Cutting assembly for tape lamination machine

Abstract

A cutting assembly for a tape laying head that applies a plurality of composite tape segments includes a cutting device carriage configured to slide relative to the tape laying head adjacent the composite tape in the direction of movement of the composite tape, and a cutting device assembly carried by the cutting device carriage that includes a cutting blade and a cutting anvil, the cutting blade configured to cut the composite tape while the cutting carriage moves at a speed equal to the movement of the composite tape through the tape laying head.

Description

Technical Field

[0001] Cross - reference to Related Patent Applications

[0001] This application is a patent application under the Patent Cooperation Treaty claiming the benefit of priority of U.S. Provisional Patent Application No. 62 / 971,040, filed on February 6, 2020, the entire content of which is incorporated herein by reference.

[0002]

[0002] This application relates to a tape lay - up machine, and more particularly, to a cutting assembly included in a tape lay - up head.

Background Art

[0003]

[0003] Tape lay - up machines are used to create composite workpieces. Composite materials in the form of fiber materials impregnated with resin are attached by a tape lay - up machine at precise locations and lengths in order to integrally form a composite workpiece. The tape lay - up machine moves a tape lay - up head in order to accurately attach the composite material tape in the final shape of the composite workpiece. As the tape lay - up head moves, it leaves a plurality of composite material tape segments, also referred to as a course or an index. Automatically attaching these composite material tape segments involves the cooperation of a variety of assemblies of machines that hold, move, and ultimately cut the composite material tape.

Summary of the Invention

Problems to be Solved by the Invention

[0004]

[0004] After a predetermined amount of composite material tape has been moved through the tape lay - up head, the tape lay - up head can cut the tape, creating a composite material tape of a selected length. However, during the cutting process, the tape lay - up head may need to stop the movement of the composite material tape in order to accurately cut the tape. Stopping the movement of the composite material tape through the tape lay - up head can reduce the speed at which a composite workpiece can be formed. [Means for solving the problem]

[0005]

[0005] In one implementation, the cutting assembly for a tape lamination head for attaching a plurality of composite tape segments comprises: a cutting device carriage configured to slide relative to the tape lamination head adjacent to the composite tape in the direction of movement of the composite tape; a linear motor configured to move the cutting device carriage in the direction of movement of the composite tape; and a cutting blade and a cutting anvil, wherein the cutting blade is configured to cut the composite tape while the cutting carriage moves at a speed equal to the speed at which the composite tape moves through the tape lamination head.

[0006]

[0006] In another implementation, a tape lamination head for attaching a plurality of composite tape segments comprises a frame that carries a composite tape supply reel and a plurality of reversing rollers, and a cutting assembly slidably connected to the frame, the cutting assembly comprising: a cutting device carriage configured to slide relative to the tape lamination head adjacent to the composite tape in the direction of movement of the composite tape; a linear motor configured to move the cutting device carriage in the direction of movement of the composite tape at a speed equal to the speed at which the composite tape moves through the tape lamination head; and a cutting device assembly supported by the cutting device carriage, the cutting device assembly comprising a cutting blade and a cutting anvil, wherein the cutting blade is configured to cut the composite tape while the cutting carriage moves at a speed equal to the speed at which the composite tape moves through the tape lamination head. [Brief explanation of the drawing]

[0007] [Figure 1]

[0007] This is a perspective view showing the mounting configuration of the tape stacking machine. [Figure 2]

[0008] This is a perspective view showing the mounting configuration of a tape stacking head. [Figure 3]

[0009] This is another perspective view showing a portion of the mounting configuration of the tape stacking head. [Figure 4]

[0010] This is another perspective view showing a portion of the mounting configuration of the tape stacking head. [Figure 5]

[0011] This is another perspective view showing the mounting configuration of the cutting assembly used with the tape stacking head. [Figure 6]

[0012] This is a profile diagram showing the mounting configuration of the cutting assembly used with the tape stacking head. [Modes for carrying out the invention]

[0008]

[0013] A tape lamination machine has a cutting assembly that slides along the composite tape path, adjacent to the composite tape path. The cutting assembly may have a cutting device carriage that moves at the same speed as the composite tape passes adjacent to the cutting assembly, so that composite tape segments can be cut as they move. Therefore, the cutting assembly can move in coordination with the movement of the composite tape so that the cutting blade is positioned adjacent to the edge of the composite tape, either when there is no relative movement between the cutting blade and the composite tape, or when there is a certain degree of relative movement between the cutting blade and the composite tape only until the cutting blade crosses the tape. This can help to perform certain cuts, such as plum cuts, with greater precision.

[0009]

[0014] Figure 1 shows an implementation configuration of the tape laminating machine 10. The tape laminating machine 10 has a gantry 12 that movably supports a tape laminating head 14 on a table base 16, and a composite part is formed on the table base 16 from multiple composite tape segments. The gantry 12 may have horizontal supports 20 attached to the upper end of a vertical support 18, or vertical supports 18 joined via beams. The gantry 12 may be implemented as a multi-axis tape laminating machine 10, such as a Cincinnati CHARGER ATL or GEMINI. In one implementation configuration, the tape laminating machine 10 can enable six-axis movement of the tape laminating head 14. The bottom of the vertical support 18 can move linearly along the X-axis relative to the table base 16. The bottom of the vertical support 18 can move on rails 22 or wheels to move the gantry 12 along the X-axis. In one embodiment, rails 22 may be included on the table base 16, resulting in the vertical support 18 being placed on the table. In an alternative configuration, the rail 22 may be formed on the floor on which the tape stacking machine 10 is mounted. A ram 24 can support the tape stacking head 14 to raise and lower it relative to the table base 16 along the Z axis. The tape stacking head 14 may be slidably connected to a horizontal support 20 at the distal end of the ram 24 relative to the tape stacking head. This slidable connection can allow the frame to be moved along the Y axis on the table base 16. A detachable connection 26 between the tape stacking head 14 and the ram 24 can allow the tape stacking head to be removed and replaced. The vertical support 18 and the ram 24 can be moved along the X, Y, and Z axes to position the tape stacking head 14 relative to the exchange station 28. Another tape stacking head 14 may then be connected to the ram 24 and moved to a fixed position on the table base 16 by the gantry 12.

[0010]

[0015] The movement of the gantry 12, including the vertical support 18 and ram 24, may be controlled by an operator station 30. The operator station 30 has one or more microprocessors (not shown) in communication with a computer-readable storage medium having executable instructions that can control the movement of a fluid ram, electric motor, or other drive element for the purpose of controlling the motion and position of the gantry 12 and the operation of the tape stacking head 14. The microprocessor may be any type of device capable of processing electronic instructions, including a microcontroller, host processor, control unit, and application-specific integrated circuit (ASIC). The microprocessor may be a dedicated processor used solely for controlling the gantry 12, or it may be shared with other mechanical functions. The microprocessor executes various types of digitally stored instructions, such as software programs or firmware programs stored in a storage device. Communication between the microprocessor and the mechanism, such as a fluid ram or electric motor, that moves the gantry 12 and the tape stacking head 14, may be performed via a communication bus.

[0011]

[0016] The tape lamination head 14 has a frame 32 coupled to a releasable connector 26 that releasably attaches the head to a ram 24. The frame 32 can support a supply reel 34 carrying composite tape 36, which is ultimately supplied to a compression assembly 38, which applies the tape 36 to a table base 16. Along the way, the composite tape 36 can pass over a supply dancer 40, a first direction change roller 42, a second direction change roller 44, and a scrap crack-off roller 46, which together determine the path of the tape 36 so that it is adjacent to the cutting assembly 48. The composite tape 36 can be wound around the supply reel 34 in one of several widths. For example, a composite tape 36 having a width of 3.81 cm (1.5") to 30.5 cm (12") may be wound around a supply reel 34 so that it is unwound when the composite tape 36 is later passed through a tape lamination head 14. The composition of the composite tape 36 is known, and as an example of a composite tape, it may include carbon fiber. Backing paper (in other words, backing paper) 50 may be attached to one side of the composite tape 36 so that the surface of the composite tape 36 later does not come into contact with the subsequent layer on which the composite tape 36 is wound. A supply dancer 40, a first reversing roller 42, and a second reversing roller 44 may be attached to a dancer mechanism 52, which controls the tension acting on the composite tape 36 as it is pulled from the supply reel 34 and fed to the compression assembly 38. The dancing mechanism 52 may allow linear movement of the rollers under the control of a spring, such as a pneumatic air spring with programmably adjustable pressure. One or more electric motors may be used to apply rotational force to the supply reel 34, the supply dancer 40, the first direction change roller 42, or the second direction change roller 44.A backing paper reel 54 is included in the tape lamination head 14, and the backing paper reel 54 is capable of receiving backing paper 50 that is removed from the composite tape 36 before the composite tape 36 is applied to the table base 16. In one configuration, a servo motor powered by a servo drive is used to control the movement of the composite tape 36 along the supply reel 34, the supply dancer 40, or the backing paper reel 54.

[0012]

[0017] The cutting assembly 48 is contained within the tape lamination head 14, and the cutting assembly 48 moves along a linear path in the direction of movement of the composite tape via the cutting device carriage 56. The linear path may be a rail 58 or a slot, on which the cutting assembly 48 moves in a straight line adjacent to the path of the composite tape moving toward the compression assembly 38. In this configuration, the cutting assembly 48 moves vertically from the top portion 60 of the tape lamination head 14 to the bottom portion 62 of the tape lamination head 14. A linear motor 64 can move the cutting assembly 48 along the rail 58 in the same direction or plane as the composite tape 36 moves toward the compression assembly 38. When the cutting assembly 48 approaches the end of its movement, a crash stop 66 can help stop the downward movement of the assembly 48.

[0013]

[0018] The cutting assembly 48 may have a cutting blade 68 that presses against the cutting anvil 70 as the composite tape 36 passes toward the compression assembly 38 to cut a section of the composite tape 36. Rather than stopping the movement of the composite tape 36 through the tape lamination head 14, the cutting assembly 48 may be moved together with the composite tape 36, so that the cutting blade 68 moves at the same speed as the composite tape 36. In this way, when the cutting blade 68 is moved to cut the composite tape 36, only relative motion occurs between the composite tape 36 and the cutting blade 68. Furthermore, the speed at which the composite tape 36 passes through the tape lamination head 14 is reduced compared to when the composite tape 36 is not cut. In one implementation, the cutting blade 68 may move in four axes to create a more complex shape in which at least a portion of it is angled relative to the edge 72 of the composite tape 36, in addition to creating a butt cut shape perpendicular to the movement of the composite tape 36. The knife rotation axis 74 and the knife depth axis 76 can be controlled using electric motors that rotate the knife relative to axes 74 and 76 or move the knife linearly. In one implementation, the knife height can be adjusted within a range of movement from 5 millimeters (mm) to 30 mm. The positioning angle of the cutting blade 68 and the tape cutting depth can be monitored by a blade angle sensor 78 and a blade depth sensor 80, respectively. The cutting assembly 48 can be implemented as an ultrasonic cutting device, such as the Sonotec SF 8500.

[0014]

[0019] The cutting blade 68 can be moved across the composite tape 36 along the cutting transverse axis (C). In some implementations, a linear actuator, such as a ball screw, can move the cutting blade 68 across the composite tape 36 to form composite tape segments. This cutting motion can separate one section of the composite tape 36 from another, while the backing paper 50 remains attached to these two sections. Connecting the composite tape 36 using the backing paper 50 can help move the composite tape segments through the tape lamination head 14. Furthermore, the cutting of the composite tape 36 can be controlled using a cutting anvil 70, against which the cutting blade 68 presses when cutting the tape. For example, the cutting anvil 70 may have a non-rectangular shape, such as a trapezoidal surface, and may be pivoted around an anvil pivot axis 82 to expose a cutting surface of a particular shape. In some implementations, the cutting assembly 48 may have a press roller 80 positioned adjacent to the cutting blade 68. A retaining roller may be positioned on the tape side of the composite tape opposite the cutting anvil 70. The retaining roller 80 may have a flange on its outer edge, which is adjustable along the roller rotation axis, for the purpose of centering the composite tape for cutting and / or accommodating various tape sizes. The retaining roller 80 can hold a portion of the composite tape 36 in place. The retaining roller 80 may be able to spin freely, and can slightly curve the composite tape backward to maintain it pressed against the cutting anvil 70, and further, can press a portion of the composite tape 36 to contact the cutting anvil 70 and hold it in place.

[0015]

[0020] 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 solely by the claims below. Furthermore, the descriptions contained herein relate to specific embodiments and should not be construed as limiting the definitions of terms used in the scope of the present invention or in the claims unless terms or phrases are specifically defined above. Various other embodiments, as well as various modifications and alterations to the disclosed embodiments, will be apparent to those skilled in the art. All such other embodiments, modifications, and alterations are intended to fall within the scope of the appended claims.

[0016]

[0021] As used herein and in the claims, the terms “eg,” “for example,” “for instance,” “such as,” and “like,” as well as the verbs “comprising,” “having,” and “including,” and other verbal forms, respectively, when used with a list or other item of one or more components, are to be interpreted as open, meaning that the list is not to be interpreted as excluding any other additional components or items. Other terms are also to be interpreted in their broadest and most reasonable sense unless used in a context requiring a different interpretation.

Claims

1. A cutting assembly for a tape lamination head that applies multiple composite tape segments, A cutting device carriage configured to slide linearly with respect to the tape lamination head adjacent to the composite material tape in the direction of movement of the composite material tape, A cutting device assembly supported by a cutting device carriage, comprising a cutting blade and a cutting anvil, wherein the cutting blade is configured to move across the composite material tape along a cutting transverse axis (C) while the cutting device carriage moves at a speed equal to the speed at which the composite material tape moves through the tape lamination head, thereby cutting the composite material tape; A blade depth sensor configured to monitor the depth of tape cutting formed by the cutting blade, A cut assembly comprising the above.

2. The cutting assembly according to claim 1, further comprising a rail, wherein the cutting device carriage slides on the rail relative to the tape stacking head.

3. The cutting assembly according to claim 1, wherein the cutting device carriage moves in the direction of movement of the composite material tape at a speed equal to the speed at which the composite material tape moves through the tape lamination head.

4. The cutting assembly according to claim 1, wherein the cutting anvil pivots.

5. The cutting assembly according to claim 1, wherein the cutting assembly has a knife height axis.

6. The cutting assembly according to claim 1, wherein the cutting assembly has a knife rotation axis.

7. The cutting assembly according to claim 1, further comprising a blade angle sensor.

8. The cutting assembly according to claim 1, wherein the cutting device assembly is an ultrasonic cutting device.

9. The cutting assembly according to claim 1, further comprising a linear motor configured to move the cutting device carriage in the direction of movement of the composite material tape.

10. A tape lamination head for applying multiple composite tape segments, A frame supporting a composite material tape supply reel and multiple direction-changing rollers, A cut assembly slidably connected to the frame, The cut assembly is equipped with, A cutting device carriage configured to slide adjacent to the composite material tape and relative to the tape lamination head in the direction of movement of the composite material tape, A linear motor configured to move the cutting device carriage in the direction of movement of the composite material tape at a speed equal to the speed at which the composite material tape moves through the tape lamination head, and A cutting device assembly supported by a cutting device carriage, comprising a cutting blade and a cutting anvil, wherein the cutting blade is configured to move across the composite material tape along a cutting transverse axis (C) while the cutting device carriage moves at a speed equal to the speed at which the composite material tape moves through the tape lamination head, thereby cutting the composite material tape. Equipped with, The cutting assembly further includes a blade depth sensor configured to monitor the depth of the tape cut formed by the cutting blade. Tape stacking head.

11. The tape stacking head according to claim 10, further comprising a rail, wherein the cutting device carriage slides on the rail relative to the tape stacking head.

12. The tape lamination head according to claim 10, wherein the cutting anvil pivots.

13. The tape lamination head according to claim 10, wherein the cutting assembly has a knife height axis.

14. The tape lamination head according to claim 10, wherein the cutting assembly has a knife rotation axis.

Images