Fiber tow wrap resistant fiber placement head

Abstract

To provide a fiber placement head that prevents wrapping of fiber placement tows.SOLUTION: There is provided a fiber placement head for applying a plurality of composite tape segments on a mold, including one or more powered wheels that are configured to engage and move the composite tape; and one or more elongated fingers that closely conform to or abut an outer surface of the powered wheel(s) such that a portion of the elongated fingers forms at least a portion of a lane path.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] Cross-reference to related patent applications

[0001] This application is an international patent application claiming the benefit of priority from U.S. Provisional Patent Application No. 62 / 949,655, filed December 18, 2019, the entire contents of which are incorporated herein by reference.

[0002] This application relates to fiber placement machines, and more particularly to fiber placement heads that prevent wrapping of fiber placement tows. [Background technology]

[0003] Fiber placement machines are used to create composite workpieces. Composite material in the form of resin-impregnated fibrous mass is mechanically applied to a mold or mandrel in precise locations and lengths to collectively form the composite workpiece. The fiber placement machine moves a fiber placement head over the mold to precisely apply the composite tape to the final shape of the composite workpiece. As the fiber placement head moves, it leaves multiple composite tape segments, also called courses or tows, on the mold. While multiple composite tape strands may be applied simultaneously as part of a course, the fiber placement head can individually control each tow as part of applying the course. Automated application of these composite tape segments to the mold involves the cooperation of a diverse group of machines that hold, move, and ultimately cut the composite tape. For example, a fiber placement head that applies 16 tows of composite tape onto a mold may include a separate lane for each tow, as well as mechanisms for holding and cutting the tape. Summary of the Invention [Problem to be solved by the invention]

[0004] Each individual lane can receive and deliver composite tape to the mold. However, as the composite tape passes through the lane on its way to the mold, the tape, particularly the ends, can move outside the lane, thereby obstructing the tape's passage through the mold. Removing the tape from an undesirable location can involve disassembling at least a portion of the fiber placement machine to remove the tape from where it left the lane and then properly guide the tape through the lane. Disassembly and attention to the fiber placement machine can be time consuming, thereby reducing the efficiency of the machine. [Means for solving the problem]

[0005]

[0005] In one embodiment, a fiber placement head for applying a plurality of composite tape segments to a mold includes one or more motor wheels configured to engage and move the composite tape, and one or more elongated fingers that closely conform to or abut an outer surface of the motor wheels so that a portion of the elongated finger is adjacent to or forms at least a portion of the lane path.

[0006]

[0006] In another embodiment, a fiber placement head for applying multiple composite tape segments to a mold includes a plurality of motor wheels configured to engage with and move the composite tape, a central block positioned between the motor wheels and having a first mounting surface and a second mounting surface, and a plurality of elongated fingers that closely fit or abut the outer surface of the motor wheels and are attached to the central block at the first and second mounting surfaces.

[0007]

[0007] In another embodiment, a fiber placement head for applying multiple composite tape segments to a mold includes one or more motor wheels configured to engage and move the composite tape, a central block positioned between the motor wheels and having at least one mounting surface, and a plurality of elongated fingers that closely fit or abut the outer surface of the motor wheels and are biased to engage the outer surface of the motor wheels. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a perspective view of one embodiment of a fiber placement machine. [Figure 2]

[0009] FIG. 10 is another perspective view of an embodiment of a fiber placement head. [Figure 3]

[0010] FIG. 1 is a perspective view of one embodiment of a portion of a fiber placement head. [Figure 4]

[0011] FIG. 10 is another perspective view of one embodiment of a portion of a fiber placement head. [Figure 5]

[0012] FIG. 10 is another perspective view of one embodiment of a portion of a fiber placement head. [Figure 6]

[0013] FIG. 10 is another perspective view of one embodiment of a portion of a fiber placement head. [Figure 7]

[0014] FIG. 10 is another perspective view of one embodiment of a portion of a fiber placement head. [Figure 8]

[0015] FIG. 10 is another perspective view of one embodiment of a portion of a fiber placement head. [Figure 9]

[0016] FIG. 1 is a cross-sectional view of one embodiment of a portion of a fiber placement head. [Figure 10]

[0017] FIG. 1 is a cross-sectional view of one embodiment of a portion of a fiber placement head. [Figure 11]

[0018] FIG. 10 is another perspective view of one embodiment of a portion of a fiber placement head. [Figure 12]

[0019] FIG. 10 is another perspective view of one embodiment of a portion of a fiber placement head. [Figure 13]

[0020] FIG. 10 is another perspective view of one embodiment of a portion of a fiber placement head. [Figure 14]

[0021] FIG. 1 is an exploded view of one embodiment of a portion of a fiber placement head. [Figure 15]

[0022] FIG. 1 is a profile view of one embodiment of a portion of a fiber placement head. [Figure 16]

[0023] FIG. 10 is a profile view of another embodiment of a portion of a fiber placement head. [Figure 17]

[0024] FIG. 10 is a profile view of another embodiment of a portion of a fiber placement head. [Figure 18]

[0025] FIG. 10 is a profile view of another embodiment of a portion of a fiber placement head. [Figure 19]

[0026] FIG. 10 is a profile view of another embodiment of a portion of a fiber placement head. DETAILED DESCRIPTION OF THE INVENTION

[0009]

[0027] A fiber placement machine may use a robotic arm carrying a fiber placement head with a modular cut, clamp, and restart (CCR) assembly. The CCR assembly may include multiple cut lane modules, clamp lane modules, and restart lane modules, each of which may be removably coupled to the fiber placement head. Each lane module may be designed to process one or more strands of composite tape passing through it. Additionally, any one or more of the modules may be removed from the fiber placement head without affecting the performance of other lane modules still attached to the head. For example, a fiber placement head that applies 16 lanes of fiber tape may include lane modules that individually control two lanes of fiber tape. In such an embodiment, the CCR assembly may include 24 lane modules (eight cut lane modules, eight clamp lane modules, and eight restart lane modules, each controlling two lanes of fiber). At least one of the lane modules may include one or more elongated arms attached to the CCR assembly or lane module and extending adjacent to a restart roller within the lane. In that sense, the CCR assembly may include multiple elongated arms, each corresponding to a lane. The outer surfaces of the elongated arms may closely conform to or abut the restart roller, and the distal ends of the arms may form a portion of the lane adjacent the roller. In some implementations, the elongated arms may include a resilient or biasing element that biases the arms into proximity or engagement with the restart roller.

[0010]

[0028] The lane module can be further modified by including removable sub-modules. For example, a cutting lane module may include a cutting subassembly that is removably attached to the module. Composite tape used to create composite workpieces is often composed of a fibrous material impregnated with resin, which provides strength to the composite workpiece after being heat-activated. One example of a composite material is carbon fiber, which is often referred to as a "prepreg" composite. The resin contained in the composite tape is quite sticky and can adhere to machinery it comes into contact with. As the composite tape continues to pass through the cutting lane module, more and more resin carried by the tape is left behind, which can clog the cutting machinery within the subassembly. Removal and replacement of the cutting subassembly from the cutting lane module can increase the speed and frequency at which the cutting machinery can be serviced. The cutting subassembly includes a cutting blade and one or more lane paths through which the composite tape passes. The lane paths may be formed in a blade shoe and / or a base, and the cutting blade may be moved reciprocally relative to the blade shoe and / or the base to selectively cut the composite tape. A connecting element may engage or disengage the cutting subassembly and cutting lane module for removal and reattachment after servicing.

[0011]

[0029] One embodiment of a fiber placement machine 10 is shown in FIG. 1. The fiber placement machine 10 includes a robotic arm 12 detachably coupled to a fiber placement head 14. The robotic arm may be supported by a base 16, on which the robotic arm moves linearly about an axis (x). Extending outward from the base 16 may be multiple movable segments 18 that may move, for example, by pivoting, rotating, or extending and retracting. The robotic arm 12 may move about multiple axes relative to the base 16. For example, a first segment 18a may be rotatably coupled to the base 16 at one end such that the robotic arm 12 can rotate about the base 16. A second segment 18b may be pivotally coupled to the first segment 18a, and a third segment 18c may be pivotally coupled to the second segment. A fourth segment 18d may be coupled to the third segment 18c and telescopically move away from and toward the third segment 18c. The segments 18 may be moved relative to one another using a fluidic ram, an electric motor, or a combination thereof, or other drive element to move the distal end of the robot arm 12 relative to a mold 20 or mandrel used to create a workpiece.

[0012]

[0030] A microprocessor (not shown), in communication with a computer-readable storage medium having executable instructions, may control the movement of the fluid ram, electric motor, or other drive elements, thereby controlling the motion and position of the movable segment 18 of the robotic arm 12. The microprocessor may be any type of device capable of processing electronic instructions, including a microcontroller, a host processor, a controller, and an application-specific integrated circuit (ASIC). The microprocessor may be a dedicated processor used solely to control the robotic arm 12, or may be shared with other machine functions. The microprocessor executes various types of digitally recorded instructions, such as software or firmware programs stored in memory. Communication between the microprocessor and mechanisms, such as the fluid ram or electric motor, that move the robotic arm may occur via a communication bus.

[0013]

[0031] The robotic arm 12 can move the fiber placement head 14 along three axes to position the head 14 for servicing or to apply composite tape to the form 20. This is one embodiment of a robotic arm 12 that may be used with a fiber placement head, although other embodiments of a robotic arm or mechanical device that applies composite tape may be used as well.

[0014]

[0032] The end of the robotic arm 12 distal to the base 16 can include a chuck 22 that releasably engages the fiber placement head 14. The chuck 22 and a portion of the fiber placement head 14 can have corresponding features that allow the chuck 22 to releasably grasp the fiber placement head 14. In one embodiment, the fiber placement head 14 includes a cylindrical shank that extends perpendicular to the surface of the head 14. The robotic arm 12 can position the chuck 22 so that the chuck 22 engages the shank and the fiber placement head 14 is resiliently coupled to the arm 12.

[0015]

[0033] As shown in FIGS. 2-4 , the fiber placement head 14 may include a creel frame 24, multiple spools 26 that carry composite tape as a supply of composite tape for the head 14, and a cut-nip-restart (CCR) assembly 32 (shown in more detail in FIGS. 5-9 ). The CCR assembly 32 may include a compression roller 34 (or compression slide) that can receive the composite tape from the spool 26 and apply it to the mold 20 to create a composite part. The creel frame 24 includes multiple outer surfaces 36 and a spindle 38 mounted perpendicular to the outer surfaces 36. The spindle 38 can be moved to generate tape tension using a pneumatically, mechanically, or fluidically controlled dancer element, which helps maintain tension on the composite tape as the tape is applied to the mold 20. The composite tape may be unwound from the spool 26 and moved into the compression roller 34 for final application to the mold 20.

[0016]

[0034] The fiber placement head 14 may include a CCR frame 40 for supporting the components of the fiber placement head 14, the CCR assembly 32, and the compression roller 34, which ultimately presses the composite tape web against the mold 20. Before reaching the compression roller 34, a portion of the composite tape may pass through an upper feed section 42 and another portion of the composite tape may pass through a lower feed section 44. The upper feed section 42 may process the even-numbered composite tapes, and the lower feed section 44 may process the odd-numbered composite tapes that meet at the compression roller 34. As an example, for a fiber placement head 14 having eight fiber paths or lanes, the upper feed section 42 may process the composite tapes identified by the numbers 2, 4, 6, and 8, while the lower feed section 44 may process the composite tapes identified by the numbers 1, 3, 5, and 7. The upper feed section 42 and the lower feed section 44 may be separated by an angle (α). Upper and lower feed rollers 46, 48 may feed the composite tape from the spool 26 to the upper and lower feed sections 42, 44, respectively. A plurality of lane modules 54 may be included in the upper and lower feed sections 42, 44.

[0017]

[0035] Each of the upper and lower feed sections 42, 44 can include a manifold 64 for receiving a plurality of mounting bases 52, which in turn can releasably receive a plurality of lane modules 54. The mounting bases 52 can include valve mounting elements 68 that align the bases 52 with respect to the manifold 64 and releasably couple the plurality of lane modules 54 to the fiber placement head 14. The valve mounting features 68, such as ball locks, help align the fluid passageways 66 from the mounting bases 52 to the manifold 64 and form a fluid-tight seal between the rear air block 53 and the base 52. The base 52 includes a plurality of mounting sites 58 ( FIG. 7 b), where the lane modules 54 ultimately couple to the base 52. The base 52 can be a separate element that couples to the manifold 64, allowing the plurality of solenoid valves 62 and lane modules 54 to be simultaneously removed or installed. In one embodiment, the mounting site 58 may be a female dovetail that receives a corresponding male dovetail included on an element of the lane module 54 or on the rear air block 53. The lane module 54 may slide relative to the mounting base 52 via the dovetail connection during installation or removal of the module 54 from the fiber placement head 14. However, multiple lane modules 54 may be mounted on the mounting base 52. 4 may be ultimately secured to the mounting base 52 using a cross pin 60 that passes transverse to the direction in which the module 54 slides relative to the dovetail and engages a portion of the mounting base 52 to prevent movement of the lane module 54 relative to the mounting base 52.

[0018]

[0036] The electromechanical valve 62 abuts the lane module 54 and may be coupled to the mounting base 52 via the rear air block 53. Each lane module 54 may abut a solenoid valve 62 such that the valve 62 selectively supplies compressed air to the module 54 for operation. The mounting base 52 may be coupled to a manifold 64, with fluid passages 66 routing compressed air from a source (not shown) through the rear air block 53 and the electromechanical valve 62 and ultimately to the lanes 54 and lane modules 54 coupled to the base 52. The assembly of the rear air block 53, solenoid valve 62, and lane module 54 may be removably secured to the mounting base 52 using a cross pin 60. Compressed air may be selectively supplied to the lane modules 54 by the solenoid valve 62, which routes air from the manifold 64 and rear air block 53. In one embodiment, the solenoid valve 62 includes a solenoid that receives a voltage controlled by a switch that a microprocessor opens and closes to control the operation of the lane modules 54.

[0019]

[0037] 10-13, each lane module 54 may include a subassembly 70 that performs the function of the fiber placement head 14 and one or more lane paths 72 through which the composite tape passes. A pneumatic cylinder 74 for each subassembly 70 may control the function of the fiber placement head 14. An element of the subassembly 70 may be coupled to the pneumatic cylinder 74, and compressed air flowing from the manifold 64 into the pneumatic cylinder 74 may have an effect on the composite tape passing through the lane paths. In one embodiment, the fluid passage 66 may route compressed air from the electromechanical valve 62 to a pneumatic piston assembly 80 that includes a piston. The pneumatic piston assembly 80 slides relative to the cylinder 74, thereby performing some action on the composite tape depending on the subassembly 70 attached to the lane module 54.

[0020]

[0038] The cutting lane module 54a may include a cutting subassembly 70a. The cutting subassembly 70a may be removably attached to the cutting lane module 54a and may include a cutting blade 82, an anvil plate 84, a blade shoe 86, and a base 88. The cutting subassembly 70a may include a portion of the lane path 72 through which the composite tape passes. For example, the cutting blade 82 may be biased toward the anvil plate 84 by the blade shoe 86 to create a scissoring cut when the pneumatic piston assembly 80 moves relative to the pneumatic cylinder 74, severing the composite tape as it passes through the lane path 72 of the cutting subassembly 70a. The blade shoe 86 in this embodiment may be spring biased to assist in the scissoring. However, in other embodiments, the anvil plate may not be spring biased, and the cutting blade may be separated from the anvil plate by a small gap. The cutting blade 82 and the anvil plate 84, when positioned in a first position relative to one another, can allow the composite tape to pass through the lane path 72, and the tape can be cut as the cutting blade 82 is moved relative to the anvil plate 84. When in the first position, the openings in the cutting blade 82 and the openings in the anvil plate 84 and base 88 can at least partially define the lane path 72. A fastener 92, such as an elongated member, pin, dowel, or screw, can pass through the opening 90 in the cutting lane module 54a and engage with the cutting subassembly 70a to secure the cutting subassembly 70a to the cutting lane module 54a. The fastener 92 can be removed from the cutting lane module 54a and the cutting subassembly 70a to release the subassembly 70a from the cutting lane module 54a for servicing or replacement. In this embodiment, the fiber placement head 14 includes eight cutting lane modules 54a-on The feed section 42 includes four cutting lane modules 54a and the lower feed section 44 includes four cutting lane modules 54a. However, other embodiments including more or fewer cutting lane modules 54a are possible. Other lane modules 54 include a nip lane module 54b and a restart lane module 54c. The nip lane module 54b and the restart lane module 54c can include multiple lane paths 72 and can include a pneumatic piston 80 for each lane path 72 that can be selectively actuated to slide and hold the composite tape in place. The nip subassembly 70b and the restart subassembly 70c can each include a guide wheel 94 for holding the composite tape while it is being applied to the mold 20.

[0021]

[0039] A restart module 102, shown in more detail in FIGS. 14-15 , may be carried by the CCR assembly 32 so that it can be removed from the CCR assembly 32 as a separate unit. The restart module 102 may include a power wheel 96, which may be positioned on one side of the composite tape opposite a corresponding guide wheel 94. The power wheel 96 may be formed from an elongated shaft including a plurality of raised annular portions 104 that can engage with the fiber or composite tape as it passes through the fiber placement head 14. However, in other embodiments, the power wheel and / or guide wheel may be formed without the raised annular portions and be approximately cylindrically shaped. The power wheel 96 may be axially restrained between a base plate 106 and an end plate 108. One or more fasteners 110 may attach the base plate 106 and the end plate 108 to opposite ends of a center plate 112. The center plate 112 may be elongated and extend across the width of the lane path 72. A plurality of bearings 114, gear spacers 116, shims 118, and gear cover plates 120 may be axially positioned between the base plate 106 and the end plates 108. A handle 71 may be affixed to the base plate 106 and may be used to slide the CCR assembly 32 from the fiber placement head 14 in a direction perpendicular to the travel of the composite tape through the lane path 72. The motive wheels 96 may be driven by electric motors 98 having an output shaft coupled to at least one of the motive wheels 96. In some embodiments, a drive gear 122 may transfer rotational motion from one motive wheel 96 to another motive wheel 96. The motive wheels 96 may be rotated by the electric motors 98 to move the composite tape, or the motive wheels 96 may be held stationary to securely hold the composite tape. The composite tape can be held stationary against sprag (one-way) bearings, a clutched shaft, or a fixed plate.

[0022]

[0040] The central plate 112 may be positioned between a power wheel 96 positioned above the plate 112 that engages with a guide wheel 94 associated with the upper feed section 42 and a power wheel 96 disposed below the plate 112 that engages with a guide wheel 94 associated with the lower feed section 44. A plurality of elongated arms 124 or fingers shaped to prevent undesired fiber wrapping around one of the guide wheels 94 or power wheels 96 may be secured to a first mounting surface 126 of the central plate 112 and extend outwardly away from the plate 112 toward one of the power wheels 96, and another plurality of elongated arms 124 or fingers shaped to prevent undesired fiber wrapping around one of the guide wheels 94 or power wheels 96 may be secured to a second mounting surface 128 and extend outwardly away from the plate 112 toward the other of the power wheels 96. In some embodiments, the elongated arms 124 may be rigidly secured to the fixed surfaces 124, 126 using fasteners 130, such as screws, pins, or bolt / nut combinations. The elongated arms 124, 126 may have an arcuate shape along a section 132 that extends away from the mounting surfaces 126, 128 of the center plate 112. In some implementations, the elongated arms 124 may be separate elements for each lane path 72, while in other implementations, the elongated arms 124 may be rigidly attached to one another so that they are fixed relative to one another. The arcuate shape contours the elongated arms 124 so that they are secured to the motor cars 96. The elongated arms 124 may conform closely to the outer surface 134 of the lane path 72 so as to be in close proximity to or in direct contact with the outer surface 134 of the lane path 72. The elongated arms 124 may also include a flat surface 136 at their distal ends 138. The flat surface 136 may be flush with the lane path 72 to fill or block gaps that may tend to catch the fiber tape as it travels down the lane path 72. In some embodiments, the flat surface 136 may be angled relative to the surface of the lane path 72 so as not to be flush with the lane path 72. The angled relationship of the flat surface to the lane path 72 may be used to guide the direction of the fiber tape as it travels down the lane path 72 and contacts the flat surface 136. The elongated arms 124 may be cast from any one of a number of metal alloys, water-cut from metal bar stock, formed from a plastic that maintains its shape when exposed to temperatures sustained during fiber placement, or created using a three-dimensional printer.

[0023]

[0041] Other embodiments of the restart module are possible. For example, turning to FIG. 16 , the restart module 102b is shown in outline view having multiple elongated arms 124b that are opposably biased to engage the motor wheel 96. The elongated arms 124b may be fixed relative to one another in some embodiments, while in other embodiments, the arms 124b may be independent of one another and rotate about a pivot 140 carried by the gear cover plate 120 to engage the motor wheel 96. In other embodiments, the pivot may be omitted if the elongated arms are sufficiently rigid. Alternatively, in other embodiments, a pivot rod may be carried by the gear cover plate. A resistance block 142 may be affixed to the first mounting surface 126 or the second mounting surface 128 of the center plate 112 to capture a biasing element 144, such as a coil spring, between the elongated arms 124b and the block. The biasing element may maintain the elongated arm in contact with the motor wheel 96 .

[0024]

[0042] 17, another embodiment of a restart module 102c is shown in outline view having multiple elongated arms 124c that are opposably biased to engage the motor car 96. The elongated arms 124c can each move independently of one another, but in other embodiments, they can be fixed relative to one another. The elongated arms 124c can also be rigidly coupled with biasing elements 144c. Each elongated arm 124c can be engaged with its own biasing element 144c, or in other embodiments, a single biasing element 144c can move all of the elongated arms 124c. In this embodiment, the biasing elements 144c can be leaf springs. The leaf spring biasing element 144c urging the elongated finger 124c into engagement with the power wheel 96 closest to the upper feed portion 42 may push the elongated finger 124c into engagement with the power wheel 96 from the mounting surfaces 126, 128 adjacent the outer surface 134 of the power wheel 96 that contacts the elongated finger 124c measured relative to the axis (a) of rotation of the power wheel 96. The leaf spring biasing element 144c urging the elongated finger 124c into engagement with the power wheel 96 closest to the lower feed portion 44 may push or pull the elongated finger 124c into engagement with the power wheel 96 from the support surfaces 126, 128 opposite the outer surface 134 of the power wheel 96 that contacts the elongated finger 124c measured relative to the axis (a) of rotation of the power wheel 96. The biasing element 144c may maintain the elongated arm 124c in contact with the power wheel 96.

[0025]

[0043] 18, yet another embodiment of a restart module 102d is shown in outline view having a plurality of elongated arms 124d that are opposably biased into engagement with the power wheel 96. The elongated arms 124d can move independently of one another and rotate about a pivot 140 carried by the gear cover plate 120 to engage the power wheel 96. However, in other embodiments, the elongated arms 124d can be fixed relative to one another. A link member 146 can be rigidly attached to the elongated arms 124d such that a force applied to a distal end 148 of the link member 146 can force the elongated arms 124d into contact with the power wheel 96. A biasing element 144d, such as a coil spring, can be attached to the center plate 11. 2 and the distal end 148 of the link member 146. The biasing element 144 can maintain the elongated arm 124d in contact with the motor wheel 96.

[0026]

[0044] Turning to FIG. 19 , yet another embodiment of the restart module 102e is shown in outline view having multiple elongated arms 124e that are opposably biased into engagement with the power wheel 96. The elongated arms 124e are fixed relative to one another and can rotate about a pivot 140 carried by the gear cover plate 120 to engage the power wheel 96. However, in other embodiments, the elongated arms 124e can move independently of one another. A link member 146 can be rigidly attached to the elongated arms 124e such that a force applied to a distal end 148 of the link member 146 urges the elongated arms 124e into contact with the power wheel 96. A pneumatic force, such as that applied by compressed gas via a piston, can be transmitted through the center plate 112 to contact the distal end 148 of the link member 146. The pneumatic force can maintain the elongated arms in contact with the power wheel 96.

[0027]

[0045] The guide wheel 94 contacts the side of the composite fiber tape opposite the side contacted by the power wheel 96, thereby crushing the tape between the wheels. The guide wheel 94 can operate in cooperation with the power wheel 96 to move the composite tape through the lane path 72 or to hold the composite tape in place. The power wheel 96 can be driven by an electric motor 98, while the guide wheel 94 can be free to rotate and allow the composite fiber tape to move. Alternatively, to hold the tape in place, the electric motor 98 can hold the power wheel 96 stationary and the pneumatic piston 80 can be actuated to prevent the guide wheel 94 from rotating. The pneumatic piston 80 can move in response to receipt of compressed air to selectively hold the guide wheel 94 stationary, thereby holding the composite fiber tape in place. In this embodiment, the fiber placement head 14 includes eight nip lane modules 54b and eight restart lane modules 54c—four nip lane modules and four restart lane modules on the upper feed section 42, and four nip lane modules 54b and four restart lane modules 54c on the lower feed section 44. In this embodiment, the fiber placement head 14 may include 24 lane modules 54, including the cutting lane module 54a. However, other embodiments including more or fewer lane modules 54 are possible.

[0028]

[0046] The robotic arm 12 can move the fiber placement head 14 relative to the mold 20 to create a composite part. The robotic arm 12, power car 96, cutting lane module 54a, nip lane module 54b, and restart lane module 54c cooperate to apply the composite tape to the mold 20. The restart lane module 54c can move the composite fiber through the lane 72 until it reaches the compaction roller 34. The nip lane module 54b can then be actuated to hold the composite fiber and prevent it from moving within the lane 72. The compaction roller 34 can then be brought into contact with the mold 20 to apply one end of the composite tape to the mold 20. The nip lane module 54b can release the composite fiber, the robotic arm 12 can move the fiber placement head 14 over the mold 20, and the compaction roller 34 can apply the composite tape to the mold 20. Once a predetermined amount of composite tape has been applied to the mold 20, the nip lane module 54b can be actuated to hold the composite tape in place from the spool 26, and the cut lane module 54a can be actuated to cut the desired length of composite tape to be applied to the mold 20. The restart lane module 54c can be engaged and the nip module 54b can be disengaged to allow additional composite tape to be fed to the compression roller 34 so that a new stretch of composite tape can be applied to the mold 20.

[0029]

[0047] What has been described above is a description of one or more embodiments of the present invention. It should be understood that the present invention is not limited to the specific embodiments disclosed herein, but rather is defined solely by the claims that follow. Moreover, the statements contained in the above description relate to specific embodiments and should not be construed as limitations on the scope of the invention or on the definition of terms used in the claims, unless a term or phrase is expressly defined above. Various other embodiments, as well as various changes and modifications to the disclosed embodiments, will be apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to be included within the scope of the appended claims.

[0030]

[0048] In this specification and claims, the terms "eg," "for example," "for instance," "such as," and "like," as well as the verbs "comprising," "having," "including," and other verb forms thereof, when used in conjunction with a list of one or more components or other items, should each be construed as open-ended; that is, the list should not be considered to exclude other additional components or items. Other terms should be construed using their broadest reasonable meaning unless those terms are used in a context requiring a different interpretation. The present invention includes the following aspects. 1. A fiber placement head for applying a plurality of composite tape segments to a mold, comprising: one or more powered cars configured to engage and move the composite tape; one or more elongated fingers that closely conform to or abut an exterior surface of the motor vehicle such that a portion of the elongated finger is adjacent to or forms at least a portion of a lane path; 1. A fiber placement head comprising: 2. The fiber placement head of claim 1, wherein the power wheel and elongated fingers are carried by a restart module that is removable from the fiber placement head. 3. The fiber placement head of claim 1, wherein the elongated fingers include an arcuate shape extending away from the mounting surface. 4. The fiber placement head of claim 1, wherein the elongated fingers include flat surfaces that form at least a portion of the lane path. 5. The fiber placement head of claim 1, further comprising a biasing element that biases the elongated finger into engagement with the motor wheel. 6. The fiber placement head of claim 5, further comprising a resistance block coupled to a central plate and a pivot positioned on an elongated finger, the biasing element being constrained between the resistance block and the elongated finger to rotate the elongated finger about the pivot and engage the power wheel. 7. The fiber placement head of claim 5, wherein the biasing element is a leaf spring or a coil spring. 8. The fiber placement head of claim 5, further comprising a link member rigidly attached to the elongated finger, the biasing element abutting the link member and urging the elongated finger to rotate about a pivot. 9. A fiber placement head for applying a plurality of composite tape segments to a mold, comprising: a plurality of motor cars configured to engage and move the composite tape; a center block positioned between the motor cars, the center block having a first mounting surface and a second mounting surface; a plurality of elongated fingers that closely conform to or abut an exterior surface of the motor vehicle and are attached to the center block at the first and second mounting surfaces; 1. A fiber placement head comprising: 10. The fiber placement head of claim 9, wherein the power wheel and elongated fingers are carried by a restart module that is removable from the fiber placement head. 11. The fiber placement head of claim 9, wherein the elongated fingers include an arcuate shape extending away from the mounting surface. 12. The elongated finger includes a flat surface that forms at least a portion of a lane path. 10. The fiber placement head of claim 9. 13. The fiber placement head of claim 9, further comprising a biasing element that biases the elongated finger into engagement with the motor wheel. 14. The fiber placement head of claim 13, further comprising a resistance block coupled to the central plate and a pivot positioned on the elongated finger, the biasing element being constrained between the resistance block and the elongated finger to rotate the elongated finger about the pivot and engage the power wheel. 15. The fiber placement head of claim 14, wherein the biasing element is a leaf spring or a coil spring. 16. A fiber placement head for applying a plurality of composite tape segments to a mold, comprising: one or more powered cars configured to engage and move the composite tape; a center block positioned between said motor cars, said center block having at least one mounting surface; a plurality of elongated fingers that closely conform to or abut an exterior surface of the motor vehicle and are biased into engagement with the exterior surface of the motor vehicle; 1. A fiber placement head comprising: 17. The fiber placement head of claim 16, wherein the power wheel and elongated fingers are carried by a restart module that is removable from the fiber placement head. 18. The fiber placement head of claim 16, wherein the elongated fingers include an arcuate shape extending away from the mounting surface. 19. The fiber placement head of claim 16, wherein the elongated fingers include flat surfaces that form at least a portion of the lane paths. 20. The fiber placement head of claim 16, wherein the elongated fingers are biased by a leaf spring or a coil spring.

Claims

1. a fiber placement head for applying a plurality of composite tapes to a mold, the fiber placement head comprising: one or more powered cars configured to engage and move the composite tape; one or more elongated fingers extending toward or contoured to abut an exterior surface of the one or more motor cars; a fiber placement head, wherein a portion of the one or more elongated fingers is adjacent to or forms at least a portion of a lane path and is positioned between the one or more motorized cars and a fiber placement head.

2. The fiber placement head of claim 1 , wherein the power wheel and elongated fingers are carried by a restart module that is removable from the fiber placement head.

3. The fiber placement head of claim 1 , wherein the elongated fingers include an arcuate shape extending away from the mounting surface.

4. The fiber placement head of claim 1 , wherein the elongated finger includes a flat surface that forms at least a portion of a lane path.

5. The fiber placement head of claim 1 , further comprising a biasing element that biases the elongated finger into engagement with the motor wheel.

6. 6. The fiber placement head of claim 5, further comprising a resistance block coupled to a center plate and a pivot positioned on an elongated finger, the biasing element being constrained between the resistance block and the elongated finger to rotate the elongated finger about the pivot into engagement with the power wheel.

7. The fiber placement head of claim 5 , further comprising a link member attached to the elongated finger, the biasing element abutting the link member and urging the elongated finger to rotate about a pivot.

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