A laying head for automated laying of strips of polymer composite material onto a forming surface

Abstract

This utility model relates to equipment for the automated laying of tapes of thermosetting and thermoplastic polymer composite material onto a forming surface, primarily of complex curved shapes, and can be used in automated laying systems for fibrous and tape composite materials. The technical result of the claimed utility model is the creation of a laying head for the automated laying of tapes of thermosetting polymer composite material, enabling a more uniform and customized application of clamping force to the respective tapes being laid on a curved forming surface.The technical result is achieved due to the fact that the laying head for the automated laying of tapes made of a polymer composite material onto a shaping surface comprises a housing configured to interact with an unwinding and tensioning unit, a tape feed channel and a clamping module, a feed module, a cutting module, a cooling module, a heating module, a module for pressing the tapes onto the shaping surface, located along the feed channel, the pressing module is designed as a segmented pressure roller consisting of segments located across the width of the roller, each of which is mounted with the possibility of independent rotation and independent movement relative to the roller axis, wherein the segments are configured to individually apply a pressing force to the corresponding tapes being laid on a curved surface, wherein the roller comprises a chamber with a working fluid and a quick-change unit. 9 c.p. fils, 1 fig.

Description

[0001] The utility model relates to equipment for automated laying out tapes of thermosetting and thermoplastic polymer composite material on a shaping surface, mainly of a complex curved shape, and can be used as part of installations for automated laying out of fibrous and tape composite materials.

[0002] U.S. Patent 6,390,169 B1 discloses a pressing device for a fiber placement machine comprising a plurality of independent segments arranged side by side. The segments are mounted so as to be independently movable relative to one another, allowing the roller to adapt to complex surfaces, including concave and convex areas, and ensure more uniform compaction of the material being placed. This solution also discloses the use of at least one expandable element, which, when filled with air or another fluid, transmits force to the roller segments.

[0003] US Patent 7,810,539 B2 describes a clamping device for a fiber placement head that interacts with individual ribbons or bundles of material. This source confirms the development of designs aimed at ensuring a stable clamping action on the composite material being laid out.

[0004] A solution is known from US Patent Application No. 2007 / 0044922 A1, in which the segments of a pressure roller are mounted so as to be movable relative to the roller axis, and cavities, channels, and reservoirs for a pressurized working fluid are provided within the roller. This source confirms the known features associated with the use of a fluid system in a segmented pressure device for transmitting and equalizing force between the segments. EP 2035214 A2 discloses a device comprising a series of segments capable of moving relative to one another, with force being transmitted to the segments via pressure elements. Such elements are disclosed, in particular, as elastomeric chambers filled with a pressurized fluid, as well as designs using an incompressible fluid. This source confirms the known use of liquid and pneumatic chambers in segmented pressure devices designed to ensure roller adaptation to surface geometry and pressure distribution between the segments.

[0006] US Patent 9,248,591 B2 discloses a technical solution comprising a segmented roller comprising several independent roller segments. This solution is designed to enable the adaptability of a pressure roller to a curved surface when laying composite material. In terms of its intended purpose and the combination of its essential features, it is the closest prior art to the claimed utility model.

[0007] European application EP 3848188A1 discloses a modular device in which the head is detachable from and reattachable to the machine. Electrical, air, and fluid lines can be releasably connected to the head during this connection. This source confirms the prior art of modular laying heads and quick-release interfaces for their replacement and maintenance.

[0008] Thus, the prior art separately discloses laying heads for automated laying of composite materials, segmented pressure rollers, independent mobility of segments when working on a curved surface, the use of a fluid medium in cavities or chambers of the pressure device, as well as a modular design of the head with the possibility of quick disconnection and reconnection.

[0009] The closest equivalent to the claimed utility model is the technical solution in US Patent No. 9,248,591 B2, which discloses a laying head for a fiber laying machine containing a segmented pressure roller consisting of several independent segments and designed to press the laid material against a complex-shaped surface. This source is the closest in purpose, scope of application, and the design of the pressure module as a segmented roller operating within the laying head.

[0010] The drawback of the closest analog is that, when the segmented pressure roller is opened, it does not reveal the combination of features that simultaneously provide for the presence of a working fluid chamber and a quick-change unit within the laying head, while maintaining the functionality of individually applying pressure to the respective belts being laid on a curved surface. In other words, the closest analog solves the problem of adapting the roller to the surface geometry, but does not describe in a single technical solution the combined implementation of a segmented roller with a working fluid chamber and a quick-change head interface.

[0011] Furthermore, prior art solutions related to fluid chambers and fluid systems of clamping devices are disclosed primarily as standalone improvements aimed at equalizing the load between segments and compensating for surface unevenness, but not in combination with a modular, quick-change laying head in the combination claimed in the utility model. Similarly, solutions describing modular or quick-release laying heads are aimed primarily at simplifying maintenance and head replacement, but do not simultaneously disclose a complete design implementation of a segmented roller with working fluid for individually pressing the corresponding belts on a curved surface.The technical result achieved by using the claimed utility model is improved quality of the press of the laid-out belts on a curved surface due to the individual operation of the pressure roller segments, and increased stability of the press force distribution due to the presence of a chamber containing the working fluid. This result logically correlates with known technological advances, confirmed by the cited sources, but in the claimed utility model, it is achieved by combining them into a single structural system of the laying head.

[0012] The technical result of the claimed utility model is the creation of a laying head for the automated laying out of tapes of thermosetting polymer composite material, which provides the possibility of a more uniform and individualized application of pressing force to the corresponding laid out tapes on a curved shaping surface.

[0013] The technical result is achieved due to the fact that the laying head for the automated laying out of tapes of thermosetting polymer composite material on a shaping surface, containing a housing, an unwinding and tensioning unit, a tape feed channel and a clamping module, a feed module, a cutting module, a cooling module, a heating module, a module for pressing the tapes to the shaping surface, located along the feed channel, wherein the pressing module is made in the form of a segmented pressure roller, consisting of a set of segments located along the width of the roller, each of which is installed with the possibility of independent rotation and independent movement relative to the axis of the roller, wherein the segments are intended for individual application of pressing force to the corresponding tapes being laid out on a curved surface, and the roller contains a chamber with a working fluid and a quick-change unit.

[0014] The preferred width of each segment is 6.35mm.

[0015] Preferably, each segment corresponds to one laid out prepreg tape.

[0016] Preferably, the chamber with the working fluid is made common for all segments.

[0017] Preferably, the chamber with the working fluid is designed with the possibility of transmitting pressure to the segments through individual movable elements.

[0018] Preferably, the return fingers simultaneously function as guide elements of the segments.

[0019] Preferably, the quick-change unit is designed to ensure removable installation of the roller without dismantling the remaining units of the laying head.

[0020] Preferably, the quick-change unit is designed to ensure repeatable basing of the roller relative to the tape feed channel.

[0021] The preferred number of segments is 4, 8, 12 or 16.

[0022] Preferably, the segments are designed with the ability to compensate for differences in the local curvature of the forming surface across the width of the laid out package of tapes.

[0023] A laying head for automated laying of thermosetting polymer composite tapes onto a forming surface. It comprises a housing, an unwinding and tensioning unit, a tape feed channel, and a clamping module, a feeding module, a cutting module, a cooling module, a heating module, and a tape pressing module positioned along the feed channel. The integration of all these functional units (unwinding, tensioning, feeding, clamping, cutting, cooling, heating, and pressing) into a single design ensures complete process autonomy of the head. This means that integration into the system does not require retrofitting with external tape processing systems, and replacing the head eliminates the need to reconfigure each unit individually.At the same time, the integration of heating and cooling modules allows for precise control of the belt's temperature immediately before the contact zone with the segment roller, which is critical for uniform consolidation on curved sections. Taken together, this enables more uniform and customized application of clamping force to the respective belts being laid out on the curved forming surface.

[0024] The pressure module is designed as a segmented pressure roller, consisting of a set of segments arranged across the roller's width, each of which is mounted for independent rotation and movement relative to the roller's axis. Dividing the solid pressure element into multiple kinematically independent segments allows each segment to deflect normally when moving along a curved surface by an amount corresponding to the local topography. The absence of rigid connections between the segments eliminates the "bridge" effect (when one segment hangs over a depression, held by its neighbors). Independent rotation prevents slippage and displacement of the deposited package.As a result, the specified design of the pressing module directly ensures the possibility of a more uniform and individualized application of pressing force to the corresponding laid out tapes on a curved forming surface, since adaptation to the geometry occurs automatically and does not require complex mechatronic adjustment.

[0025] The segments are designed to individually apply clamping force to the corresponding belts being laid out on a curved surface. The functionality of each segment is strictly for interaction with a single, predetermined belt (rather than with a group of belts or any arbitrary section of the stack) meaning that the force generated by a given segment is not transferred to adjacent belts. This design feature becomes crucial when laying out on a surface with variable curvature across its width, for example, when the left belt is placed on a concave section, and the right belt on a convex one. This individual correspondence allows each segment to independently compensate for the local curvature under its own belt, without averaging the force.The consequence of this is the possibility of a more uniform and individualized application of pressing force to the corresponding laid out tapes on a curved forming surface, since the need for complex mechanical or electronic systems for synchronizing forces between different tapes is eliminated.

[0026] The roller contains a chamber containing working fluid and a quick-change unit. The chamber, containing the working fluid (hydraulic or pneumatic), creates a uniform background pressure, which is transmitted to the segments through moving elements. When a segment encounters a localized elevation, it experiences increased resistance and displaces the fluid toward the segment located in a depression, automatically equalizing the linear pressing force across the entire width. The quick-change unit allows the roller to be removed and installed as a single, replaceable module without disassembling the head housing or other components. The combined effect of these two features—hydraulic alignment improves pressing quality, and quick change improves processability. Together, this enables a more uniform and customized application of pressing force to the corresponding belts being laid out on a curved forming surface, with each feature reinforcing the effect of the other, without creating design conflicts.

[0027] Each segment corresponds to one laid-out prepreg tape. This feature establishes a one-to-one functional relationship between the roller elements and the laid-out tapes. This means that the head control system and the mechanics themselves can unambiguously direct the clamping force to a specific tape, and when replacing a roller with another with a different number of segments, the number of simultaneously laid-out tapes automatically changes. The absence of such a correspondence would require the introduction of additional force selection mechanisms. The causal chain is: one-to-one correspondence → each segment is loaded only by its own tape → independent curvature compensation under each tape is possible without cross-influence.As a result, it is possible to apply the pressing force more uniformly and individually to the corresponding tapes laid out on a curved forming surface, since the control algorithm is simplified and the transfer of force from one tape to another is eliminated.

[0028] The working fluid chamber is shared by all segments. This shared chamber means that all segments are connected to a single hydraulic volume. When the segment that first encounters a local elevation is loaded, the pressure within the chamber increases and is instantly transmitted to all other segments, causing them to press together with greater force, if their mobility allows. This creates a hydraulic equalization effect: the difference in force between segments is minimized without the use of electronics or individual regulators. Furthermore, the shared chamber is structurally simpler than a system of isolated chambers with valves, increasing reliability and maintainability.This allows for a more uniform and individualized application of clamping force to the respective laid out belts on a curved forming surface, since the common chamber does not require a separate connection of each segment to the pressure source, which reduces the time for mounting / dismounting the roller when replacing it through a quick-change unit.

[0029] The working fluid chamber is designed to transmit pressure to the segments through individual moving elements. Individual moving elements (e.g., pistons, plungers, or membranes) act as connecting links between the fluid volume and each segment. When a segment moves upward due to a convex surface, it pushes its piston, which displaces fluid into the common chamber. This fluid, through other pistons, transfers force to adjacent segments, forcing them to press more firmly into their depressions. Without such elements, the fluid would simply flow around the segment without creating a return force. The pistons enable precise force distribution to each segment while maintaining hydraulic communication. The design with individual moving elements allows for easy disassembly of the roller to replace individual pistons or segments without compromising the integrity of the chamber.This allows for a more uniform and individualized application of clamping force to the respective strips being laid out on a curved forming surface, as repairability is increased and hydraulic alignment is maintained during the individual stroke of each segment.

[0030] The quick-change unit is designed to allow for the roller to be removed without disassembling the rest of the laying head. This design solution means that replacing the pressure roller does not require removing the feed, cutting, heating, cooling, or other modules attached to the head body. Thanks to special quick-release clamps (eccentrics, bayonets, and latches), the roller can be removed and installed like a cartridge in a matter of seconds to a minute. This results in a dramatic reduction in equipment downtime when switching to a different belt size or when the roller wears out, while maintaining the same pressure quality, as all other modules remain intact.As a result, it is possible to apply clamping force more uniformly and individually to the corresponding strips laid out on a curved forming surface, since the quick-release installation does not require recalibration of adjacent units and allows the head to be quickly returned to operating mode.

[0031] The quick-change unit is designed to ensure repeatable roller alignment relative to the tape feed channel. Repeatable alignment means that after each removal and reinstallation, the roller maintains exactly the same spatial position relative to the tape feed channel. This is achieved through the use of conical pins, prisms, magnetic locking devices with stops, or other high-precision locking elements. Without this feature, even with quick changes, the roller position would have to be adjusted each time, which would negate the time savings. Repeatable alignment maintains the alignment of each segment with its tape guide track, which is critical for customized clamping.This allows for a more uniform and individualized application of clamping force to the corresponding tapes being laid out on a curved forming surface, since the operation of re-adjusting the head after replacing the roller is eliminated, and the risk of the tape shifting relative to the segment is reduced to zero.

[0032] The number of segments is 4, 8, 12, or 16. These numbers correspond to the most common industrial numbers of tapes simultaneously laid out in automated systems (4 to 16). Selecting these values, rather than arbitrary ones, allows for standardization of the mounting locations and quick-change unit interface for rollers with different numbers of segments. A fixed number of segments allows for quick roller changes, for example, from 4 to 8 segments, without changing the remaining head modules, since the quick-change unit is standardized. The width of each segment remains 6.35 mm, and the overall width of the tape stack is scalable.This allows for a more uniform and customized application of clamping force to the respective strips being laid out on a curved forming surface, as the user can select a roller with the required number of segments for a specific product and replace it in a minute without reworking the head.

[0033] The claimed utility model is illustrated by the diagram shown in Fig. 1. This figure shows a laying head for the automated laying of tapes of thermosetting and / or thermoplastic polymer composite material onto a forming surface. The laying head comprises a housing 1, which is the supporting part of the structure, on which the functional units and modules of the head are located and mutually arranged. In the upper part of the structure is an unwinding and tensioning unit 2, designed to accommodate feed reels with the composite material, unwind the tapes and maintain the required tension when they are fed into the head. From the unwinding and tensioning unit, the tapes are directed into a feed channel 3, passing inside the housing of the laying head and ensuring the directed movement of the tapes to the zone of their technological processing and subsequent laying.

[0034] Functional modules sequentially arranged along the feed channel in the housing ensure the performance of technological operations with the belts. Clamping module 4 is designed to temporarily fix the belts in the required position, including when stopping the feed process, during the cutting operation, and when switching between process modes. Feed module 5 is designed to forcibly move the belts along the feed channel in the direction of the forming surface. Cutting module 6 is used to separate the required section of the belt after the completion of the laying operation or when moving to a new section of the trajectory. Heating module 7 is designed to apply heat to the belts before they are pressed against the forming surface, and cooling module 8 is designed to controllably reduce the temperature of the material and / or head elements, including to prevent material sticking to the feed channel elements and functional modules.At the bottom of the head there is a pressing module 9, which ensures the application of pressing force to the laid out tapes in the area of ​​their contact with the forming surface.

[0035] As can be seen from Fig. 1, the unwinding and tensioning unit 2 is located above the housing 1 of the laying head, which ensures a compact vertical arrangement of the structure and the directed feeding of several tapes into the feed channel 3. The housing 1 is designed to accommodate the feed channel and the listed modules within it in a functionally determined sequence, in which the tapes sequentially undergo the stages of feeding, clamping, heating, possible cooling, cutting, and pressing. This arrangement ensures the technological integrity of the laying head and the possibility of integrating all the main operations of transporting and laying tapes within a single structural unit.

[0036] According to Fig. 1, the pressing module 9 is located at the lower exit section of the laying head, i.e., in the area of ​​direct contact between the tapes and the forming surface. This arrangement is functionally determined, since it is after passing through the feed channel, clamping, feeding, heating, cooling, and, if necessary, the tape sections enter the final pressing zone. In one preferred embodiment, the pressing module is implemented as a segmented pressure roller, ensuring individualized application of pressing force to the respective tapes being laid on a curved surface.

[0037] It should be understood that the diagram presented in Fig. 1 illustrates only one particular example of the structural implementation of the claimed utility model. The specific relative positioning of the units and modules, their geometric shape, dimensions, fastening method, the number of individual elements, as well as the sequence of placement within the housing 1 may be changed depending on the purpose of the equipment, the number of simultaneously laid out belts, the type of polymer composite material used, the requirements for the feed trajectory and operating conditions, without departing from the essence of the claimed utility model. In other words, the embodiment shown in Fig. 1 should not be considered as limiting the scope of legal protection, since the scope of legal protection is determined solely by the set of essential features listed in the formula of the utility model, while the description and drawings serve to clarify the essence of the claimed technical solution and examples of its implementation.

[0038] The utility model is a laying head for the automated laying of tapes of thermosetting and thermoplastic polymer composite material onto a shaping surface, primarily onto a surface of complex geometry, including curved geometry. The laying head comprises a housing 1, which is a supporting structure for accommodating and mutually fixing functional units, an unwinding and tensioning unit 2, which ensures the feeding of the initial tape material while maintaining the required tension, a tape feed channel 3, along which the laid tapes move towards the laying zone, as well as a clamping module 4, a feed module, a cutting module 6, a cooling module 8, a heating module 7 and a module for pressing the tapes to the shaping surface 9 located along the said feed channel.

[0039] The housing 1 may be implemented as a frame structure, a plate, a framework, or other supporting base, on which the specified units and modules are secured in a functionally determined sequence corresponding to the technological process of laying out the tapes. The unwinding and tensioning unit 2 is designed to receive tapes of thermosetting or thermosetting polymer composite material, unwind them from supply reels, spools, or other carriers, and maintain a predetermined tension of the tapes through the feed channel 3. The tape feed channel 3 may be formed by guide elements, grooves, guide surfaces, rollers, plates, or other means that determine the trajectory of the tapes along the laying head.

[0040] Clamping module 4 is designed to temporarily fix the tapes in a predetermined position within the feed channel, including when stopping the feed, performing a cutting operation, or when switching between process modes. Feed module 5 is designed to forcibly move the tapes along the feed channel to the deposition zone. Cutting module 6 is designed to separate the required section of the tape after completing the deposition operation or when moving to the next section of the trajectory. Cooling module 8 is designed to controllably reduce the temperature of the material being deposited, thereby preventing the material from sticking to the channels and modules of the deposition head. When using thermoplastic material, cooling module 8 is disabled. Heating module 7 is designed to apply heat to the tapes and / or the deposition zone in order to ensure the required conditions for adhesion and shaping of the material during deposition.Heating module 7 can be configured using a laser, an infrared lamp, or heated inert gas. This allows the laying head to be configured for thermosetting and thermoplastic materials. Heating module 7 is designed to apply heat to the tapes and / or the laying area to ensure the required adhesion and shaping conditions for the material during laying. Pressing module 9 applies pressure to the laid tapes in the area where they contact the forming surface.

[0041] A significant feature of the claimed utility model is that the pressing module 9 is designed as a segmented pressure roller. This roller consists of a set of segments arranged across the roller's width. Segments arranged across the roller's width are understood to be positioned next to each other in the transverse direction such that the total working width of the roller corresponds to the width of the tape bundle being laid out, or part thereof.

[0042] Each segment is mounted with independent rotation and movement relative to the roller axis perpendicular to the roller axis. Independent rotation of each segment allows it to roll individually along the surface of the tape being laid and the forming surface without necessarily rigidly following the kinematic movement of adjacent segments. Independent movement of each segment relative to the roller axis allows for local segment displacement depending on the actual geometry of the forming surface and / or the local thickness of the material being laid, thereby achieving roller adaptability to curved surfaces transversely across the width of the tape package being laid.

[0043] The segments are designed to individually apply clamping force to the respective belts being laid on a curved surface. In other words, when laying multiple belts, each segment interacts primarily with its corresponding belt or with a localized area of ​​the belt stack. This distributes the clamping force not as a single, general force across the entire width of a solid roller, but as a combination of individualized forces across individual contact areas. This ensures more precise conformity with the forming surface across the width of the laid belt, reduces the likelihood of localized under- or over-pressure of individual belts, and improves the uniformity of material compaction in areas with varying local curvatures.

[0044] The segmented pressure roller contains a chamber containing a working fluid. This chamber enables the transmission, redistribution, and stabilization of the clamping force acting on the roller segments. The working fluid may be a liquid suitable for transmitting pressure in a confined space, such as hydraulic fluid, oil, or another fluid with appropriate performance characteristics. The working fluid chamber may be located within the roller housing, in its supporting structure, in a cavity communicating with the movable elements of the segments, or in another manner that ensures pressure transfer from the fluid to the segments. This chamber helps equalize the clamping force between the segments, compensate for localized surface geometry deviations, and improve the operational stability of the pressure module.

[0045] An additional significant feature is that the roller includes a quick-change unit. Within the scope of the claimed utility model, a quick-change unit is defined as a design feature that enables the removable installation and replacement of a segmented pressure roller within a laying head in a reduced time, without the need to disassemble a significant portion of the head's other components. The quick-change unit may include locking, guiding, locating, locking, snapping, threaded, pin, eccentric, bayonet, or other elements that enable the rapid removal and reinstallation of the roller. The presence of a quick-change unit improves the operational efficiency of the laying head, simplifies maintenance, repair, and roller replacement when switching between operating modes, and reduces equipment downtime.

[0046] Taken together, the specified features ensure the achievement of a technical result consisting of improving the quality of pressing of the laid out tapes on a curved shaping surface, increasing the uniformity of the distribution of the pressing force across the width of the laid out package of tapes, and improving the adaptation of the pressing module to the local geometry of the surface.

[0047] In one particular embodiment, the width of each segment is 6.35 mm. Producing segments of this width allows for the design to match the width of the segment to the typical width of the prepreg tape being laid out, ensuring more precise, individual application of clamping force to each tape and reducing mutual interference between adjacent clamping areas.

[0048] In one embodiment, each segment corresponds to a single prepreg strip. This design correspondence ensures individualized contact between the segment and the corresponding strip, promotes more uniform compaction of each strip, and allows for more accurate compensation for differences in local surface curvature across the width of the stack.

[0049] In one embodiment, the working fluid chamber is shared by all segments. This shared chamber simplifies the roller design, ensures pressure transmission through a single hydraulic volume, and helps equalize the clamping force between the segments while maintaining their individual mobility.

[0050] In another embodiment, the working fluid chamber is configured to transmit pressure to the segments through individual moving elements. These moving elements can be pistons, pushers, plungers, membrane elements, or other components capable of absorbing the working fluid pressure and transmitting it to the corresponding segments. This design allows for a combined common or distributed hydraulic pressure source with individualized action on each segment.

[0051] In one embodiment, the spring-loaded return pins simultaneously serve as guide elements for the segments. This design combines these functions to reduce the number of parts, simplify the roller layout, ensure the segments return to their original position after passing through localized areas of curvature, and simultaneously control the directional movement of the segments relative to the roller axis.

[0052] In one embodiment, the quick-change unit allows for the roller to be removed without dismantling the rest of the stacking head. This reduces maintenance time, simplifies roller replacement when worn or when reconfiguring the equipment, and reduces the labor intensity of maintenance operations.

[0053] In one embodiment, the quick-change unit is designed to ensure repeatable roller alignment relative to the belt feed channel. Repeatable alignment means the ability to install the roller with a reproducible position of its working area relative to the belt path, which helps maintain process accuracy after roller replacement and reduces the need for additional adjustments.

[0054] In one embodiment, the number of segments is 4, 8, 12, or 16. The number of segments can be determined by the number of tapes being simultaneously deposited, the overall width of the stack, the required degree of adaptation to curved surfaces, and the design parameters of the pressure roller. Increasing the number of segments allows for more granular distribution of the pressure force across the width of the tape stack.

[0055] In one embodiment, the segments are designed to compensate for differences in the local curvature of the forming surface across the width of the tape bundle being laid out. This means that individual segments can occupy different positions relative to the roller axis depending on the local surface shape in the corresponding contact zone. This allows the pressure roller to more accurately follow the profile of the forming surface, ensuring more uniform tape compaction across the entire width of the bundle.

[0056] The utility model is implemented as part of an installation for automated laying out tapes of thermosetting polymer composite material on a forming surface.

[0057] In one embodiment, the installation is designed as a gantry machine with a spatial movement system for the laying head. The installation comprises a laying head, a means for moving the laying head in space, a unit for unwinding material from reels, a support and rotary module, and a mechanism for attaching the tooling onto which the material is laid. In a particular embodiment, the installation has five axes of movement. In another particular embodiment, the installation has six axes of movement. In other embodiments, the means for moving the laying head may be implemented as a robotic technological complex, including an industrial robot, optionally mounted on a rail system.

[0058] The unit can be designed as a modular system. This modular design allows for the replacement of individual functional units, the reconfiguration of the equipment for different product sizes, and the modification of the unit's layout depending on the process task.

[0059] The laying head comprises a body 1, an unwinding and tensioning unit 2, a tape feed channel 3 and a clamping module 4, a feed module 5, a cutting module 6, a cooling module 8, a heating module 7 and a module for pressing tapes to a forming surface 9 located along the feed channel.

[0060] The housing 1 serves as a supporting element for accommodating and securing the aforementioned units and modules. The unwinding and tensioning unit 2 is designed to unwind the composite material from the spools, direct it into the feed channel 3, and maintain the required tension during transport to the lay-up area. In one embodiment, the unwinding unit is designed as a multi-position module with several spools mounted on a common supporting plate. In a specific embodiment, the unwinding unit ensures smooth feeding of the composite prepreg to the head, quick material changeover, material availability monitoring, and tape tension control. In one embodiment, the tension is adjustable up to 4 N per tape. The winding speed in this specific embodiment can reach 400 mm / s.

[0061] Tape feed channel 3 is designed to guide the laid tapes from the unwinding and tensioning unit to the heating, pressing, and stacking zone. Feed channel 3 may be formed by guide elements, rollers, support surfaces, clamping elements, and other means that determine the tape path. In one embodiment, the feed channel is configured to transport multiple tapes simultaneously.

[0062] Clamping module 4 is designed to temporarily secure the belts in the desired position in the feed channel. Feeding module 5 is designed to move the belts toward the forming surface. Cutting module 6 is designed to separate a section of the belt after placement is complete or when moving to the next section of the trajectory. In this particular embodiment, the accuracy of the cutting and restarting operation is ±1 mm.

[0063] Heating module 7 is designed to heat the tapes before pressing them against the forming surface. In one embodiment, the heating module is adjustable. In a specific embodiment, control is performed in a closed loop, including using PID control. The heating temperature of the thermosetting polymer composite material in one embodiment ranges from 50 to 300°C. Heating can be accomplished using various methods, such as laser, infrared lamp, or inert hot gas. For thermoplastic materials, the heating temperature must be at least 500°C. Cooling module 8 is designed to controllably reduce the material temperature. In one embodiment, tape cooling is passive, and roller cooling is active. In a specific embodiment, the material cooling temperature ranges from 25 to -7°C.

[0064] The module for pressing the tapes onto the forming surface 9 is designed as a segmented pressure roller. The segmented pressure roller consists of a set of segments arranged across the roller's width. Each segment is mounted for independent rotation and independent movement perpendicular to the roller axis. Independent rotation of each segment ensures its individual rolling along the tape being laid out and the forming surface. Independent movement of each segment relative to the roller axis ensures the roller adapts to the local geometry of the forming surface across the width of the tape package being laid out.

[0065] The segments are designed to individually apply clamping force to the respective belts being laid out on a curved surface. This ensures separate clamping of individual belts or individual sections of a belt stack, improving the uniformity of material consolidation and compensating for differences in local surface curvature across the width of the stack.

[0066] In one embodiment, each segment corresponds to one laid out prepreg tape. In a particular embodiment, the width of each segment is 6.35 mm. Moreover, in various embodiments, the segment width can vary in the range from 6.35 to 150. In other particular embodiments, the segment width can correspond to the nominal tape width with a manufacturing tolerance, including 6.35 ± 0.125 mm or 6.35 ± 0.25 mm. Depending on the equipment configuration, the number of segments can be 4, 8, 12, or 16. In one embodiment, the head is designed for laying out four tapes. In other embodiments, the number of simultaneously laid out tapes is increased to 8, 12, or 16, with the number of segments corresponding to the number of tapes.

[0067] The roller contains a chamber containing a working fluid. The chamber is designed to transmit and redistribute pressure to the roller segments. In one embodiment, the working fluid chamber is common to all segments. In another embodiment, the chamber is configured to transmit pressure to the segments through individual moving elements, such as pistons, pushers, plungers, or other elements interacting with the corresponding segments. The presence of a working fluid chamber ensures equalization of the clamping force between the segments, compensation for localized surface deviations, and increased stability of the belt clamping.

[0068] In one embodiment, the pressing module is configured to adjust the pressing force. In a specific embodiment, the pressing force is adjustable from 10 to 500 N. In another embodiment, the pressing force in the laying zone ranges from 10 to 100 N. Adjusting the pressing force, in conjunction with adjusting the heating and cooling temperatures, allows for the material consolidation mode to be modified depending on the type of binder, tape thickness, the number of tapes being laid simultaneously, and the geometry of the forming surface.

[0069] The implementation of the utility model may include the cyclic execution of the following operations: feeding the material into the laying head, heating the material, laying and pressing the material onto the tooling, and then cutting the material. After laying, the product, in one embodiment, can be used without additional curing, while in another embodiment, it can be subjected to subsequent heat treatment.

[0070] In one specific embodiment, after the laying is complete, a vacuum bag is formed and then polymerized in an oven. In another embodiment, the product is thermoformed. Subsequent heat treatment can be aimed at reducing the material's porosity, relieving residual thermal stress, and improving the product's mechanical properties. Post-processing, including flash trimming and die cleaning, can be performed after heat treatment.

[0071] The laying head is positioned relative to the tooling with high precision. In one version for a gantry machine, the positioning accuracy is 0.05 mm. In another version for a robotic process complex, the positioning accuracy is 0.7 mm, and the repeatability is ±0.08 mm. In one version, the nominal linear working length is 6000 mm. The horizontal travel speed in certain versions can range from 0 to 60 m / min or from 5 to 120 mm / s.

[0072] The system can be optionally equipped with a heated chamber to improve consolidation and enhance the mechanical properties of the material. Other versions of the system may include a turning axis for producing rotating parts, a positioning control system, a milling head for machining the product directly in the layup area, and integration with 3D printing technology for producing three-layer shells.

[0073] By using a laying head with the specified set of features, automated laying of composite tapes onto a forming surface is ensured with individualized application of pressing force to the corresponding tapes, compensation for differences in local curvature across the width of the laid package, and increased uniformity of material consolidation.

[0074] In one additional embodiment, the working fluid chamber is designed as a longitudinal cavity located within the roller's supporting portion across the entire working width of the segmented pressure roller, with each segment interacting with said cavity through an individual movable element. This design enables overall hydraulic load balancing while maintaining the individual mobility of the segments.

[0075] In another embodiment, the roller segments are mounted in a cassette holder, forming a replaceable module, with the quick-change unit designed to allow for simultaneous replacement of the entire cassette module of segments. This solution is convenient when switching between different numbers of tapes being loaded or when replacing a roller with a different segment width.

[0076] In another embodiment, the roller is made in several replaceable versions, differing in the number of segments, the width of the segments and the range of permissible movement of the segments relative to the roller axis, and the choice of the roller version is carried out depending on the local curvature of the forming surface and on the width of the laid out package of tapes.

[0077] In one embodiment, the quick-change unit is designed as a quick-action mechanical lock with locating surfaces and locking elements that ensure the roller is positioned in a precisely defined position relative to the tape feed channel. In another example, the quick-change unit additionally includes means to prevent erroneous roller installation, such as asymmetrical locating elements or mutually matching mounting surfaces.

[0078] In one additional embodiment, the pressure module is configured to allow the segment pressure roller to be replaced with a roller with a different segment pitch without changing the position of the remaining head assemblies. This allows the delivery head to be adapted to tapes of different widths or to a different number of tapes being delivered simultaneously.

[0079] In another embodiment, the unwinding and tensioning unit is designed to allow independent tension adjustment for each tape. This design is particularly useful when laying out multiple tapes in areas with varying curvatures, as it further reduces differences in feed conditions between adjacent tapes.

[0080] In one embodiment, the tape feed channel contains individual guide tracks for each tape, with the tracks converging toward the contact area with a segmented pressure roller. This design helps maintain the relative position of the tapes across the width of the package being deposited and improves the accuracy of alignment of each tape with its corresponding roller segment.

[0081] In another embodiment, the heating module and cooling module are located on opposite sides of the pressing zone, with the material being heated before the belts enter the contact zone with the roller, and the roller or adjacent area being cooled after passing the pressing zone. This design allows for separate thermal exposure to the material and stabilization of the roller's temperature.

[0082] In one embodiment, the moving means for the laying head is configured to change the angular position of the head relative to the forming surface. This allows for maintaining the desired position of the roller axis and the optimal angle of application of the clamping force when passing curved sections of the tooling.

[0083] In one additional embodiment, the system includes a control system that ensures coordinated operation of the unwinding and tensioning unit, feed module, heating module, cooling module, cutting module, and pressing module depending on the head speed, the laying path, the number of tapes, and the material parameters. In a particular embodiment, the control system is configured to set different modes for thermosetting and thermoplastic materials.

[0084] In one embodiment, the roller segments are individually removable, allowing worn segments to be replaced without replacing the entire roller. In another embodiment, the segments are grouped in pairs or other arrangements, as required by the specific layout and load distribution.

[0085] In another embodiment, the roller is designed to be used on shaping surfaces of double curvature, wherein the range of independent movement of the segments is selected in such a way as to ensure contact of individual segments with corresponding sections of the surface when the curvature changes across the width of the package being laid out.

[0086] The above embodiment examples do not exhaust all possible implementation options for the utility model. It is obvious to those skilled in the art that individual design elements, parameters, and operating modes may be modified without departing from the essence of the utility model, as defined by the formula.

Claims

1. A laying head for the automated laying of tapes made of a polymer composite material onto a shaping surface, comprising a housing configured to interact with an unwinding and tensioning unit, a tape feed channel and a clamping module, a feed module, a cutting module, a cooling module, a heating module, a module for pressing the tapes onto the shaping surface, located along the feed channel, characterized in that the pressing module is made in the form of a segmented pressure roller consisting of segments located across the width of the roller, each of which is mounted with the possibility of independent rotation and independent movement relative to the roller axis, wherein the segments are configured to individually apply a pressing force to the corresponding tapes being laid out on a curved surface, wherein the roller contains a chamber with a working fluid and a quick-change unit.

2. A laying head for automated laying of strips of polymer composite material onto a forming surface according to paragraph 1, characterized in that the width of each segment is 6.35 mm.

3. A laying head for automated laying of tapes of polymer composite material onto a forming surface according to paragraph 1, characterized in that each segment corresponds to one laid out prepreg tape.

4. A laying head for automated laying of strips of polymer composite material onto a forming surface according to paragraph 1, characterized in that the chamber with the working fluid is made common for all segments.

5. A laying head for automated laying of strips of polymer composite material onto a forming surface according to paragraph 1, characterized in that the chamber with the working fluid is designed with the possibility of transmitting pressure to the segments through individual movable elements made in the form of pistons, plungers, pushers or membranes.

6. A laying head for automated laying out of tapes made of polymer composite material onto a forming surface according to paragraph 1, characterized in that the return spring-loaded fingers simultaneously perform the function of guiding elements of the segments.

7. A laying head for automated laying of ribbons made of polymer composite material onto a forming surface according to paragraph 1, characterized in that the quick-change unit is designed to provide for removable installation of a roller without dismantling the remaining units of the laying head.

8. A laying head for automated laying of tapes made of polymer composite material onto a forming surface according to paragraph 1, characterized in that the quick-change unit is designed to ensure repeatable positioning of the roller relative to the tape feed channel.

9. A laying head for automated laying of tapes made of polymer composite material onto a forming surface according to paragraph 1, characterized in that the number of segments is 4, 8, 12 or 16.

10. A laying head for automated laying of tapes made of polymer composite material onto a forming surface according to paragraph 1, characterized in that the segments are designed with the ability to compensate for differences in the local curvature of the forming surface across the width of the laid out package of tapes.

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