, the tow material does not contact any other part of the shearing mechanism 5 before reaching the gripping area.

[0295] This is shown, for example, in FIGS. 19 - 21. In FIG. 19, the shearing mechanism 5 is in the home position (e.g., the tow material 22 is positioned substantially centrally along the compression shoe 51). FIG. 20 shows the same device, but with slip occurring, and the original tow material is shown in dashed lines for reference. FIG. 21 shows the shearing mechanism 5 at one extreme of its position relative to, for example, the creel unit 600.

[0296] The lateral movement that can be achieved in this way can be restricted (e.g., by the length of the rail or each rail 402 or the driving device). Therefore, during operation, it is necessary to reset (or "home") the position of the shearing mechanism 5 relative to the tape supply unit 4 and / or the backing material recovery unit 6 (in the reset operation). This can be achieved, for example, by releasing the gripping area (i.e., by releasing the thread guide roller 52 and / or the gripping shoe 53 from each other) while the compression shoe 51 (or the compression roller 300) is not in contact with the mold 3. The shearing mechanism 5 can then be moved before the gripping area is re-engaged. The tension of the backing material 21 can be increased again after this is completed but before the laying (or resumption) of the thread material 22 is started.

[0297] In some embodiments, the slip compensation mechanism 400 includes one or more boundary members (not shown). The boundary member or each boundary member is configured to suppress or substantially prevent the lateral movement of the thread material during the reset operation. The boundary member or each boundary member can be positioned such that the thread material 22 will abut against the boundary member and prevent the lateral movement (or further movement) of the thread material 22. The boundary member or each boundary member can be part of a guiding member through which or over which the thread material 22 passes (e.g., before reaching the gripping area). The guiding member can include a pair of upright boundary members arranged such that one of the pair is on either side of the thread material 22. The guiding member can include a plate through which the thread material 22 can pass above and from which the boundary member extends.

[0298] In some embodiments, the slip compensation mechanism 400 may be configured to identify an operation that has caused slippage. These may be parameters of the operation of the system 100 and / or the head 1 (such as the moving speed of the compression shoe 51 or the compression roller 300 relative to the mold 3), for example. The slip compensation mechanism 400 may be configured to feedback these to the controller 73, and the controller 73 may adjust the operation of the system 100 and / or the head 1 to reduce the risk of slippage, for example, by avoiding one or more of their operations or compensating for them. This may include slowing down the movement of the release of the tow material 22 from the tape supply unit 4 or adjusting the tension of the tow material 22.

[0299] The embodiments have been described with reference to the shearing mechanism 5 which is attached to the rail or each rail 402 as a whole and is moved by the slip compensation mechanism 400. However, in some embodiments, only the gripping shoe 53 and the tow guide roller 54 are attached to the rail or each rail 402 and are moved by the slip compensation mechanism 400 (such movement is relative to the compression shoe 51, for example). In some embodiments, the gripping shoe 53 and the two guide rollers 54 may be combined (without the compression shoe 51) and referred to as a pinch assembly.

[0300] Laying operation As will be appreciated, the embodiments include a method of laying the tow material 22 in the mold 3 in which the shearing of the tow material 22 is used to steer the tow material 22 being laid. During the laying operation, the tension control system 7 acts to adjust the tension of the tow material 22 in the shearing mechanism 5 as described.

[0301] Others The operation of the tension control system 7 and / or the web mechanism 200 and / or the slip compensation mechanism 400 can be controlled by the controller 73, which can execute instructions (instructions stored in the computer-readable medium 73c) using a processor or each processor 73a. Accordingly, embodiments can include instructions that can form a computer program. Embodiments also include a computer-readable medium storing these instructions.

[0302] Reference to the tension of the tow material 22 in the shearing mechanism 5 is a reference to the tension of the tow material 22 between the shearing boundaries. In the illustrated embodiment, these are defined by the compression shoe 51 (e.g., its leading edge), and the gripping shoe 53 (e.g., its most distal end), but other forms of the shearing mechanism 5 are possible, which can result in shearing boundaries defined by different physical characteristics of the tow laying head 1. It should be understood that the same control techniques described herein can be applied to a wide variety of tow laying heads 1 having different forms of steering mechanisms (the shearing mechanism 5 is just one example).

[0303] As used herein and in the claims, the terms "comprising" and "including" and their variations mean that the specified features, steps, or integers are included. The terms should not be construed to exclude the presence of other features, steps, or components.

[0304] With respect to the features disclosed in the foregoing description, or in the following claims, or in their specific forms, or in the means expressed for performing the disclosed functions, the accompanying drawings, or the disclosed effects, the appropriate methods or steps for achieving them can be utilized, individually or in any combination of such features, in their various forms, to embody and realize the present invention.

[0305] Although some exemplary embodiments of the present invention have been described, the scope of the appended claims is not intended to be limited to only these embodiments. The claims should be construed literally, intentionally, and / or to include equivalents.

Claims

1. A tape laying head configured to lay a tow material on a mold in the construction of a composite structure, the tape laying head including a shearing mechanism, the shearing mechanism receiving the tow material from a tow supply section and configured to direct the tow material by applying shear deformation to the tow material between a pair of shear boundaries defined by the shearing mechanism, the shearing mechanism further configured to apply a driving force to the tow material, the driving force having a longitudinal component and a lateral component with respect to the tow material during the direction of the tow material, The shearing mechanism includes a compression roller and a gripping shoe or roller, a first shear boundary of the pair of shear boundaries being defined by a contact point between the compression roller and the mold in normal operation, and a second shear boundary of the pair of shear boundaries being defined by a contact point between the compression roller and the gripping shoe or roller, characterized by a tape laying head.

2. The tape laying head according to claim 1, characterized in that the radius of a cross section passing through the compression roller is larger than the distance between the contact point of the gripping shoe or roller and the compression roller.

3. The tape laying head according to claim 2, characterized in that the contact point is below the midpoint of the compression roller.

4. The tape laying head according to any one of claims 1 to 3, characterized in that the compression roller is configured to rotate about an axis substantially perpendicular to the path of the tow material.

5. The tape laying head according to any one of claims 1 to 4, characterized in that the compression roller is configured to rotate with respect to the gripping shoe or roller and the mold.

6. The tape laying head according to claim 5, characterized in that the rotation of the compression roller with respect to the gripping shoe or roller and the mold is driven by one of movement of the compression roller on the mold and direct drive by a motor.

7. A tape laying head according to any one of claims 1 to 4, wherein the compression roller is fixed from rotation with respect to the gripping shoe or roller and the mold.

8. A tape laying head according to any one of claims 1 to 7, wherein the compression roller is formed of a silicone roller having a PTFE sleeve.

9. A tape laying head according to any one of claims 1 to 8, wherein the compression roller is flexible along its length such that the compression roller forms a curve.

10. A tape laying head according to claim 9, wherein the gripping shoe or roller is correspondingly flexible along its length so as to form a curve.

11. In the tape laying head according to claim 10, an elastic biasing member is provided along the length of the gripping shoe or roller to maintain contact with the compression roller.

12. A tape laying head according to claim 11. Each elastic biasing member includes a piston with a spring.

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