Tape Laying Head with Tape Tension Control System

Abstract

A tape laying head for applying composite tape onto a mold or mandrel during the formation of a composite workpiece is disclosed. However, the tape laying head is only one component of a larger tape laying machine and assembly. Among its many components, the tape laying head has a tape supply reel, a backing paper take-up reel, and a tape tension control system. The tape tension control system has a first dancer roller assembly located downstream of the tape supply reel and a second dancer roller assembly located upstream of the backing paper take-up reel. The first dancer roller assembly can have a first roller, a first guide, a first actuator, a first locking device, and a first position sensor. The second dancer roller assembly can have a second roller, a second guide, a second actuator, a second locking device, and a second position sensor.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is an International Patent Cooperation Treaty patent application claiming benefit of priority to U.S. Provisional Patent Application No. 62 / 971,052, filed February 6, 2020, the entire contents of which are incorporated herein by reference.

[0002]

[0002] This application relates to tape lamination machines, and more particularly to a tape lamination head mounted within the tape lamination machine for depositing a composite tape onto a mold or mandrel during the formation of a composite workpiece. [Background technology]

[0003]

[0003] Tape laying machines are used in the production of composite workpieces. Tape laying machines are employed in aerospace applications for aerospace parts as well as other applications for other parts. Composite material in the form of resin impregnated fibrous material is applied to a mold or mandrel in precise locations and lengths by the tape laying machine to integrally form the composite workpiece. The tape laying machine moves a tape laying head over the mold to precisely apply the composite tape in the final shape of the composite workpiece. As the tape laying head moves, it leaves a number of composite tape segments, also called courses, on the mold. The automated application of these composite tape segments to the mold involves the cooperation of a diverse collection of machines that hold, move and finally cut the composite tape. Summary of the Invention [Problem to be solved by the invention]

[0004] A conventional tape laying head has, among its many components, a tape supply reel and a backing paper take-up reel. A servo motor may drive the rotation of both the tape supply reel and the backing paper take-up reel. The composite tape leaving the tape supply reel typically travels through the tape laying head over a number of rollers before being deposited onto the underlying mold. Tension and tension in the composite tape on its route through the tape laying head may be maintained in part by the driven tape supply reel and the driven backing paper take-up reel, as well as by tension as a result of the deposition procedure itself. Tension in a conventional tape laying head is generally maintained at an equal level at all times during the deposition procedure, including tension at the beginning of the start of a tape section, at the end of a tape section, and even in between. [Means for solving the problem]

[0005] In one implementation, the tape laying head can have a tape supply reel, a backing paper take-up reel, and a tape tension control system. The tape supply reel is driven to rotational motion by a first servo motor. The backing paper take-up reel is driven to rotational motion by a second servo motor. The tape tension control system can have a first dancer roller assembly and a second dancer roller assembly. The first dancer roller assembly is located downstream of the tape supply reel. The first dancer roller assembly can have a first roller, a first guide, a first actuator, and a first position sensor. The first roller is carried by the first guide and is movable on the first guide by the first actuator. The first position sensor detects the position of the first roller on the first guide. The second dancer roller assembly is located downstream of the backing paper take-up reel. The second dancer roller assembly can have a second roller, a second guide, a second actuator, and a second position sensor. A second roller is carried by the second guide and is movable on the second guide by a second actuator. A second position sensor detects the position of the second roller on the second guide. During the operating mode, a rotational speed of the tape supply reel is adjusted via the first servo motor. The adjustment of the rotational speed is based on the position of the first roller on the first guide detected via the first position sensor.

[0006]

[0006] In another implementation, the tape laying head can have a tape supply reel, a backing paper take-up reel, and a tape tension control system. The tape supply reel is driven to rotational motion by a first servo motor. The backing paper take-up reel is driven to rotational motion by a second servo motor. The tape tension control system can have a first dancer roller assembly and a second dancer roller assembly. The first dancer roller assembly is located downstream of the tape supply reel. The first dancer roller assembly can have a first roller, a first guide, a first actuator, a first locking device, and a first position sensor. The first roller is carried by the first guide and is movable on the first guide by the first actuator. Movement of the first roller on the first guide can be locked by the first locking device. The first position sensor detects the position of the first roller on the first guide. The second dancer roller assembly is located downstream of the backing paper take-up reel. The second dancer roller assembly may have a second roller, a second guide, a second actuator, a second locking device, and a second position sensor. The second roller is carried by the second guide and is movable on the second guide by the second actuator. Movement of the second roller on the second guide may be locked by the second locking device. The second position sensor detects a position of the second roller on the second guide. During an operational mode, the first locking device is set to an unlocked state. The first roller is moved to a first location on the first guide by the first actuator. A tape tension control system controls the first roller to maintain the first location based on the position of the first roller detected on the first guide via the first position sensor. Furthermore, the tape tension control system controls the first roller to maintain the first location by adjusting the rotational speed of the tape supply reel via the first servo motor.

[0007]

[0007] In another implementation, the tape tension control system of the tape laying head can have a dancer roller assembly. The dancer roller assembly is located near the tape laying reel. The dancer roller assembly can have a roller, a guide, a pneumatic cylinder actuator, a locking device, and a position sensor. The guide movably supports the roller. The pneumatic cylinder actuator moves the roller on the guide as commanded. The locking device functions to lock the movement of the roller on the guide. The position sensor detects the position of the roller on the guide. During an operating mode, the locking device is set to an unlocked state. The roller is moved to a predetermined position on the guide by the pneumatic cylinder actuator. The predetermined location of the roller on the guide can be generally maintained based on the position of the roller on the guide detected via the position sensor and by adjusting the rotation speed of the tape laying reel. Furthermore, during an operating mode, the maintained predetermined location of the roller on the guide can follow a rapid increase in tension experienced in the tape web via the pneumatic cylinder actuator and via the movement of the roller on the guide from the maintained predetermined location. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view showing an implementation of a tape lamination machine and assembly. [Diagram 2]

[0009] FIG. 1 is a perspective view showing an implementation of a tape laying head that may be installed within a tape laying machine and assembly. [Diagram 3]

[0010] FIG. 2 is a side view of the tape laying head demonstrating the composite tape path. [Figure 4]

[0011] FIG. 13 is an enlarged view of an area of ​​the tape laying head showing the packing paper path after it has been removed from the composite tape. [Diagram 5]

[0012] FIG. 1 is a perspective view of an embodiment of a tape tension control system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009]

[0013] These figures present an embodiment of a tape laying head 10 mounted within a larger tape laying machine and assembly 12. Unlike conventional tape laying heads, the tape laying head 10 has a tape tension control system 14 that can accommodate and absorb sudden increases in tension in the tape web without substantially subjecting the tape web itself to sudden increases in tension. The tape tension control system 14, in a sense, provides a buffering effect on the tape web. Such sudden increases often occur during rapid accelerations of the tape laying head 10, jerks, and possibly other times during the tape application procedure of the tape laying head 10. The tape tension control system 14 avoids the use of a tape web under increased tension, thereby minimizing or completely eliminating the undesirable occurrence of backing paper breakage, bridging, delamination, and / or other consequences. Thus, the tape tension control system 14 allows the tape laying head 10 to operate at higher speeds and with higher accelerations than previously possible, for example, during the tape cutting function and during advancement and retraction of its compactor. Furthermore, as used herein, the terms downstream and upstream are used with reference to the direction of movement of the composite tape at the tape laying head. Thus, downstream means a direction consistent with the direction of movement and upstream means a direction against the direction of movement.

[0010]

[0014] Referring to FIG. 1, a tape laying machine and assembly 12 is used to prepare composite workpieces by applying composite tape 16 to a mold. The aerospace industry employs machines and assemblies for aerospace workpieces such as long and thin flat parts, nested laminates of multiple parts, draped skins, spars, stringers, beams, flaps, shear ties, ply packs, wing and empennage skins, and many other parts. However, these machines and assemblies are also suitable for use in other industries and other parts. The tape laying machine and assembly 12 can have a variety of layouts, setups, and equipment depending on the particular application and the particular part it is intended to prepare. In the implementation of FIG. 1, the tape laying machine and assembly 12 generally has a gantry 20, a vacuum table 22, and an operator station 24. The tape laying head 10 is coupled to a gantry 20, which provides a certain degree of movement of the tape laying head 10 during application of the composite tape 16. Movement in the X-axis direction is performed via a pair of longitudinal ways (i.e. tracks) 26, which may be achieved, for example, by a rack-and-pinion drive unit. Movement in the Y-axis direction is performed via a cross saddle 28, which may be achieved, for example, by a linear motor and a permanent magnet. Movement in the Z-axis direction is performed via a vertical slide 30, which may be achieved, for example, by a high-precision ball screw actuator with a gearbox and a servomotor. The vertical slide 30 may further provide a rotational movement in the C-axis, which may be achieved, for example, by a servomotor and a gearbox. However, the tape laying head 10 may be implemented by other equipment and its movement may be achieved in other ways. For example, the tape laying head 10 may be mounted on a robot arm that operates its movement in a different way than the way described above.

[0011]

[0015] Continuing to refer to FIG. 1 , a vacuum table 22 holds a mold (not shown) while it receives application of composite tape 16 from tape laying head 10. An operator station 24 can function as a human-to-machine interface (HMI) site, allowing a degree of operator control and management of tape laying machine and assembly 12. Additionally, as shown in FIG. 1 , tape laying machine and assembly 12 can have an auxiliary gantry 32 with trimming capabilities for parts, as well as a secondary tape laying head and a replacement station 34 for replacing the tape laying head at gantry 20 as needed for composite tape supply or for other reasons. Although shown and described with these layouts, setups, and equipment, tape laying machine and assembly 12 can have more, less, and / or different layouts, setups, and / or equipment in other implementations.

[0012]

[0016] The exact nature of the composite tape 16 laid down by the tape laying head 10 will be determined by the particular application and part. In an aerospace example, the composite tape 16 may be in the form of a unidirectional carbon fiber tape impregnated with a thermoset or thermoplastic resin, having a carrier or backing paper 36 on one of the two sides of the composite tape 16. The end-to-end width of the composite tape 16 may vary (again depending on the application and part), and in an aerospace example may be fifty millimeters (50 mm), seventy-five millimeters (75 mm), one hundred fifty millimeters (150 mm), or three hundred millimeters (300 mm). However, other width dimensions are possible. Prior to being loaded into the tape laying head 10, the composite tape 16 is wound on a tape supply spool 38 with an adhesive or sticky side 40 of the composite tape 16 facing radially outward and a backing paper side 42 of the composite tape 16 facing radially inward.

[0013]

[0017] The tape laying head 10 can have a variety of designs, configurations, and components depending on the particular application for which it is intended to be used and the particular parts it is intended to prepare. In the embodiment of Figures 2-5, the tape laying head 10 generally includes a frame 44, a coupler 46, a tape supply reel 48, a set of rollers 50, a cutting device 52, a scrap collection device 54, a backing paper removal assembly 56, a compactor 58, and a tape tension control system 14. However, in other embodiments, the tape laying head 10 can have more, fewer, and / or different components than those described herein.

[0014]

[0018] 2 and 3, a frame 44 serves as the main structure of the tape laying head 10 to which and around which other components are mounted. The frame 44 may form an enclosed housing or may be an open-sided structure as shown. A coupler 46 provides a mating interface for mounting and dismounting the tape laying head 10 to and from the gantry 20. A tape supply reel 48 receives the tape supply spool 38 for loading the tape supply spool 38 and the composite tape 16 wound thereon into the tape laying head 10. The tape supply reel 48 is driven in rotational motion via a first servo motor 60 for removing the composite tape 16 from the tape supply spool 38 and for feeding the composite tape 16 through the tape laying head 10 for downstream use. The first servo motor 60 may be paired with a rotary encoder. Rollers 50 help carry the composite tape 16 from downstream of the tape supply spool 38 and tape supply reel 48. The composite tape 16 generally follows a path via rollers 50 and internally through the tape laying head 10 to an outlet 62 (FIG. 3) for application to an underlying mold layup surface 64. Along the way, the composite tape 16 may be carried and supported by other components separate from the rollers 50. A cutting device 52 cuts off the composite tape 16 during use of the tape laying head 10 to create terminations of composite tape segments as needed for that particular mold and as needed to terminate a composite tape section. A scrap collector 54 collects scrap pieces of the composite tape 16 generated by cutting the composite tape 16. The scrap collector 54 may have a container for containing the scrap pieces.

[0015]

[0019] The path of the composite tape 16 through the tape laying head 10 is generally set by the location of the rollers 50, which path defines a composite tape path 66. The composite tape 16 maintained under tension along the composite tape path 64 constitutes the tape web 68 of the tape laying head 10. The composite tape path 66 is shown generally in FIG. 3 by multiple arrowed lines running parallel to the composite tape 16 along its extent of tension from the tape supply spool 38, over the rollers 50, to the outlet 62. In the embodiment of FIG. 3, the composite tape path 66 routes the composite tape 16 in an opposite manner to that of a conventional tape laying head. This opposite movement causes the backing paper side 42 of the composite tape 16 to face downward, facing the layup surface 64. However, in other embodiments, the composite tape path 66 may take a more conventional path through the tape laying head 10 and need not exhibit the opposite path presented in the figure. Additionally, a tape web sensor or tape web encoder 69 may be provided within the tape laying head 10 for sensing and indicating the position of the tape web 68 as the composite tape 16 takes its path through the tape laying head 10. The tape web encoder 69 may be employed in certain operational modes of the tape laying head 10 and may be in the form of a rotary encoder.

[0016]

[0020] A backing paper removal assembly 56 separates and peels the backing paper 36 from the tape body of the composite tape 16. Referring now to FIG. 4, this separation occurs downstream of the roller 50 and also upstream of the outlet 62 and upstream of the compactor 58. In the embodiment of FIGS. 2-4, the backing paper removal assembly 56 includes a pair of rollers 70 and a backing paper take-up reel 72. The rollers 70 help carry the backing paper 36 as it is separated from the tape body. Downstream of the rollers 70, the backing paper take-up reel 72 deposits the backing paper 36 and winds up the backing paper 36 being fed. The backing paper take-up reel 72 is driven in rotational motion via a second servo motor 74 for the purpose of winding up the peeled backing tape 36. The second servo motor 74 may be paired with a rotary encoder.

[0017]

[0021] Compactor 58 applies a compressive pressure and load to the tape body of composite tape 16 as the tape body is applied to layup surface 64. In this embodiment, with reference to Figures 2 and 3, compactor 58 is in the form of a compaction roller 76. Compaction roller 76 is located at or near outlet 62 such that compaction roller 76 can abut the tape body as it is discharged through outlet 62. In the illustrated embodiment, compaction roller 76 is a single soft polyurethane compaction roller.

[0018]

[0022] Additionally, the tape laying head 10 is provided with an electronic control unit (ECU) 78 ( FIG. 2 ) for performing certain operations and for managing one or more electrical systems and / or one or more electrical subsystems of the tape laying head 10. By way of example, the ECU 78 may issue commands to control the rotational speeds of the first servo motor 60 and the second servo motor 74, and may communicate with sensors of the tape laying head 10, such as a tape web encoder 69, and may further communicate with sensors of the tape tension control system 14. Some of these sensors are mentioned below.

[0019]

[0023] The tape tension control system 14 functions to provide and maintain tension and tension in the tape web 68 as the composite tape 16 moves through the tape laying head 10. The tape tension control system 14 is able to absorb sudden increases in tension that the tape web 68 would be subjected to more directly in the absence of the tape tension control system 14. This sudden increase in tension can result in backing paper breakage, bridging, delamination, and / or other undesirable events. By using the tape tension control system 14, the undesirable events are minimized or eliminated entirely. The tape tension control system 14 can have a variety of designs, configurations, and components in alternative embodiments. In the illustrated embodiment, referring to FIGS. 3-5, the tape tension control system 14 is a two-dancer control system having a first dancer roller assembly 80 and a second dancer roller assembly 82. The first dancer roller assembly 80 is immediately downstream of the tape supply reel 48 and is initially responsible for engaging the composite tape 16 as it leaves the tape supply spool 38, while the second dancer roller assembly 82 is upstream of the backing paper take-up reel 72 and is responsible for engaging the backing paper 36 as it is pulled from the tape body via the backing paper removal assembly 56 and fed to the backing paper take-up reel 72.

[0020]

[0024] Similar to the tape tension control system 14, the first dancer roller assembly 80 and the second dancer roller assembly 82 can have a variety of designs, configurations, and components in alternative embodiments. One embodiment is presented in FIG. 5. FIG. 5 depicts a side view of the tape laying head 10 opposite that depicted in FIG. 3, and in particular shows an enlarged area of ​​the second dancer roller assembly 82. Reference is made to FIG. 5 in the present description of both the first dancer roller assembly 80 and the second dancer roller assembly 82 because they have corresponding components. The first dancer roller assembly 80 has a first roller 84, a first guide 86, a first actuator 88, a first locking device 90, and a first position sensor 92. Similarly, the second dancer roller assembly 82 has a second roller 94, a second guide 96, a second actuator 98, a second locking device 100, and a second position sensor 102. However, in other embodiments, the first dancer roller assembly 80 and the second dancer roller assembly 82 can have more, fewer, and / or different components compared to those described herein, and do not necessarily have to have the same components.

[0021]

[0025] The rollers 84, 94 are carried by guides 86, 96 and can move back and forth across the guides 86, 96 in response to urging by actuators 88, 98. The rollers 84, 94 can rotate freely as the respective composite tapes 16 and backing papers 36 move over the rollers 84, 94 during use of the tape laying head 10. At the rear side of the rollers 84, 94, a carriage 104 helps guide the rollers 84, 94 along the guides 86, 96. Each roller 84, 94 is coupled to its own carriage 104. The carriage 104 can slide along the guides 86, 96 and carries the rollers 84, 94 along the guides 86, 96 by virtue of being coupled to the rollers 84, 94. In this embodiment, the carriage 104 has an extension 106 for interacting with the position sensors 92, 102. In an embodiment of the position sensor 92, 102 in the form of a laser distance feedback sensor, the extension 106 serves as a target for an associated emitting laser. The guides 86, 96 are defined by a pair of slots 108 extending linearly between a first end 110 and a second end 112. Thus, movement of the rollers 84, 94 along the guides 86, 96 is essentially linear and reciprocating, such that the rollers 84, 94 move forward in one direction and rearward in the opposite direction on the guides 86, 96.

[0022]

[0026] To induce movement of the rollers 84, 94 along the guides 86, 96, the actuators 88, 98 are activated. The actuators 88, 98 and the rollers 84, 94 are coupled together. The actuators 88, 98 may take different forms in alternative embodiments. In the illustrated embodiment, the actuators 88, 98 are in the form of pneumatic cylinder actuators 114, 116, specifically double acting pneumatic cylinder actuators employing air power for their extension and retraction strokes and movement. Here, the rods 118 of the pneumatic cylinder actuators 114, 116 are connected to the carriage 104 such that the extension and retraction movement of the rods 118 induces the forward and backward movement of the rollers 84, 94. Locking devices 90, 100 stop the movement of the rollers 84, 94 and hold the rollers 84, 94 in place on the guides 86, 96. In this embodiment, the locking devices 90, 100 are in the form of a rod lock 120 incorporating a rod 118. Additionally, position sensors 92, 102 detect the position of the rollers 84, 94 on the guides 86, 96 and may communicate their output to the ECU 78. In this embodiment, the position sensors 92, 102 are in the form of a laser distance feedback sensor 122 that emits a laser beam 124 that is intended to impinge on the extension portion 106.

[0023]

[0027] Finally, the tape tension control system 14 may have a third position sensor 126 and a fourth position sensor 128. The third position sensor 126 and the fourth position sensor 128 are depicted diagrammatically in FIG. 3. The third position sensor 126 detects the diameter of the composite tape 16 wound on the tape supply spool 38. This detection may be instantaneous, during use, when the composite tape 16 is depleted from the tape supply spool 38. The output of the third position sensor 126 may be communicated to the ECU 78. Similarly, a fourth position sensor 182 indicates the diameter of the backing paper 36 wound on the backing paper take-up reel 72. This indication may be instantaneous, during use, when the backing paper 36 accumulates on the backing paper take-up reel 72. The output of the fourth position sensor 128 may be communicated to the ECU 78.

[0024]

[0028] During use, the tape tension control system 14 may operate under a variety of operating modes depending on the particular tape application procedure being performed by the tape laying head 10. For example, in a first operating or position mode, the tape laying head 10 may perform initiation of a composite tape section on the layup surface 64 or termination of a composite tape section on the layup surface 64 involving the use of the cutting device 52. However, the first operating mode may also be required in other cases requiring high tape application accuracy. In a second operating or tension mode, the tape laying head 10 may apply a main section of a composite tape section while the composite tape 16 is under compressive pressure applied by the compactor 58. The application of the main section typically occurs between the initiation and termination of a composite tape section. The tape tension control system 14 may transition between the first and second operating modes during use of the tape laying head 10 more smoothly than previously possible. Such a transition may occur at any time on an ad-hoc basis, and may occur at multiple times during a particular tape deposition procedure without explicitly stopping the deposition procedure at the transition. Thus, a more efficient and effective tape deposition procedure is achieved. Whether the tape tension control system 14 operates in the first or second mode of operation is determined, in part, by the particular expectations encountered during the tape deposition procedure, and whether the expectations can be adequately handled in the first or second mode of operation.

[0025]

[0029] The tape tension control system 14 can function in different manners in the first and second operating modes. In the first operating mode, one of the first locking device 90 or the second locking device 100 is set to a locked state, while the other of the first locking device 90 or the second locking device 100 is set to an unlocked state. In a particular embodiment, the first locking device 90 is set to its locked state, and the second locking device 100 is set to its unlocked state. The tape web 68 can be advanced a predetermined degree via the first servo motor 60 and the second servo motor 74, and the tape web encoder 69 can detect the position of the tape web 68. The ECU 78 can issue commands for the rotational movement of the first servo motor 60 and the second servo motor 74 in response to the indicated position and in response to its comparison with the intended position. Thus, the first operating mode can exhibit closed-loop functionality.

[0026]

[0030] In a second mode of operation, the first locking device 90 is set to its unlocked state and the second locking device 100 is set to its unlocked state. The unlocked state allows the first roller 84 to move a certain amount on the first guide 86 and the second roller 94 to move a certain amount on the second guide 96. The first actuator 88 is activated to induce movement of the first roller 84 to a first predetermined position and location in the linear extent of the first guide 86. The first predetermined location may be a position on the first guide 86 that provides a certain extent and clearance between the first roller 84 and the first end 110 and that provides a certain extent and clearance between the first roller 84 and the second end 112. In one embodiment, the first predetermined location is a first approximate mid-location on the first guide 86 or a mid-stroke of the first pneumatic cylinder actuator 114. These ranges and clearances on either side of the first roller 84 on either side of the first guide 86 allow the first roller 84 to move back and forth as rapid increases in tension in the tape web 68 are transmitted to the first roller 84. This movement of the first roller 84, and the concomitant compliance of the first actuator 88, acts to absorb rapid increases in tension. In the embodiment of the first pneumatic cylinder actuator 114, this compliance is achieved by air compression within the first pneumatic cylinder actuator 114. The tape tension control system 14 requires that the position of the first roller 84 be maintained at a first predetermined location during the second mode of operation. In this embodiment, the first position sensor 92 monitors the position of the first roller 84 on the first guide 86. When the first roller 84 is moved out of position and away from the first predetermined location, the rotational speed of the tape supply reel 48 may be adjusted, i.e., increased or decreased, via the first servo motor 60 depending on which direction the first roller 84 needs to move on the first guide 86 to maintain the first predetermined location.

[0027]

[0031] In a similar manner, and simultaneously with the above steps, the second actuator 98 is activated to induce movement of the second roller 94 to a second predetermined position and location in the linear range of the second guide 96. The second predetermined location may be a position on the second guide 96 that provides a range and clearance between the second roller 94 and the first end 110 and a range and clearance between the second roller 94 and the second end 112. In one embodiment, the second predetermined location is a second approximately mid-location on the second guide 96 or a mid-stroke of the second pneumatic cylinder actuator 116. These ranges and clearances on either side of the second roller 94 on either side of the second guide 96 allow for back and forth movement of the second roller 94 as a rapid increase in tension in the tape web 68 is transferred to the second roller 94. This movement of the second roller 94 in conjunction with the movement of the first roller 84 and the concomitant compliance of the second actuator 98 serves to absorb the rapid increase in tension. In the embodiment of the second pneumatic cylinder actuator 116, this compliance is achieved by air compression within the second pneumatic cylinder actuator 116. As before, the tape tension control system 14 requests that the position of the second roller 94 be maintained at a second predetermined location during the second mode of operation. In this embodiment, the second position sensor 102 monitors the position of the second roller 94 on the second guide 96. When the second roller 94 is moved out of position away from the second predetermined location, the rotational speed of the backing paper take-up reel 72 may be adjusted, i.e., increased or decreased, via the second servo motor 74, depending on which direction the second roller 94 needs to move on the second guide 96 to maintain the second predetermined location.

[0028]

[0032] It should be understood that the above description is a description of one or more embodiments of the present invention. The present invention is not limited to the specific embodiments disclosed herein, but rather is defined only by the following claims. Furthermore, the descriptions contained in the above description relate to specific embodiments and are not to be construed as limiting the scope of the present invention or the definition of the terms used in the claims, unless the term or phrase is specifically 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 fall within the scope of the appended claims.

[0029]

[0033] As used in this specification and claims, the terms "eg," "for example," "for instance," "such as," and "like," as well as the verbs "comprising," "having," and "including" and other verb forms, when used with a list of one or more components or other items, are each to be construed as open-ended, meaning that the list is not to be construed as excluding other additional components or items. Other terms are also to be construed using their broadest reasonable meaning unless used in a context that requires a different interpretation.

Claims

1. A tape laying head for forming a composite workpiece integrally by moving a tape body of a plurality of composite tape segments so as to adhere them to a mold, the tape laying head comprising: a tape supply reel driven in rotational motion via a first servomotor for supplying said composite tape segment; a backing paper take-up reel driven in rotational motion via a second servo motor for taking up the backing paper separated from the tape body of the composite tape segment; 1. A tape tension control system comprising: a first dancer roller assembly located downstream of the tape supply reel, the first dancer roller assembly including a first roller, a first guide, a first actuator, and a first position sensor, the first roller being carried by the first guide and movable on the first guide via the first actuator, and the first position sensor detecting a position of the first roller on the first guide; and a second dancer roller assembly located upstream of the backing paper take-up reel, the second dancer roller assembly comprising a second roller, a second guide, a second actuator, and a second position sensor, the second roller being carried by the second guide and movable on the second guide via the second actuator, and the second position sensor detecting a position of the second roller on the second guide. a tape tension control system comprising: Equipped with during a mode of operation, a rotational speed of the tape supply reel is adjusted by the first servo motor based on a position of the first roller on the first guide as detected by the first position sensor; Tape stacking head.

2. 2. The tape laying head of claim 1, wherein during said one mode of operation, the rotational speed of the backing paper take-up reel is adjusted by the second servo motor based on the position of the second roller on the second guide as detected by the second position sensor.

3. 3. The tape laying head of claim 2, wherein during the one mode of operation, the first roller is moved via the first actuator to a first location on the first guide between the ends of the first guide, the second roller is moved via the second actuator to a second location on the second guide between the ends of the second guide, the tape tension control system controls the first roller to maintain the first location based on a position of the first roller on the first guide detected by the first position sensor and by adjusting a rotational speed of the tape supply reel by the first servo motor, and the tape tension control system controls the second roller to maintain the second location based on a position of the second roller on the second guide detected by the second position sensor and by adjusting a rotational speed of the backing paper take-up reel by the second servo motor.

4. 2. The tape laying head of claim 1, wherein the first dancer roller assembly includes a first locking device, and movement of the first roller on the first guide is lockable via the first locking device, and the first dancer roller assembly includes a second locking device, and movement of the second roller on the second guide is lockable via the second locking device.

5. 5. The tape laying head of claim 4, wherein during another mode of operation, one of the first locking device or the second locking device is set to a locked state to lock the movement of the first roller or the second roller on the first guide or the second guide, and the other of the first locking device or the second locking device is set to an unlocked state.

6. 2. The tape laying head of claim 1, wherein movement of the first roller on the first guide is capable of tracking rapid increases in tension experienced in the tape web via the first actuator and via movement of the first roller on the first guide, and movement of the second roller on the second guide is capable of tracking rapid increases in tension experienced in the tape web via the second actuator and via movement of the second roller on the second guide.

7. A tape laying machine and assembly comprising the tape laying head of claim 1.

8. a tape supply reel driven for rotational movement via a first servomotor; a backing paper take-up reel driven in rotational motion via a second servomotor; 1. A tape tension control system comprising: a first dancer roller assembly located downstream of the tape supply reel, the first dancer roller assembly comprising a first roller, a first guide, a first actuator, a first locking device, and a first position sensor, the first roller being carried by the first guide and movable on the first guide via the first actuator, movement of the first roller on the first guide being lockable via the first locking device, and the first position sensor detecting a position of the first roller on the first guide; and a second dancer roller assembly located upstream of the backing paper take-up reel, the second dancer roller assembly comprising a second roller, a second guide, a second actuator, a second locking device, and a second position sensor, the second roller being carried by the second guide and movable on the second guide via the second actuator, the movement of the second roller on the second guide being lockable via the second locking device, and the second position sensor detecting a position of the second roller on the second guide. A tape tension control system comprising: Equipped with During an operational mode, the first locking device is set to an unlocked state, the first roller is moved to a first location on the first guide via the first actuator, and the tape tension control system controls the first roller to maintain the first location based on a position of the first roller on the first guide detected by the first position sensor and by adjusting the rotational speed of the tape supply reel by the first servo motor. Tape stacking head.

9. 9. The tape laying head of claim 8, wherein during the one operating mode, the second locking device is set to an unlocked state, the second roller is moved to a second location on the second guide via the second actuator, and the tape tension control system controls the second roller to maintain the second location based on the position of the second roller on the second guide detected by the second position sensor and by adjusting the rotational speed of the backing paper take-up reel by the second servo motor.

10. 10. The tape lamination head of claim 9, wherein the first location is a first approximately intermediate location on the first guide and the second location is a second approximately intermediate location on the second guide.

11. 9. The tape laying head of claim 8, wherein during another mode of operation, one of the first locking device or the second locking device is set to a locked state to lock the movement of the first roller or the second roller on the first guide or the second guide, and the other of the first locking device or the second locking device is set to an unlocked state.

12. 9. The tape laying head of claim 8, wherein movement of the first roller on the first guide is capable of tracking rapid increases in tension experienced in the tape web via the first actuator and via movement of the first roller on the first guide.

13. 13. The tape laying head of claim 12, wherein movement of the second roller on the second guide is capable of tracking rapid increases in tension experienced in the tape web via the second actuator and via movement of the second roller on the second guide.

14. 9. The tape laying head of claim 8, wherein the tape tension control system comprises a third position sensor indicative of a diameter of the composite tape received on the tape supply reel, and wherein the tape tension control system comprises a fourth position sensor indicative of a diameter of the backing paper received on the backing paper take-up reel.

15. 1. A tape tension control system for a tape laying head comprising a dancer roller assembly positioned adjacent a tape laying reel, the dancer roller assembly comprising: roller, A guide that movably supports the roller; a pneumatic cylinder actuator for moving the roller on the guide; a locking device for locking the roller from moving on the guide; and A position sensor that detects the position of the roller on the guide. Equipped with During an operational mode, the locking device is set to an unlocked state, the roller is moved to a location on the guide by the pneumatic cylinder actuator, and the location of the roller on the guide is maintained generally based on the position of the roller on the guide as detected by the position sensor and by adjusting the rotational speed of the tape lamination reel; during said operating mode, the location of said roller on said guide maintained is capable of tracking rapid increases in tension experienced in the tape web by said pneumatic cylinder actuator and by movement of said roller on said guide from said maintained location; Tape tension control system for tape laying head.

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