Fiber arrangement device, fiber arrangement method, and composite material molding method

Abstract

To allow multiple tape materials such as prepreg tape or dry tape, which are used as FRP materials, to be stacked simultaneously without overlapping each other, and to allow the width of the multiple tape materials as a whole to vary after stacking.SOLUTION: The fiber arranging apparatus according to the embodiment comprises: a first plurality of guides for guiding the feeding of a first plurality of tapes comprising fibers or prepreg; a first movement mechanism for varying the spacing of the first guides so that the first tapes are fed out at a first interval; a second plurality of guides for guiding the feeding of the second plurality of tapes; a second movement mechanism for varying the spacing of the second guides so that the second tapes are fed out at a second interval; and rollers arranged so that the first tape fed out from the first guide and the second tape fed out from the second guide are fed out in the same direction in an alternating arrangement.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] FIELD OF THE INVENTION An embodiment of the present invention relates to a fiber arrangement device, a fiber arrangement method, and a composite material molding method. [Background technology]

[0002] To mold fiber-reinforced plastics (FRPs), also known as composite materials such as glass fiber reinforced plastics (GFRP) and carbon fiber reinforced plastics (CFRP), it is necessary to laminate prepreg sheets, which are sheets of fiber impregnated with uncured resin, and then cure the resin. Alternatively, it is necessary to laminate sheets of fiber before impregnation with resin, then impregnate them with resin and cure them. The FRP molding method in which fibers are laminated and then impregnated with resin is called RTM (Resin Transfer Molding).

[0003] In recent years, automated fiber placement (AFP) devices that automatically layer tape-shaped prepregs or fibers have become commercially available, and in addition to prepreg tapes for layering with AFP devices, tape-shaped fibers before being impregnated with resin, known as dry tapes, are also commercially available (see, for example, Patent Documents 1, 2, and 3).

[0004] When laminating tape materials such as prepreg tape and dry tape in an AFP device, laminating multiple tape materials simultaneously can improve lamination efficiency, i.e., the length of tape material laminated per unit time. For this reason, AFP devices equipped with multiple lamination heads have been devised so that multiple tape materials can be laminated simultaneously. Furthermore, a technology has been proposed that allows the amount of overlap between adjacent prepreg tapes to be adjusted in a multi-head AFP device that simultaneously laminates multiple prepreg tapes (see, for example, Patent Document 4). [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 01-247146 [Patent Document 2] Japanese Patent Application Laid-Open No. 2004-181683 [Patent Document 3] Special Publication No. 2011-527648 [Patent Document 4] Japanese Patent Publication No. 2020-059145 Summary of the Invention [Problem to be solved by the invention]

[0006] However, conventional AFP devices equipped with multiple stacking heads can only stack tape materials with a specific width. Therefore, in order to change the width of multiple tape materials after stacking, the amount of overlap between the tape materials must be changed. In other words, unless the tape materials are partially overlapped, the overall width of the tape materials after stacking cannot be changed. Therefore, it is impossible to make the thickness of the tape materials uniform after stacking.

[0007] In addition, because prepreg tape is adhesive, when overlapping prepreg tapes are laminated, it may be difficult to laminate multiple prepreg tapes in a curved shape. Specifically, when attempting to laminate multiple prepreg tapes in a curved shape while overlapping each other, the laminate length differs between the prepreg tapes on the inside and the prepreg tapes on the outside, and it may not be possible to lay multiple prepreg tapes as ideal. For this reason, when overlapping multiple prepreg tapes, it is necessary to laminate the prepreg tapes along a straight line or a curve with a very small curvature.

[0008] This also applies when the tape itself is wide. That is, in order to stack multiple tape materials along a curve with a large curvature, it is necessary to stack multiple narrow tape materials without overlapping them. Moreover, since the stacking efficiency of the tape material decreases as the tape width becomes narrower, it is necessary to stack more tape materials simultaneously to avoid or reduce the decrease in stacking efficiency.

[0009] However, a typical AFP device has a lamination head consisting of a brake that secures the tape, a feed roller that feeds the tape, a cutter that cuts the tape, and a compaction roller that presses the tape against a mold. Because the width of these lamination head components is greater than the width of the tape, the lamination heads cannot be aligned in the width direction of the tape to avoid interference between the components. In other words, multiple lamination heads, the same number as the number of tapes, must be positioned at different positions in the tape feed direction, such as staggered. As a result, in order to simultaneously feed multiple tapes, a large-scale AFP device equipped with multiple lamination heads is required, and it is not easy to increase the number of tapes.

[0010] Therefore, the present invention aims to simultaneously stack multiple tape materials, such as prepreg tape or dry tape, which are the raw materials for FRP, without overlapping each other, and to make it possible to change the overall width of the multiple tape materials after stacking.

[0011] Another object of the present invention is to make it possible to laminate a larger amount of tape material without making the laminating head of the AFP device complex and large. [Means for solving the problem]

[0012] A fiber arrangement device according to an embodiment of the present invention includes a first plurality of guides for guiding the feeding of a first plurality of tapes made of fiber or prepreg in a first feeding direction; a first movement mechanism for changing the interval between the first plurality of guides so that the first plurality of tapes are fed in the first feeding direction at first intervals; a second plurality of guides for guiding the feeding of a second plurality of tapes made of fiber or prepreg in a second feeding direction different from the first feeding direction; a second movement mechanism for changing the interval between the second plurality of guides so that the second plurality of tapes are fed in the second feeding direction at second intervals; and rollers arranged so that the first plurality of tapes fed from the first plurality of guides at the first intervals and the second plurality of tapes fed from the second plurality of guides at the second intervals are fed in the same feeding direction in an alternating arrangement. a first sensor for detecting the width of the first plurality of tapes; and a second sensor for detecting the width of the second plurality of tapes. It has the following characteristics. The first movement mechanism is configured to control the spacing of the first plurality of guides based on the width of the second plurality of tapes detected by the second sensor, while the second movement mechanism is configured to control the spacing of the second plurality of guides based on the width of the first plurality of tapes detected by the first sensor. Moreover, a fiber arrangement device according to an embodiment of the present invention includes a first plurality of guides for guiding the feeding of a first plurality of tapes made of fiber or prepreg in a first feeding direction; a first moving mechanism for changing the spacing between the first plurality of guides so that the first plurality of tapes are fed in the first feeding direction at a first interval; a second plurality of guides for guiding the feeding of a second plurality of tapes made of fiber or prepreg in a second feeding direction different from the first feeding direction; a second moving mechanism for changing the spacing between the second plurality of guides so that the second plurality of tapes are fed in the second feeding direction at a second interval; and rollers arranged so that the first plurality of tapes fed from the first plurality of guides at the first intervals and the second plurality of tapes fed from the second plurality of guides at the second intervals are fed in the same feeding direction in an alternating arrangement. The first moving mechanism has one or more rotating bodies that rotate around a common rotation axis and have a plurality of different outer diameters, and a plurality of closed-curve power transmission members that receive power from each of the portions of the rotating body that have the different outer diameters and move in the longitudinal direction, and are each connected to one of the first plurality of guides, thereby moving each of the first plurality of guides by different movement amounts corresponding to the different outer diameters.

[0013] In addition, a fiber arrangement method according to an embodiment of the present invention uses the above-mentioned fiber arrangement device to produce a plurality of arranged tapes including the first plurality of tapes having the first spacing and the second plurality of tapes having the second spacing, such that adjacent tapes in the width direction do not overlap in the width direction.

[0014] In addition, a composite molding method according to an embodiment of the present invention includes the steps of producing a laminate of the arranged tapes by stacking the arranged tapes produced by the above-mentioned fiber arrangement method, and molding a composite using the laminate. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a front view showing the configuration of a fiber array device according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a left side view of the fiber array device shown in FIG. 1. [Figure 3]2 is a diagram showing an example of a plurality of tapes after being arranged and fed out from the fiber arrangement device shown in FIG. 1. FIG. [Figure 4] 2 is a diagram showing an example of a plurality of tapes after being arranged and fed out from the fiber arrangement device shown in FIG. 1. FIG. [Figure 5] 2 is a plan view showing a specific example of the configuration of each tape feeding device shown in FIG. 1. [Figure 6] 6 is a cross-sectional view of the tape feeding device shown in FIG. 5 at position AA. [Figure 7] 7A and 7B are diagrams illustrating the principle of moving each wire by a different distance using the stepped drive rollers shown in FIGS. 5 and 6. FIG. [Figure 8] 7A and 7B are diagrams illustrating how the wires shown in FIGS. 5 and 6 are wound around the drive rollers. [Figure 9] 7A and 7B are diagrams illustrating how the wires shown in FIGS. 5 and 6 are wound around the drive rollers. [Figure 10] A diagram showing an example of the direction and amount of movement of each guide when the spacing between guides for feeding out a wide tape as illustrated in Figure 3 is changed to the spacing between guides for feeding out a narrow tape as illustrated in Figure 2. [Figure 11] 2 is a flowchart showing an example of the flow when FRP is molded using a prepreg tape as a material using the fiber arrangement device and AFP device shown in FIG. 1. [Figure 12] 2 is a flowchart showing an example of a flow when FRP is formed using a dry tape as a material, using the fiber arrangement device and AFP device 4 shown in FIG. [Figure 13] FIG. 4 is a configuration diagram of a fiber array device according to a second embodiment of the present invention. [Figure 14] 14 is a plan view showing examples of shapes of a plurality of tapes that can be arranged by the fiber arrangement device shown in FIG. 13. [Figure 15] FIG. 14 is a diagram showing an example of a control block diagram when feedback control of the width adjusting device is performed based on the tape width measured by the sensor shown in FIG. 13. DETAILED DESCRIPTION OF THE INVENTION

[0016] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A fiber array device, a fiber array method, and a composite material molding method according to embodiments of the present invention will be described with reference to the accompanying drawings.

[0017] (First embodiment) (Configuration and function of fiber arrangement device) FIG. 1 is a front view showing the configuration of a fiber array device according to a first embodiment of the present invention, and FIG. 2 is a left side view of the fiber array device shown in FIG.

[0018] The fiber arrangement device 1 is a device that feeds out multiple tapes T, which are FRP materials, in the same direction while arranging them without overlapping so that they can be stacked simultaneously. In other words, the fiber arrangement device 1 is a device that arranges multiple tapes T, which are supplied from different directions, so that their length directions are roughly parallel and feeds them out without overlapping.

[0019] Note that if it is permissible to stack multiple tapes T with gaps between them, in other words, if the width of the stacking area is wider than the total width of the multiple tapes T to be arranged, the multiple tapes T may be arranged with gaps between them by the fiber arrangement device 1. However, hereinafter, an example will be described in which multiple tapes T are arranged without generating gaps or overlaps with negligible error.

[0020] Examples of tapes T to be arranged include prepreg tape and dry tape. Prepreg tape is a tape made from prepreg, which is made by impregnating fibers with resin. Dry tape is a tape made from fibers before they are impregnated with resin.

[0021] 3 and 4 are diagrams showing an example of a plurality of tapes T after being fed out from the fiber arraying device 1 shown in FIG. 1 and arranged.

[0022] Tapes T of different widths can be supplied to the fiber arraying device 1. Therefore, if multiple wide tapes T are supplied to the fiber arraying device 1 as illustrated in Fig. 3, the widths of the multiple tapes T after arrangement and fed out from the fiber arraying device 1 will also be wide. On the other hand, if multiple narrow tapes T are supplied to the fiber arraying device 1 as illustrated in Fig. 4, the widths of the multiple tapes T after arrangement and fed out from the fiber arraying device 1 will also be narrow.

[0023] Increasing the width of each tape T, as illustrated in Fig. 3, allows for a larger area of ​​tape T to be laminated per unit time. On the other hand, decreasing the width of each tape T, as illustrated in Fig. 4, allows for the tapes T to be laminated along a curve with a larger curvature. Therefore, it is possible to supply tapes T having an appropriate width to the fiber arrangement device 1 according to the shape of the FRP to be molded, and to arrange multiple tapes T to have an appropriate width.

[0024] The supply device for multiple tapes T provided upstream of the fiber array device 1 may be a bobbin 2 of tape T having a fixed width, or a width adjustment device 3 that changes the width of the tape T as needed may be disposed between the bobbin 2 of tape T and the fiber array device 1, as illustrated in Figure 1. The configuration of the width adjustment device 3 may be any configuration as long as it is possible to change the width of the tape T.

[0025] Known examples of devices for widening the width of dry tapes include the fiber spreading device disclosed in International Publication No. 2010 / 137525. Furthermore, the device disclosed in Japanese Patent Application Laid-Open No. 2020-93454 may be used as the width adjusting device 3 as a device capable of narrowing the width of not only dry tapes but also prepreg tapes.

[0026] By providing the width adjustment device 3, the width of the tape T supplied from the bobbin 2 can be changed to a desired width and supplied to the fiber arrangement device 1. On the other hand, if the width adjustment device 3 is not provided, tapes T having different widths can be supplied to the fiber arrangement device 1 by replacing the bobbin 2 with one having a tape T of a different width.

[0027] An AFP device 4 is provided downstream of the fiber arrangement device 1. In other words, the fiber arrangement device 1 can be an attachment or part of a component of the AFP device 4 for supplying a plurality of arranged tapes T to the AFP device 4. A typical AFP device 4 includes a table 5 for stacking the tapes T, a compaction roller 6 for pressing the tape T against the table 5, and a movement mechanism 7 for moving the compaction roller 6 relative to the table 5. If the bottom surface of the tape T is not flat, a jig J such as a lower mold can be placed on the table 5, and the tape T can be stacked on the jig J, as exemplified in FIG. 1.

[0028] If the compaction roller 6 is moved relative to the table 5 while pressing the aligned tapes T against the table 5, the aligned tapes T can be fed in the opposite direction to the movement of the compaction roller 6 while applying tension to each tape T. In other words, after the leading edge of each tape T reaches the compaction roller 6, each tape T can be fed without necessarily applying tension to the aligned or unaligned tapes T with a powered roller. Therefore, it is not necessary to provide a power source for feeding each tape T in the fiber alignment device 1 provided upstream of the AFP device 4.

[0029] Conversely, before the leading edge of each tape T reaches the compaction roller 6, the compaction roller 6 cannot apply tension to each tape T. For this reason, a roller that rotates with the power of a motor may be positioned at a desired position to apply tension to each tape T while feeding it out. A typical AFP device 4 is equipped with a powered roller called a feed roller that applies tension to the tape T while feeding it out, as well as a brake that stops the feeding of the tape T and a cutter that cuts the tape T.

[0030] Furthermore, even if the compaction roller 6 alone is not able to apply sufficient tension to each tape T, a roller that rotates with the power of a motor can be disposed at a desired position to apply tension to each tape T. Therefore, the fiber arrangement device 1 provided upstream of the AFP device 4 may also be provided with a power source such as a motor for feeding each tape T as needed, and a roller that rotates by receiving power from the power source.

[0031] By using the AFP device 4 having the above-described configuration, it is possible to stack multiple tapes T arranged by the fiber arrangement device 1 as exemplified in Fig. 3 or 4 on the table 5. In the example shown in Fig. 1, the table 5 is moved in the desired drive axis direction by the movement mechanism 7, but it is also possible to move a gantry that holds the compaction roller 6 by the movement mechanism 7. Furthermore, enabling rotational movement in addition to linear movement in three orthogonal axis directions is practical from the viewpoint of being able to mold FRP having more complex shapes.

[0032] The fiber array device 1 is composed of multiple tape feeding devices 8 and a gathering roller 9. Each tape feeding device 8 is a device that adjusts the spacing to feed multiple tapes T in the same feeding direction, in other words, so that the length directions of the multiple tapes T are roughly parallel. However, in order to avoid interference between the tape feeding devices 8, the feeding directions of the tapes T differ between the tape feeding devices 8. The gathering roller 9 is a columnar or cylindrical roller that alternately arranges the multiple tapes T fed in different directions from the multiple tape feeding devices 8 and feeds them in the same feeding direction.

[0033] The number of tape feeding devices 8 and the number of tapes T fed from each tape feeding device 8 are determined according to the number of tapes T to be arranged by the fiber arrangement device 1. In other words, the number of tape feeding devices 8 and the number of tapes T fed from each tape feeding device 8 are determined so that the total number of tapes T fed from the multiple tape feeding devices 8 is the number of tapes T fed from the fiber arrangement device 1 to the AFP device 4.

[0034] The total number of tapes T fed from the fiber array device 1 to the AFP device 4 may be changed by pausing some of the tape feeding devices 8 or reducing the number of tapes T fed from the same tape feeding device 8. In this case, the number of tape feeding devices 8 and the number of tapes T fed from each tape feeding device 8 are determined according to the maximum total number of tapes T that can be fed from the fiber array device 1 to the AFP device 4. Also, at least one of the number of tape feeding devices 8 and the number of tapes T fed from each tape feeding device 8 may be increased in the fiber array device 1. In this case, the maximum total number of tapes T that can be fed from the fiber array device 1 to the AFP device 4 itself can be changed.

[0035] Each tape feeding device 8 has multiple tape feeding guides 10 and a guide movement mechanism 11. Each tape feeding guide 10 is a device for guiding the feeding of a tape T made of fiber or prepreg in the feeding direction. Therefore, the number of tape feeding guides 10 is equal to the number of tapes T fed from each tape feeding device 8.

[0036] The tape feed guide 10 can be a device that regulates the direction of travel of the tape T while maintaining the tension of the tape T, for example, by fixing an appropriate number of feed rollers 13 to a feed table 12 to maintain the tension of the tape T, as illustrated in Figure 1.However, as long as it is possible to regulate the direction of travel while maintaining the tension of the tape T, the tape feed guide 10 can be configured as desired, such as a belt conveyor in which a belt supported by pulleys moves.

[0037] Tapes T that should be arranged adjacently without overlapping are fed from different tape feeding devices 8. For this reason, it is necessary to provide intervals between the multiple tapes T fed from each tape feeding device 8 so that tapes T fed from other tape feeding devices 8 can be arranged.

[0038] Conversely, if tapes T that should be arranged adjacently without overlapping are fed from different tape feeding devices 8 and there is a gap between the multiple tapes T fed from each tape feeding device 8, interference between the tape feeding guides 10 can be avoided without requiring the tape feeding guides 10 to have a complex structure. Therefore, multiple tape feeding guides 10 for feeding multiple tapes T that are arranged adjacently at intervals within the same tape feeding device 8 can be arranged adjacently at intervals corresponding to the gap between the multiple tapes T.

[0039] If the width of the tape T guided by each tape feeding guide 10 is not a specific width, that is, if tapes T of different widths must be guided by each tape feeding guide 10, it is necessary to change the spacing between multiple tapes T fed from the same tape feeding device 8 according to the width of the tape T. Therefore, it is also necessary to change the spacing between multiple tape feeding guides 10 arranged adjacent to the same tape feeding device 8 according to the width of the tape T.

[0040] Furthermore, even if the width of the tape T guided by each tape feeding guide 10 is the same, if some tape feeding devices 8 are put into a resting state or, conversely, if tape feeding devices 8 can be added, the number of tapes T arranged alternately will change, and therefore it will be necessary to change the spacing between multiple tapes T fed from the same tape feeding device 8 and the spacing between tape feeding guides 10 according to the number of tape feeding devices 8 and tapes T.

[0041] Therefore, the spacing between multiple tape feed guides 10 arranged adjacent to the same tape feed device 8 can be changed by the guide movement mechanism 11. In other words, the spacing between multiple tape feed guides 10 arranged adjacent to the same tape feed device 8 is adjusted by the guide movement mechanism 11 to an appropriate spacing depending on at least one of the width and number of tapes T.

[0042] More specifically, the distance between two tape feeding guides 10 arranged adjacent to the same tape feeding device 8 is adjusted by the guide moving mechanism 11 so that the distance required to arrange at least one tape T fed from a different tape feeding device 8 without overlapping in the width direction is created between two adjacent tapes T fed from the same tape feeding device 8.

[0043] In the illustrated example, the fiber arrangement device 1 is provided with three tape feeders 8A, 8B, and 8C, each configured to feed three tapes TA, TB, and TC, so that a total of nine tapes TA, TB, and TC can be arranged and fed.

[0044] More specifically, first tape feeding guides 10A provided in first tape feeding device 8A guide the first tapes TA in a first feeding direction, respectively. A first guide movement mechanism 11A provided in first tape feeding device 8A is configured to change the spacing between first tape feeding guides 10A so that the first tapes TA are fed in the first feeding direction at first intervals.

[0045] Similarly, second tape feeding guides 10B provided in second tape feeding device 8B guide the second tapes TB in a second feeding direction different from the first feeding direction, respectively. Second guide movement mechanism 11B provided in second tape feeding device 8B is configured to feed the second tapes TB at second intervals in the second feeding direction.

[0046] Similarly, a third plurality of tape feeding guides 10C provided in a third tape feeding device 8C guide the third plurality of tapes TC in a third feeding direction different from both the first feeding direction and the second feeding direction, respectively. A third guide movement mechanism 11C provided in the third tape feeding device 8C is configured to feed the third plurality of tapes TC in the third feeding direction at third intervals.

[0047] When the tapes TA, TB, and TC fed from the three tape feeding devices 8A, 8B, and 8C are alternately arranged by the collecting roller 9, two tapes T fed from two other tape feeding devices 8 are arranged between tapes T fed from the first to third tape feeding devices 8 at intervals. Therefore, the spacing between the multiple tape feeding guides 10 provided in each tape feeding device 8 is adjusted by each guide moving mechanism 11 so that the spacing between the tapes T fed from the multiple tape feeding guides 10 becomes the sum of the widths of the two tapes T fed from the other two tape feeding devices 8.

[0048] The width of the tape T supplied to and fed from each tape feeding device 8 does not necessarily have to be the same between the tape feeding devices 8. Therefore, if the width of the tape T fed out differs between the tape feeding devices 8, the spacing between the tape feeding guides 10 is adjusted to different spacing between the tape feeding devices 8.

[0049] For example, when tapes TA, TB, and TC are fed out by three tape feeding devices 8A, 8B, and 8C, as shown in the figure, the first spacing between the first plurality of tapes TA fed out in the first feeding direction, the second spacing between the second plurality of tapes TB fed out in the second feeding direction, and the third spacing between the third plurality of tapes TC fed out in the third feeding direction are not necessarily the same.

[0050] On the other hand, when the width of the tape T fed from each tape feeding device 8 is the same, the spacing between the tape feeding guides 10 is also adjusted to be the same between the tape feeding devices 8. For example, in the case where tapes TA, TB, and TC are fed from three tape feeding devices 8A, 8B, and 8C, as shown in the figure, the first spacing between the first plurality of tapes TA fed in the first feeding direction, the second spacing between the second plurality of tapes TB fed in the second feeding direction, and the third spacing between the third plurality of tapes TC fed in the third feeding direction are adjusted to be the same spacing.

[0051] Note that each figure illustrates a case where the width of the tape T fed from each tape feeding device 8 is the same. For ease of explanation, the following description will be given taking as an example a case where the width of the tape T fed from each tape feeding device 8 is the same between tape feeding devices 8.

[0052] As described above, the number of tape feeding devices 8 and the number of tapes T fed from one tape feeding device 8 can be determined arbitrarily depending on the total number of tapes T that can be fed from the fiber array device 1 to the AFP device 4. Therefore, the fiber array device 1 is provided with at least two tape feeding devices 8, and is not limited to the example shown in the figure, and four or more tape feeding devices 8 may be arranged so that the tapes T do not interfere with each other.

[0053] Furthermore, at least two tapes T are fed from one tape feeding device 8, and it is not limited to the example shown, but four or more tapes T may be fed from one tape feeding device 8. However, if three tapes T are fed from one tape feeding device 8 as shown, there is an advantage in that the configuration of the guide movement mechanism 11 can be simplified, as in the example described below.

[0054] Each tape feeding device 8 and the collecting roller 9 arranged downstream of the tape feeding device 8 are disposed relative to each other so that the tapes T fed in different feeding directions at predetermined intervals from the multiple tape feeding guides 10 provided in the different tape feeding devices 8 reach the collecting roller 9 without interfering with each other and are arranged alternately without overlapping on the collecting roller 9. To achieve this, it is necessary to relatively dispose each tape feeding device 8 and the collecting roller 9 so that the thickness directions of the tapes T fed from the different tape feeding devices 8 are on the same plane at least immediately before the collecting roller 9 and are approximately perpendicular to the rotation axis of the collecting roller 9.

[0055] 1, the thickness directions of the tapes TA, TB, and TC fed from the first to third tape feeding devices 8A, 8B, and 8C are on the same plane and perpendicular to the rotation axis of the collecting roller 9. However, to avoid interference between the tape feeding devices 8, the thickness direction of the tapes T fed from some or all of the tape feeding devices 8 may be changed by using multiple rollers with different rotation axis directions, so that the thickness directions of the tapes T fed from all of the tape feeding devices 8 immediately before the collecting roller 9 are ultimately approximately perpendicular to the rotation axis of the collecting roller 9. Furthermore, the rotation axis of the collecting roller 9 may be slightly inclined rather than being completely perpendicular to the thickness direction of the tapes T, allowing fine adjustment of the feed directions of the multiple tapes T after arrangement.

[0056] If all the tapes T can be fed from each tape feeding device 8 to the collecting roller 9 in the appropriate direction and position, the multiple tapes T can be fed in the same feeding direction while being arranged alternately. In other words, multiple tapes T arranged so that adjacent tapes T in the width direction do not overlap in the width direction can be produced as FRP material by the fiber arrangement device 1 and supplied to the AFP device 4.

[0057] Next, a specific example of the configuration of the guide movement mechanism 11 provided in each tape feeding device 8 will be described.

[0058] FIG. 5 is a plan view showing a specific example of the configuration of each tape feeding device 8 shown in FIG. 1, and FIG. 6 is a cross-sectional view of the tape feeding device 8 at position AA shown in FIG.

[0059] The guide movement mechanism 11 is a mechanism for adjusting the spacing between the tape feed guides 10, and is therefore configured as a device that moves multiple tape feed guides 10 in parallel relative to one another. When one tape feed device 8 feeds three tapes T, the guide movement mechanism 11 can be configured as a simple power transmission mechanism, as shown in Figures 5 and 6. In other words, the three tape feed guides 10 can be moved in parallel relative to one another with a simple power transmission mechanism.

[0060] 5 and 6, the guide movement mechanism 11 can be composed of a drive roller 20, a motor 21, a wire 22, a pulley 23, and a slide mechanism 24. The drive roller 20 is a roller that rotates upon receiving power from the motor 21. The torque output from the motor 21 may not be directly transmitted to the rotating shaft of the drive roller 20 as shown in the drawings, but may be transmitted indirectly via a gear or a power transmission belt.

[0061] The drive roller 20 has a plurality of different outer diameters but is structured to rotate around a common rotation axis. For example, the drive roller 20 may be formed by forming portions with different outer diameters on a single roller that rotates on a single rotation shaft, or the drive roller 20 may be formed by coaxially connecting a plurality of sub-rollers with different outer diameters. The outer diameters of the drive rollers 20 correspond to the amount of translation of each tape feed guide 10.

[0062] The number of wires 22 provided is equal to the number of tape feed guides 10 that are to be moved in parallel. Therefore, when moving three tape feed guides 10 in parallel, three wires 22 are provided in the guide movement mechanism 11. Each wire 22 has a closed curve shape. That is, each wire 22 forms a ring-shaped endless track and has no end.

[0063] A portion of each wire 22 is fixed to a portion of the drive roller 20 having a different outer diameter so that the wire 22 moves in the longitudinal direction when power is received from the portions of the drive roller 20 having different outer diameters. Another portion of each wire 22 is coupled to one of the tape feed guides 10. In the illustrated example, in order to avoid interference between the wires 22 and the tape feed guides 10 that are not to be coupled, a through hole is formed in each tape feed guide 10 to allow the wires 22 that are not to be coupled to pass through, and the wires 22 that are to be coupled are fixed to the tape feed guides 10 with a coupling device.

[0064] The pulley 23 is a roller for supporting each wire 22 connected to the drive roller 20 and the tape feeding guide 10 and for moving each wire 22 in the length direction. In order to maintain an appropriate tension in each wire 22, a tensioner 26 for adjusting the tension in each wire 22 may be provided in the guide movement mechanism 11 as shown in the drawing.

[0065] The slide mechanism 24 is a mechanism for sliding each tape feed guide 10 in the movement direction. In the illustrated example, the slide mechanism 24 is made up of two shafts 27, and the two shafts 27 are slidably inserted into through holes formed in each tape feed guide 10.

[0066] In the guide movement mechanism 11 having the above-described configuration, when the drive roller 20 is rotated by the motor 21, each wire 22 supported by the pulley 23 moves longitudinally by a distance corresponding to the outer diameter of the drive roller 20, thereby allowing each tape feed guide 10 to move parallel by different distances.

[0067] FIG. 7 is a diagram illustrating the principle of moving each wire 22 by a different distance using the stepped drive roller 20 shown in FIGS.

[0068] 7, even if the rotation angle θ of the drive roller 20 is the same, the outer periphery lengths are different at the portions with different outer diameters, so that simply applying power to a single drive roller 20 to rotate it can translate the wires 22 and the multiple tape feeding guides 10 by distances corresponding to the lengths of the different arcs. Also, by adjusting the outer diameter of the drive roller 20, the amount of movement of each wire 22 per rotation of the drive roller 20 can be adjusted.

[0069] The rotation angle of the drive roller 20 is controlled as the amount of rotation including the rotation direction of the motor 21. For this reason, the user can preset or numerically input the amount of rotation into the control circuit of the motor 21. This allows the drive roller 20 to rotate by the rotation angle specified by the user, and each tape feed guide 10 to move in parallel by a specified distance.

[0070] Instead of the motor 21, a handle or lever may be attached to the drive roller 20 so that the user can manually rotate the drive roller 20. In this case, the handle or lever is configured to lock when the drive roller 20 has rotated by a specific rotation angle, so that the drive roller 20 can be rotated by the rotation angle specified by the user.

[0071] 8 and 9 are diagrams illustrating how the wires 22 shown in FIGS. 5 and 6 are wound around the drive roller 20, respectively.

[0072] Each wire 22 is wound around the drive roller 20 and a portion of the wire 22 is fixed to the drive roller 20. Therefore, the movement direction of each wire 22 can be determined by how the wire 22 is wound around the drive roller 20.

[0073] Specifically, as shown in Fig. 8, if the wire 22 is wound around the drive roller 20 so that the wire 22 does not cross at the position where it leaves the drive roller 20, the movement direction of the ring-shaped wire 22 can be made counterclockwise when the drive roller 20 is rotated counterclockwise. On the other hand, as shown in Fig. 9, if the wire 22 is wound around the drive roller 20 so that the wire 22 crosses at the position where it leaves the drive roller 20, the movement direction of the ring-shaped wire 22 can be made clockwise when the drive roller 20 is rotated counterclockwise.

[0074] In the examples shown in Figures 5 and 6, each tape feed guide 10 is positioned above the drive roller 20, so if the wire 22 is fed out from below the rotation axis of the drive roller 20 as shown in Figure 8, the tape feed guide 10 connected to the wire 22 will move to the left when the drive roller 20 is rotated counterclockwise. Conversely, if the wire 22 is fed out from above the rotation axis of the drive roller 20 as shown in Figure 9, the tape feed guide 10 connected to the wire 22 will move to the right when the drive roller 20 is rotated counterclockwise.

[0075] In this way, the sliding direction of each tape feed guide 10 is determined by the way each wire 22 is wound around the drive roller 20, while the movement distance of each tape feed guide 10 can be adjusted by the outer diameter of the drive roller 20. Therefore, the spacing between the tape feed guides 10 can be adjusted by rotating the drive roller 20.

[0076] Figure 10 is a diagram showing an example of the movement direction and amount of movement of each tape feed guide 10 when the spacing between the tape feed guides 10 for feeding out the wide tape T illustrated in Figure 3 is changed to the spacing between the tape feed guides 10 for feeding out the narrow tape T illustrated in Figure 2.

[0077] As shown in Figures 5 and 6, when three tapes T are fed out with one tape feeding device 8, if the spacing between the three tape feeding guides 10 is adjusted according to the width of the tape T so that the spacing between the three tape feeding guides 10 is equal, the central tape feeding guide 10 and one of the tape feeding guides 10 on each side are moved in the same direction by different appropriate movement amounts, while the other of the tape feeding guides 10 on each side is moved in the opposite direction by an appropriate movement amount, thereby changing the spacing between the three tape feeding guides 10 while maintaining equal spacing.

[0078] That is, when changing the spacing between the tape feed guides 10 for feeding a wide tape T as shown in Fig. 10 to the spacing between the tape feed guides 10 for feeding a narrow tape T, the central tape feed guide 10 and the left tape feed guide 10 are slid to the right by the appropriate distances indicated by the arrows in Fig. 10 while the right tape feed guide 10 is slid to the left by the appropriate distance indicated by the arrow in Fig. 10, thereby narrowing the spacing between the three tape feed guides 10 to match the width of the tape T while maintaining equal spacing. Furthermore, by performing a similar slide in the opposite direction, the spacing between the three tape feed guides 10 can be widened while maintaining equal spacing.

[0079] This also applies when changing the number of tapes T placed between multiple tapes T fed at intervals from the same tape feeding device 8, such as when pausing some of the multiple tape feeding devices 8 or when adding a new tape feeding device 8.

[0080] Therefore, by determining the winding method of the wire 22 around the drive roller 20 to one of the winding methods shown in Figures 8 and 9 in accordance with the movement direction of the tape feed guide 10, and determining the outer diameter of the drive roller 20 in accordance with the movement distance of the tape feed guide 10 and the wire 22 required to change the spacing while maintaining equal spacing between the tape feed guides 10, the spacing between the tape feed guides 10 can be changed by rotating the drive roller 20 while maintaining equal spacing between the tape feed guides 10.

[0081] Of course, when it is required to vary the spacing between tape feed guides 10 while keeping the spacing uneven, such as when the width of tape T differs between tape feed devices 8 or when the width of tape T differs within the same tape feed device 8, the outer diameter of the drive roller 20 can be determined to match the movement distance of the corresponding tape feed guide 10.

[0082] 5, the wire 22 fixed to the left tape feed guide 10 is wound as shown in FIG. 9 so that the left tape feed guide 10 moves to the right when the drive roller 20 is rotated counterclockwise. In addition, since the sliding distance of the left tape feed guide 10 is the greatest among the three tape feed guides 10, the wire 22 fixed to the left tape feed guide 10 is wound around the drive roller 20 at the position with the largest diameter.

[0083] On the other hand, the wire 22 fixed to the right tape feed guide 10 is wound as shown in Fig. 8 so that the right tape feed guide 10 moves leftward when the drive roller 20 is rotated counterclockwise. Also, because the sliding distance of the right tape feed guide 10 is the second largest among the three tape feed guides 10, the wire 22 fixed to the right tape feed guide 10 is wound around the position on the drive roller 20 where the outer diameter is second largest.

[0084] 9 so that the central tape feed guide 10 moves to the right when the drive roller 20 is rotated counterclockwise. In addition, since the sliding distance of the central tape feed guide 10 is the smallest among the three tape feed guides 10, the wire 22 fixed to the central tape feed guide 10 is wound around the drive roller 20 at the position with the smallest diameter.

[0085] 5 and 6 show an example in which the wire 22 is wound around the drive roller 20, but a power transmission member forming an endless track, such as a power transmission belt, may be used instead of the wire 22. Also, instead of the drive roller 20, a plurality of sprockets with different outer diameters may be arranged coaxially, and each tape feed guide 10 may be moved by a closed-curve chain that moves on each sprocket.

[0086] In other words, if a configuration is adopted as the guide movement mechanism 11 in which one or more rotating bodies, such as drive rollers 20 or sprockets, whose rotation axes are on the same straight line and have a plurality of different outer diameters, are rotated, and multiple closed-curve power transmission members, such as wire 22, power transmission belts or chains, are moved by different amounts corresponding to the different outer diameters of the rotating bodies, the configuration of the guide movement mechanism 11 can be simplified. Furthermore, when using a power transmission member, such as a power transmission belt or chain, whose movement direction cannot be easily changed by the way it is wound, like the wire 22, the rotation direction of some of the multiple rotating bodies may be changed by gears or the like.

[0087] As another example, the guide movement mechanism 11 can be configured using any desired mechanical element for linearly moving an object, such as a ball screw, a rack and pinion, or a cylinder mechanism that reciprocates a piston within a cylinder tube.

[0088] (Fiber arrangement method and composite material molding method) Next, a fiber arranging method and a composite material molding method using the fiber arranging device 1 and the AFP device 4 will be described.

[0089] FIG. 11 is a flowchart showing an example of a flow when FRP is molded from a prepreg tape using the fiber arrangement device 1 and the AFP device 4 shown in FIG.

[0090] First, in step S1, a plurality of tapes T, i.e., a plurality of prepreg tapes, are supplied from different directions to the fiber arrangement device 1. Specifically, as illustrated in Fig. 1, the tapes T are supplied from a plurality of bobbins 2 to the fiber arrangement device 1 from different directions. The width of the tapes T supplied to the fiber arrangement device 1 may be changed to a desired width by the width adjustment device 3 as necessary.

[0091] The plurality of tapes T fed into the fiber arrangement device 1 from different directions are fed into the corresponding tape feeding devices 8. The plurality of tape feeding guides 10 provided in the tape feeding device 8 are positioned in advance by driving a guide moving mechanism 11 so that the intervals correspond to the width of the tape T. Specifically, the plurality of tape feeding guides 10 are positioned by the guide moving mechanism 11 so that the tapes T fed from one tape feeding device 8 can be arranged between the plurality of tapes T fed from another tape feeding device 8 without overlapping each other.

[0092] For this reason, each tape feeding device 8 feeds out a plurality of tapes T whose spacing is regulated by a plurality of tape feeding guides 10. The plurality of tapes T fed out from each tape feeding device 8 are collected by a collecting roller 9. At the collecting roller 9, the plurality of tapes T fed out from different tape feeding devices 8 are arranged alternately, and all of the tapes T collected at the collecting roller 9 are fed out in the same feeding direction. In this way, the plurality of arranged tapes T can be manufactured as FRP material.

[0093] Next, in step S2, the aligned tapes T are stacked. To this end, the aligned tapes T arranged by the fiber array device 1 are supplied to the AFP device 4. Then, the aligned tapes T are stacked by the AFP device 4.

[0094] For example, if the AFP device 4 is configured as shown in Fig. 1 to move the compaction roller 6 relative to the table 5 using the movement mechanism 7, the multiple tapes T supplied to the AFP device 4 are pressed against the table 5 by the compaction roller 6, which moves relative to the table 5 as a result of being driven by the movement mechanism 7. As a result, the multiple tapes T pressed against the table 5 by the compaction roller 6 are fed in the opposite direction to the movement direction of the compaction roller 6.

[0095] The plurality of tapes T first fed onto the table 5 are laid out directly on the table 5 or on a lamination jig J, such as a mold, placed on the table 5. Thereafter, the plurality of tapes T fed onto the table 5 are sequentially laminated on top of the plurality of tapes T adjacent thereto below. Then, when lamination of all the plurality of tapes T is completed, a laminate of tapes T made of prepreg tapes is obtained. In other words, a laminate of the plurality of tapes T already arranged by the fiber arrangement device 1 can be produced by the AFP device 4.

[0096] Furthermore, because the multiple arranged tapes T simultaneously fed from the AFP device 4 do not overlap each other in the width direction, the adhesive force of the prepreg does not act between adjacent tapes T. This makes it possible to feed each tape T at a feed speed and length that is independent of the other tapes T. As a result, even if the compaction roller 6 moves in a curved line, each tape T can be fed without slack or excessive tension occurring in each tape T. This makes it possible to manufacture laminates of tapes T with complex shapes.

[0097] Next, in step S3, the resin contained in the laminate of tape T is cured. This allows the FRP to be molded. In other words, the laminate of tape T produced by the AFP device 4 can be used to mold the FRP, also known as a composite material.

[0098] If the resin is a thermosetting resin, it can be cured by heating it in a heating device such as an autoclave or an oven, whereas if the resin is a thermoplastic resin, it can be cured by cooling the resin that has been heated and melted in advance in a cooling device or by air-cooling it.

[0099] When curing the resin, the laminate of tapes T may be transferred from the lamination jig J to a molding jig, or the resin may be cured using a common jig J. Normally, when curing resin, it is necessary to apply pressure to the laminate of tapes T from above. For this reason, the laminate of tapes T may be pressurized with an upper mold, or atmospheric pressure may be applied to the laminate of tapes T by bagging using vacuum. Furthermore, devices necessary for molding FRP, such as an upper mold, vacuum device, heating device, or cooling device, may be integrated with the AFP device 4.

[0100] Fig. 12 is a flowchart showing an example of the flow when FRP is formed using dry tape as a material using the fiber arrangement device 1 and AFP device 4 shown in Fig. 1. Note that in Fig. 12, steps that are similar to those in Fig. 11 are given the same reference numerals, and detailed explanations will be omitted, except for whether the tape T is dry tape or prepreg tape.

[0101] Dry tapes can also be arranged by the fiber arrangement device 1 and laminated by the AFP device 4 or other dedicated lamination device. In that case, in step S2, a laminate of tapes T made of dry tapes is obtained. For this purpose, in step S10, resin is injected into the laminate of tapes T. For this purpose, the laminate of tapes T is bagged by vacuuming or sealed in a mold. Then, in step S3, the FRP is formed by hardening the resin impregnated after the tapes T are laminated.

[0102] (effect) The fiber arrangement device 1, fiber arrangement method, and composite material molding method described above are designed to arrange multiple tapes T without overlapping by alternately arranging multiple sets of tapes T consisting of prepreg tapes or dry tapes fed at adjustable intervals.

[0103] Therefore, the fiber arrangement device 1, the fiber arrangement method, and the composite material molding method make it possible to simultaneously stack a large number of tapes T. Moreover, because the feed speed and feed length can be changed between tapes T, the tapes T can be stacked in a curved pattern without generating excessive tension or slack in the tapes T. As a result, it becomes possible to mold FRP with more complex shapes.

[0104] In particular, since the spacing between the tapes T to be alternately arranged can be changed, even when FRP is formed using tapes T of different widths, it is possible to avoid the occurrence of excessive gaps (GAP) or significant overlaps (LAP) between adjacent tapes T. In other words, high-quality lamination of tapes T of various widths becomes possible.

[0105] As a result, not only can the overall width of multiple tapes T be changed after stacking, but it is also possible to use tape T with an appropriate width according to the shape of the FRP as the material, such that when multiple tapes T are fed along a curve with a large curvature, narrower tape T can be used to ensure quality, while when multiple tapes T are fed along a straight line or a curve with a small curvature, wider tape T can be used to improve stacking efficiency.

[0106] In addition, since the multiple tapes T already arranged by the fiber arrangement device 1 are fed out from the AFP device 4, there is no interference between the mechanisms for feeding out the multiple tapes T in the AFP device 4, and there is no need to feed the tapes T alternately from the AFP device 4. In other words, without providing a compaction roller for each tape T, the multiple tapes T can be fed out simultaneously while applying pressure to them with a common and single compaction roller 6.

[0107] This allows the configuration of the stacking head of the AFP device 4 to be simple and compact even when a large number of tapes T are fed out. In other words, it is possible to stack a larger number of tapes T simultaneously without making the configuration of the stacking head of the AFP device 4 complex and large.

[0108] Furthermore, since the AFP device 4 does not need to be provided with a stacking head including a compaction roller for each tape T, even if the width and number of tapes T are changed, there is no need to slide the stacking head in the width direction of the tapes T. This makes it possible to easily change not only the width of each tape T fed out from the AFP device 4 but also the number of tapes T. In other words, it is no longer necessary to provide the AFP device 4 with a stacking head having a complex mechanism for feeding out multiple tapes T with different widths and numbers.

[0109] (Second embodiment) FIG. 13 is a configuration diagram of a fiber array device according to a second embodiment of the present invention.

[0110] The fiber array device 1A of the second embodiment shown in Figure 13 differs from the fiber array device 1 of the first embodiment in that it is configured to automatically adjust the spacing of the tape feed guides 10 in real time based on the width of the tape T measured by the width sensor 30 while the tape T is being fed. Since the other configurations and functions of the fiber array device 1A of the second embodiment are substantially the same as those of the fiber array device 1 of the first embodiment, only the main components of the fiber array device 1A are shown as a block diagram, and the same or corresponding components are designated with the same reference numerals and will not be described.

[0111] Each tape feeding device 8 of the fiber arraying device 1A in the second embodiment is provided with a width sensor 30 that detects the width of each tape T. Therefore, each tape feeding device 8 is provided with width sensors 30 in a number equal to the number of tapes T, and the fiber arraying device 1A is provided with width sensors 30 equal to the total number of tapes T to be arrayed. For example, as illustrated in Figures 1 and 2, if three tapes TA, TB, and TC are fed from the first to third tape feeding devices 8A, 8B, and 8C, respectively, nine width sensors 30 are provided.

[0112] Any known sensor can be used as the width sensor 30. Known non-contact width sensors 30 for measuring the width of the tape T include those using a reflective laser displacement sensor or a transmissive laser displacement sensor. Alternatively, the tape T can be photographed with an image sensor and the width of the tape T can be detected by image processing.

[0113] When a reflective laser displacement sensor is used, the two edges on both sides of the tape T can be detected by measuring the displacement in the thickness direction of the tape T with a single or pair of reflective laser displacement sensors that emit a band-shaped laser beam that crosses the edges on both sides of the tape T. Therefore, the distance between the edges can be detected as the width. On the other hand, when a transmissive laser displacement sensor is used, a single or pair of laser oscillators that emit a band-shaped laser beam that crosses the edges on both sides of the tape T, and a single or pair of laser light detectors that detect the laser beam emitted from the laser oscillators are arranged on either side of the tape T, and the range where the laser beam is blocked by the tape T and therefore not detected by the laser light detectors can be detected as the width.

[0114] The width of the tape T measured by each width sensor 30 provided in a certain tape feeding device 8 is output to the control device 31 of the guide movement mechanism 11 provided in all other tape feeding devices 8. The control device 31 of each guide movement mechanism 11 is configured to control the spacing of the multiple tape feeding guides 10 controlled by that guide movement mechanism 11 based on the width of each tape T measured by the width sensors 30 provided in all other tape feeding devices 8. In other words, the control device 31 controls the guide movement mechanism 11 so that the spacing of the tape feeding guides 10 becomes an appropriate spacing corresponding to the width of each tape T fed from the other tape feeding devices 8.

[0115] For example, in the case where three tapes TA, TB, and TC are fed out from the first to third tape feeding devices 8A, 8B, and 8C, respectively, as illustrated in Figures 1, 2, and 13, the widths of the first plurality of tapes TA measured by the first plurality of width sensors 30A provided in the first tape feeding device 8A are output to the second control device 31B of the second guide moving mechanism 11B provided in the second tape feeding device 8B and the third control device 31C of the third guide moving mechanism 11C provided in the third tape feeding device 8C.

[0116] Similarly, the widths of the second plurality of tapes TB measured by the second plurality of width sensors 30B provided in the second tape feeding device 8B are output to the first control device 31A of the first guide moving mechanism 11A provided in the first tape feeding device 8A and the third control device 31C of the third guide moving mechanism 11C provided in the third tape feeding device 8C, and the widths of the third plurality of tapes TC measured by the third plurality of width sensors 30C provided in the third tape feeding device 8C are output to the first control device 31A of the first guide moving mechanism 11A provided in the first tape feeding device 8A and the second control device 31B of the second guide moving mechanism 11B provided in the second tape feeding device 8B.

[0117] Then, the first control device 31A of the first guide moving mechanism 11A provided in the first tape feeding device 8A controls the spacing of the first plurality of tape feeding guides 10A based on the widths of the second plurality of tapes TB measured by the second plurality of width sensors 30B provided in the second tape feeding device 8B and the widths of the third plurality of tapes TC measured by the third plurality of width sensors 30C provided in the third tape feeding device 8C so that the spacing of the first plurality of tape feeding guides 10A is an appropriate spacing corresponding to the width of the second tape TB fed from the second tape feeding device 8B and the width of the third tape TC fed from the third tape feeding device 8C, specifically, a spacing that allows the second tape TB fed from the second tape feeding device 8B and the third tape TC fed from the third tape feeding device 8C to be arranged without overlapping.

[0118] Similarly, the second control device 31B of the second guide moving mechanism 11B provided in the second tape feeding device 8B controls the spacing of the second multiple tape feeding guides 10B based on the widths of the first multiple tapes TA measured by the first multiple width sensors 30A provided in the first tape feeding device 8A and the widths of the third multiple tapes TC measured by the third multiple width sensors 30C provided in the third tape feeding device 8C so that the spacing of the second multiple tape feeding guides 10B is an appropriate spacing corresponding to the width of the first tape TA fed from the first tape feeding device 8A and the width of the third tape TC fed from the third tape feeding device 8C, specifically, a spacing that allows the first tape TA fed from the first tape feeding device 8A and the third tape TC fed from the third tape feeding device 8C to be arranged without overlapping. The same applies to the third control device 31C of the third guide movement mechanism 11C provided in the third tape feeding device 8C.

[0119] 5 and 6, if the guide moving mechanism 11 is driven by the motor 21, the control target of the control device 31 is the motor 21. Therefore, the control device 31 outputs a control command signal to the motor 21 indicating the amount of rotation of the motor 21, which corresponds to the spacing of the tape feed guides 10B, thereby controlling the spacing of the tape feed guides 10B.

[0120] In this way, by controlling the spacing of each tape feed guide 10 in accordance with the width of each tape T actually measured by each width sensor 30, even if the width of the tape T changes while the tape T is being fed, the spacing of the tape feed guides 10 can be changed to follow the width of the tape T. Therefore, each tape T can be supplied to the fiber arrangement device 1A while changing its width while being fed.

[0121] FIG. 14 is a plan view showing examples of shapes of a plurality of tapes T that can be arranged by the fiber arrangement device 1A shown in FIG.

[0122] The shape of the tape T supplied to the fiber arrangement device 1A while changing its width at a constant rate of change per unit time becomes a trapezoid as a whole, as shown in Fig. 14. That is, by arranging multiple tapes T each having a variable width using the fiber arrangement device 1A, it is possible to change the overall width of the multiple tapes T after arrangement. Of course, multiple tapes T may also be supplied to the fiber arrangement device 1A while changing their width without keeping the rate of change per unit time constant, in which case the overall shape of the multiple tapes T after arrangement can be made more complex.

[0123] When supplying a plurality of tapes T to the fiber array device 1A while changing the width, it is necessary to provide a width adjustment device 3 upstream of the fiber array device 1A as shown in Fig. 1. Then, while the tape T is being fed out, it is necessary to control in real time not only the spacing between each tape feed guide 10 but also the width adjustment device 3. Therefore, based on the width of each tape T measured by each width sensor 30, feedback control can be performed so that the width of the tape T fed out from the corresponding width adjustment device 3 becomes the target width.

[0124] FIG. 15 is a diagram showing an example of a control block diagram in which feedback control of the width adjusting device 3 is performed based on the width of the tape T measured by the width sensor 30 shown in FIG.

[0125] 15, the width of the tape T adjusted by the width adjustment device 3 is measured by the width sensor 30. The width of the tape T measured by the width sensor 30 is output to the control device 31 of the guide movement mechanism 11 in order to control the spacing of the tape feed guides 10B.

[0126] In addition, the width of the tape T measured by the width sensor 30 can also be output to the width adjustment device 3. Then, the width adjustment device 3 can be feedback-controlled so that the difference between the target width of the tape T given to the width adjustment device 3 as a time-series control command value and the actual width of the tape T measured by the width sensor 30 approaches zero.

[0127] 15 is a control block diagram focusing on one width adjustment device 3, it is possible to perform integrated control on a plurality of width adjustment devices 3, the number of which is equal to the number of tapes T. Therefore, it is possible to perform feedback control on the plurality of width adjustment devices 3, with the overall width of the plurality of tapes T after arrangement as a target value.

[0128] Furthermore, if the variation in width between tapes T fed by the same tape feeding device 8 can be ignored, the width of one tape T or only some of the tapes T among multiple tapes T fed by the same tape feeding device 8 can be measured as a representative value using at least one width sensor 30, and the width of the tapes T not measured by the width sensor 30 can be used as a representative value or an estimated value based on the representative value.

[0129] According to the second embodiment described above, in addition to the same effects as those of the first embodiment, it is possible to obtain an effect that the width of the entire plurality of tapes T after arrangement can be changed while they are fed out, which makes it possible to form FRP having a more complex shape.

[0130] Incidentally, even in the first embodiment, if a control program that determines the amount of change in the spacing between each tape feed guide 10 based on the amount of change in the width of each tape T to be supplied, i.e., a control program for time-series positioning of each tape feed guide 10, is prepared in advance, and each guide movement mechanism 11 is controlled by the control program, it becomes possible to feed out multiple tapes T while changing the overall width of the tapes T after arrangement. However, if the guide movement mechanism 11 is controlled based on the width of the tape T measured by the width sensor 30 as in the second embodiment, not only is it not necessary to create a control program for each shape of FRP, but it is also possible to eliminate the need to prepare a complex control program altogether.

[0131] (Other embodiments) Although specific embodiments have been described above, the described embodiments are merely examples and do not limit the scope of the invention. The novel methods and apparatus described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and modifications may be made in the forms of the methods and apparatus described herein without departing from the spirit of the invention. The appended claims and their equivalents include all such forms and modifications as fall within the scope and spirit of the invention. [Explanation of symbols]

[0132] 1. 1A Fiber alignment device 2 bobbins 3 Width adjustment device 4. Automated Fiber Placement (AFP) Equipment 5 tables 6 Compaction roller 7 Moving mechanism 8, 8A, 8B, 8C Tape feeding device 9. Collecting Roller 10, 10A, 10B, 10C Tape feed guide 11, 11A, 11B, 11C Guide movement mechanism 12 Feeding stand 13 Feeding roller 20 Drive roller 21 Motor 22 wires 23 Pulley 24 Slide mechanism 25 Connector 26 Tensioner 27 Shaft 30, 30A, 30B, 30C width sensor 31, 31A, 31B, 31C control device J jig T, TA, TB, TC tape θ Rotation angle of the drive roller

Claims

1. a first plurality of guides for guiding the feeding of a first plurality of tapes made of fiber or prepreg in a first feeding direction; a first moving mechanism that changes the spacing between the first plurality of guides so that the first plurality of tapes are fed in the first feeding direction at first spacings; a second plurality of guides for guiding the feeding of a second plurality of tapes made of fiber or prepreg in a second feeding direction different from the first feeding direction; a second moving mechanism that changes the spacing between the second plurality of guides so that the second plurality of tapes are fed in the second feeding direction at second spacings; rollers arranged so that the first plurality of tapes fed out from the first plurality of guides at the first intervals and the second plurality of tapes fed out from the second plurality of guides at the second intervals are fed out in the same feeding direction in an alternating arrangement; a first sensor for detecting a width of the first plurality of tapes; a second sensor for detecting the width of the second plurality of tapes; and A fiber arrangement device configured such that the first movement mechanism controls the spacing of the first plurality of guides based on the width of the second plurality of tapes detected by the second sensor, while the second movement mechanism controls the spacing of the second plurality of guides based on the width of the first plurality of tapes detected by the first sensor.

2. The first moving mechanism includes: a single or multiple rotating bodies that rotate around a common rotation axis and have multiple different outer diameters; a plurality of power transmission members each having a closed curve shape, each of which receives power from the portions of the rotor having the different outer diameters, moves in a longitudinal direction, and is connected to one of the first plurality of guides, thereby moving each of the first plurality of guides by a different movement amount corresponding to the different outer diameters; The fiber arrangement device according to claim 1, further comprising:

3. A first plurality of guides for guiding the feeding of a first plurality of tapes made of fiber or prepreg in a first feeding direction; a first moving mechanism that changes the spacing between the first plurality of guides so that the first plurality of tapes are fed in the first feeding direction at first spacings; a second plurality of guides for guiding the feeding of a second plurality of tapes made of fiber or prepreg in a second feeding direction different from the first feeding direction; a second moving mechanism that changes the spacing between the second plurality of guides so that the second plurality of tapes are fed in the second feeding direction at second spacings; rollers arranged so that the first plurality of tapes fed out from the first plurality of guides at the first intervals and the second plurality of tapes fed out from the second plurality of guides at the second intervals are fed out in the same feeding direction in an alternating arrangement; and The first moving mechanism includes: a single or multiple rotating bodies that rotate around a common rotation axis and have multiple different outer diameters; a plurality of power transmission members each having a closed curve shape, each of which receives power from the portions of the rotor having the different outer diameters, moves in a longitudinal direction, and is connected to one of the first plurality of guides, thereby moving each of the first plurality of guides by a different movement amount corresponding to the different outer diameters; A fiber arrangement device having:

4. A fiber arrangement method using the fiber arrangement device described in any one of claims 1 to 3, which produces a plurality of arranged tapes including the first plurality of tapes having the first spacing and the second plurality of tapes having the second spacing, such that adjacent tapes in the width direction do not overlap in the width direction.

5. a step of manufacturing a stack of the arranged tapes by stacking the arranged tapes manufactured by the fiber arrangement method according to claim 4; forming a composite material using the laminate; A composite molding method comprising:

Images