Processing method

Abstract

A processing method according to the present disclosure comprises: rotatably supporting a lamination mold with a rotation axis around the axis; and enabling a floating operation in which a lamination head for laminating a sheet-shaped member on the lamination mold is stroked in a direction intersecting with the rotation axis, while laminating the sheet-shaped member on the lamination mold by the lamination head.

Description

Processing method

[0001] The present disclosure relates to a processing method for laminating sheet-like members onto a lamination mold.

[0002] A processing method is known in which composite sheets, such as fiber-reinforced resin sheets, are automatically laid on a laying mold using a laying head attached to a robot hand. The laminate obtained by the automatic laying is subjected to, for example, a heat and pressure treatment to produce a desired molded part. Patent Document 1 discloses a processing device that lays composite sheets using a laying head while rotating a cylindrical laying mold around its axis using a work positioner. Patent Document 2 discloses a processing device similar to Patent Document 1, in which composite sheets are laid using a plurality of laying heads that sandwich the laying mold.

[0003] In conventional processing devices, when the stacking mold is heavy or a long cylindrical body, the stacking mold itself may bend due to its own weight, or the work positioner may bend. In this case, a problem occurs in which the composite sheet cannot be stacked in the desired position on the stacking mold. It is possible to reduce the impact of this bending by sandwiching the stacking mold between multiple stacking heads, as in the processing device of Patent Document 2. However, adopting such a processing device requires a large and complex mechanism, such as a carriage to hold the multiple heads, which complicates the device structure.

[0004] Patent No. 5822696 Publication Special Publication No. 2008-521656

[0005] An object of the present disclosure is to provide a processing method that can accurately stack sheet-like members in a stacking mold without complicating the device structure.

[0006] A processing method according to one aspect of the present disclosure includes supporting a stacking mold having a rotation axis so that it can rotate around the axis, and stacking a sheet-like material onto the stacking mold using a stacking head that is capable of floating by stroking the stacking head in a direction intersecting the rotation axis, while stacking the sheet-like material onto the stacking mold using the stacking head.

[0007] According to the present disclosure, it is possible to provide a processing method that can accurately stack sheet-like members in a stacking mold without complicating the device structure.

[0008] FIG. 1 is a side view of a processing system to which the processing method of the present disclosure is applied. FIG. 2 is a front view of the processing system of FIG. 1. FIG. 3 is a schematic diagram showing an example of deflection of a stacking mold. FIG. 4 is a schematic diagram showing another example of deflection of a stacking mold. FIG. 5 is a diagram showing the operation of an air cylinder as a floating mechanism provided in a sheet stacking device. FIG. 6 is a diagram showing the stacking state of a sheet-like material onto a stacking mold using the stroke of the floating mechanism. FIG. 7 is a diagram showing an example of adjustment of the pitch angle of a stacking head. FIG. 8 is a diagram showing another example of adjustment of the pitch angle of a stacking head.

[0009] The processing method according to the present disclosure will be described in detail below with reference to the drawings. The processing method according to the present disclosure can be applied to various applications in which a lamination mold having a rotation axis is supported rotatably around the axis and a sheet-like member is laminated on the lamination mold. One example of a preferred application is lamination of a fiber-reinforced resin sheet onto a lamination mold using the AFP (Automated Fiber Placement) method, for example, lamination of a prepreg tape called a tow. Below, a specific example of the processing method according to the present disclosure will be described assuming the AFP method.

[0010] [Configuration of Processing System] FIG. 1 is a schematic side view of a processing system PS to which the processing method of the present disclosure is applied. FIG. 2 is a front view of the processing system PS shown in FIG. 1. The processing system PS includes a lamination mold 1 and a processing device 2. The lamination mold 1 is a mold material on which a sheet-like member is automatically laminated. In this embodiment, a prepreg tape 82 is exemplified as the sheet-like member. FIGS. 1 and 2 illustrate a cylindrical lamination mold 1 having a rotation axis RA extending in the Y direction. The rotation axis RA is the central axis of the cylinder that forms the lamination mold 1. The lamination mold 1 is not limited to a cylindrical shape. For example, the lamination mold 1 may be elliptical, or may have a square, polygonal, triangular, or irregular cross section with chamfered corners when viewed in the Y direction.

[0011] The processing device 2 performs processing to laminate the prepreg tape 82 onto the lamination mold 1 while rotating the lamination mold 1 about the rotation axis RA. The processing device 2 includes a work positioner 3 as a support device, and a sheet lamination device 4. The work positioner 3 supports both ends of the lamination mold 1 so that the lamination mold 1 can rotate about the rotation axis RA. The sheet lamination device 4 laminates the prepreg tape 82 onto the lamination mold 1 supported by the work positioner 3 while cutting it to a predetermined length.

[0012] The work positioner 3 includes a pair of support bases 31 and a positioner rotation shaft 32. The support base 31 is erected above the installation surface and supports the stacked mold 1 at a predetermined support height. One support base 31 is located on the first end 11 side of the stacked mold 1 in the longitudinal direction. The other support base 31 is located on the second end 12 side of the stacked mold 1 in the longitudinal direction. A drive motor and a reducer are installed inside one support base 31, which serve as the rotational drive source for the stacked mold 1. The pair of positioner rotation shafts 32 are connected to the first end 11 and the second end 12, respectively, on an extension of the rotation axis RA of the stacked mold 1. The rotational drive force of the drive motor is transmitted to the positioner rotation shaft 32 on the first end 11 side via the reducer. The positioner rotation shaft 32 on the second end 12 side is journaled by the other support base 31.

[0013] The sheet stacking device 4 includes a robot arm 5, a stacking head 6, an air cylinder 7 as an example of a mechanism for performing floating operation, a tape supply 8, and a control device 9. The robot arm 5 is a multi-joint robot arm having six joints. The robot arm 5 and the work positioner 3 are arranged side by side in the X direction, which is a direction intersecting the rotation axis RA.

[0014] The robot arm 5 includes six rotation axes that serve as the joints: a first axis J1, a second axis J2, a third axis J3, a fourth axis J4, a fifth axis J5, and a sixth axis J6. The robot arm 5 includes, as arm elements, a base 50, a first arm 51, a second arm 52, a third arm 53, a fourth arm 54, a fifth arm 55, and a sixth arm 56. A laying head 6 is provided as an end effector at an arm tip 5T of the robot arm 5. The laying head 6 is attached to the arm tip 5T via an air cylinder 7.

[0015] The base 50 is located at the base end of the robot arm 5. In this embodiment, the base 50 is attached to a movement mechanism 33. The movement mechanism 33 is a mechanism that moves the robot arm 5 in the Y direction, which is the extension direction of the rotation axis RA of the stacked mold 1. The base 50 may be fixedly installed on a mounting plane such as a floor or a pedestal. The first arm 51 is connected to the upper surface of the base 50 via a first axis J1. The first axis J1 is a rotation axis that extends vertically from the base 50. The first arm 51 can rotate in both forward and reverse directions around the first axis J1.

[0016] The second arm 52 has a base end connected to the first arm 51 via a second axis J2. The second axis J2 is a rotation axis that extends horizontally, i.e., in the Y direction. The second arm 52 can swing around the second axis J2. The third arm 53 has a base end connected to the tip of the second arm 52 via a third axis J3. The third axis J3 is a rotation axis that extends horizontally. The third arm 53 can swing around the third axis J3. The fourth arm 54 has a base end connected to the tip of the third arm 53 via a fourth axis J4. The fourth axis J4 is a rotation axis that extends in the arm axis direction of the third arm 53 or the fourth arm 54.

[0017] The fourth arm 54 is rotatable around the fourth axis J4. The fifth arm 55 has a base end connected to the tip end of the fourth arm 54 via a fifth axis J5. The fifth axis J5 is a rotation axis extending perpendicular to the arm axis direction of the fourth arm 54. The fifth arm 55 is oscillating around the fifth axis J5. The sixth arm 56 has a base end connected to the tip end of the fifth arm 55 via a sixth axis J6. The sixth axis J6 is a rotation axis extending in the arm axis direction of the fifth arm 55 or the sixth arm 56. The sixth arm 56 is rotatable around the sixth axis J6. The tip of the sixth arm 56 is the arm tip 5T to which an end effector is attached.

[0018] The laying head 6 layers a sheet-like material, in this embodiment, tape-like prepreg, onto the lamination mold 1. The laying head 6 cuts prepreg tape 82 supplied from a tape supply 8 to the required length and applies it to the lamination mold 1. The laying head 6 includes a compaction roller 61 as a roller member and a tape feed mechanism 62. When applying the prepreg tape 82 to the lamination mold 1, the compaction roller 61 presses the prepreg tape 82 toward the surface of the lamination mold 1. The compaction roller 61 is rotatably supported near the tip of the laying head 6.

[0019] The tape feeding mechanism 62 feeds the prepreg tape 82 toward the compaction roller 61. The tape feeding mechanism 62 includes a pair of transport rollers that nip and feed the prepreg tape 82. A tape cutter that cuts the prepreg tape 82 is disposed downstream of the tape feeding mechanism 62 in the tape feeding direction. Note that, for the sake of simplicity, the tape feeding mechanism 62 and the prepreg tape 82 are not shown in FIG. 2 .

[0020] The air cylinder 7 is a mechanism that strokes the laying head 6 in a direction intersecting the rotation axis RA of the laying mold 1. The air cylinder 7 also functions as a mechanism for adjusting the pressing force of the laying head 6 against the laying mold 1, or in this embodiment, the pressing force of the compaction roller 61 against the laying mold 1. The air cylinder 7 is attached to the arm tip 5T of the robot arm 5 and supports the laying head 6. To achieve the above-mentioned stroke of the air cylinder 7, the robot arm 5 positions the laying head 6 at a predetermined position relative to the laying mold 1.

[0021] The operation of the air cylinder 7 allows the laying head 6 to move back and forth in the arm axis direction. In other words, the laying head 6 can perform a floating operation in which it strokes in the arm axis direction of the sixth arm 56. This operation will be described in detail below with reference to FIG. 5. The laying head may also be stroked in a direction other than the arm axis direction. The floating operation of the laying head 6 by the air cylinder 7 is an operation in which the laying head 6 is stroked in a direction that coincides with or is close to the direction of gravity acting on the laying mold 1. A prerequisite for this is that the robot arm 5 is positioned at a position where the laying head 6 can be stroked in the direction of gravity. This floating operation will be described in detail below with reference to FIG. 6.

[0022] 1 and 2 show the laying head 6 approaching the laying mold 1 in the Z direction, that is, from vertically above. The robot arm 5 is oriented such that the tip of the fourth arm 54 is positioned above the laying mold 1, the fifth arm 55 swings about the fifth axis J5 and points vertically downward, and the sixth arm 56 also points vertically downward. With this approach, the stroke direction of the laying head 6 naturally coincides with the direction of gravity. Note that by rotating the sixth arm 56 about the sixth axis J6, the rotational orientation of the laying head 6 and the roller axial direction of the compaction roller 61 can be adjusted. In other words, the direction in which the prepreg tape 82 is applied to the laying mold 1 can be adjusted.

[0023] The tape supply 8 feeds prepreg tape 82 toward the laying head 6. The tape supply 8 includes a plurality of tape rolls 81 and a plurality of guide rollers 83. Prepreg tape 82 is wound around each tape roll 81. The tape roll 81 is supported within a housing so as to be rotatable about its axis, and is capable of paying out the prepreg tape 82. The plurality of tape rolls 81 are arranged on the opposite side of the laying mold 1 across the base 50 of the robot arm 5. The plurality of guide rollers 83 are arranged in appropriate positions above the robot arm 5. The prepreg tape 82 paid out from the tape roll 81 is guided by the plurality of guide rollers 83, routed so as not to interfere with the operating robot arm 5, and led to the tape feed mechanism 62.

[0024] The robot arm 5 and tape supply 8 are movable by a movement mechanism 33 in the Y direction, which is the extension direction of the rotation axis RA of the stacking mold 1. The movement mechanism 33 includes a movement base 34 and a guide rail 35. The movement base 34 is a base on which the robot arm 5 and tape supply 8 are mounted. The guide rail 35 extends in the Y direction and movably supports the movement base 34. When a driving force is applied to the movement base 34, it moves along the guide rail 35, allowing the robot arm 5 and tape supply 8 to move in the Y direction along the stacking mold 1.

[0025] The control device 9 includes a processor that operates by reading a predetermined program. The control device 9 controls the operation of each part of the processing system PS. Specifically, the control device 9 controls the rotation operation of the laying mold 1 by the work positioner 3, the operation of the six axes of the robot arm 5, the operation of the movement mechanism 33, the laying operation of the prepreg tape 82 by the laying head 6, etc.

[0026] Under the control of the control device 9, the processing system PS layers the prepreg tape 82 on the lamination mold 1. For example, when laminating the prepreg tape 82 linearly in the Y direction, the lamination head 6 applies the prepreg tape 82 to the top surface of the lamination mold 1 while the movement mechanism 33 moves the robot arm 5 in the Y direction. If the lamination mold 1 has unevenness, the lamination head 6 performs a floating motion by operating the air cylinder 7. In the example shown in FIG. 1 , the lamination head 6 strokes in the Z direction in accordance with the unevenness. After lamination of one row of prepreg tape 82 is completed, the work positioner 3 rotates the lamination mold 1 by a predetermined angle around the rotation axis RA, and the next row of prepreg tape 82 is applied. This operation is repeated until the required number of layers of prepreg tape 82 are laminated on the lamination mold 1. When laminating the prepreg tape 82 diagonally on the lamination mold 1, the work positioner 3 rotates the lamination mold 1, while the lamination head 6 applies the prepreg tape 82.

[0027] [Problems with Supporting Both Ends of the Laminating Mold] In this embodiment, the laying head 6 lays the prepreg tape 82 while the work positioner 3 supports both ends of the laminating mold 1 in the extension direction of the rotation axis RA. In this case, the laminating mold 1 bends due to its own weight and the pressing force of the laying head 6. If the above-mentioned laying operation is performed without taking any measures to deal with the bent laminating mold 1, the prepreg tape 82 cannot be accurately laid at the target position on the laminating mold 1.

[0028] FIG. 3 is a schematic diagram showing an example of deflection of the lamination mold 1 due to its own weight. FIG. 3 assumes that the lamination mold 1 is relatively heavy or has a long axial length. In such cases, the lamination mold 1, whose both ends are supported by the work positioner 3, is prone to deflection such that the axial center portion sags due to gravity G. If the lamination mold 1 is heavy, deflection may occur in the support base 31 of the work positioner 3 or the positioner rotation shaft 32. FIG. 4 is a schematic diagram showing an example of deflection of the lamination mold 1 due to the pressing force of the lamination head 6. The compaction roller 61 of the lamination head 6 applies a pressing force PR to the lamination mold 1 while attaching the prepreg tape 82. This pressing force PR may cause deflection of the lamination mold 1.

[0029] If deflection occurs in the lamination mold 1 or the work positioner 3, a discrepancy will occur between the lamination position on the lamination mold 1 that is instructed to the robot arm 5 and the actual lamination position. This may prevent the prepreg tape 82 from being laminated as designed. It is possible to suppress the effects of the deflection by increasing the material strength of the lamination mold 1 or by employing a method of increasing the rigidity of the work positioner 3. However, both methods result in increased costs.

[0030] [Floating Operation of Laminating Head] To mitigate the problem of bending of the laminating mold 1 shown in Figures 3 and 4, in this embodiment, the laminating head 6 is capable of floating operation, stroking in a direction perpendicular to the rotation axis RA. The laminating head 6 layers the prepreg tape 82 on the laminating mold 1 while stroking as needed. This stroke action allows the compaction roller 61 of the laminating head 6 to press against the laminating mold 1 with a constant pressure, even if the laminating mold 1 has recessed or protruding portions due to the above-mentioned bending. In other words, the laminating head 6 changes its position in the stroke direction in accordance with the surface irregularities of the laminating mold 1, allowing the pressing force of the compaction roller 61 to be constant. This suppresses the effects of bending of the laminating mold 1, making it easier to accurately lay the prepreg tape 82 at the desired position on the laminating mold 1.

[0031] FIG. 5 illustrates the operation of the air cylinder 7, which causes the stacking head 6 to perform a floating operation. For ease of explanation, FIG. 5 indicates the up and down directions. This up and down direction corresponds to the direction of gravity. The air cylinder 7 includes a cylinder 71, a piston 72, a rod 73, a first port 74, a second port 75, and an electropneumatic valve 7V. The cylinder 71 is a chamber that forms a sealed space. The piston 72 slides up and down inside the cylinder 71. The piston 72 divides the interior of the cylinder 71 into a head chamber 711 and a rod chamber 712. The upper end of the rod 73 is connected to the piston 72, and the lower end is connected to the stacking head 6. The first port 74 is an intake / exhaust port that communicates with the head chamber 711. The second port 75 is an intake / exhaust port that communicates with the rod chamber 712. The electropneumatic valve 7V is a valve device that switches the first port 74 and the second port 75 between an intake port and an exhaust port.

[0032] The neutral state is when the lower surface of the compaction roller 61, which serves as the pressing surface for the prepreg tape 82, is at the reference position Sd. The reference position Sd is the position of the surface of the lamination mold 1 where no deflection has occurred, or the surface of the prepreg tape 82 that has already been laminated on the lamination mold 1. In the neutral state, the piston 72 is located approximately in the center of the cylinder 71 in the vertical direction. A predetermined air pressure is applied to the head chamber 711 and the rod chamber 712.

[0033] The plus stroke is a state in which the bottom surface of the compaction roller 61 extends downward by +d from the reference position Sd. The plus stroke is an operation in which, when a recessed portion occurs in the laying mold 1, the compaction roller 61 is made to follow the recessed portion. During the plus stroke, the electropneumatic valve 7V sets the first port 74 as an intake port and the second port 75 as an exhaust port. Air is supplied to the head chamber 711 from the first port 74, and air is exhausted from the rod chamber 712 through the second port 75. This air operation causes the piston 72 to descend, and as a result, the compaction roller 61 of the laying head 6 also descends.

[0034] A minus stroke is a state in which the bottom surface of the compaction roller 61 retreats upward by -d from the reference position Sd. A minus stroke is an operation in which, when a convex portion occurs on the lamination mold 1, the compaction roller 61 is made to follow the convex portion. During a minus stroke, the electropneumatic valve 7V sets the first port 74 as an exhaust port and the second port 75 as an intake port. Air is exhausted from the head chamber 711 through the first port 74, and air is supplied to the rod chamber 712 from the second port 75. This air operation raises the piston 72, which, as a result, also raises the compaction roller 61 of the lamination head 6.

[0035] The mechanism for floating the laying head 6 is not limited to the air cylinder 7. For example, a hydraulic cylinder or a mechanical spring may be used. Alternatively, the laying head 6 may be caused to float by controlling the motion of the first axis J1 to the sixth axis J6 of the robot arm 5. In this case, a force sensor is provided at the arm tip 5T, and the control device 9 controls the motion axis of the robot arm 5 so that the pressure detected by the force sensor remains constant. However, using the air cylinder 7 eliminates the need for processing such as calculating the amount of deflection based on the detection value of the force sensor, and the laying head 6 can be easily stroked by the air intake and exhaust operation of the electropneumatic valve 7V. Furthermore, because the operating medium of the air cylinder 7 is air, it has the advantage of being less likely to cause surrounding contamination than a hydraulic cylinder.

[0036] The mechanism for mounting the laying head 6 is not limited to the robot arm 5. For example, the air cylinder 7 and the laying head 6 may be mounted on a gantry device that can move in the direction of the rotation axis RA of the laying mold 1. However, if the laying head 6 is mounted on an articulated robot arm, it becomes easier to position the laying head 6 at a desired location easily and freely. This makes it easier to adjust the approach direction of the laying head 6 with respect to the laying mold 1 and the stroke direction of the laying head 6. For example, it is easy to operate the laying head 6 such that it approaches the laying mold 1 from the side when there is no deflection, and approaches the laying head 6 only in the direction of gravity when there is deflection.

[0037] 6 is a diagram showing the state of the laying head 6 approaching the laying mold 1 using the stroke of the air cylinder 7. With the laying head 6 approaching, it lays prepreg tape 82 onto the laying mold 1. The left diagram in FIG. 6 shows the manner in which the laying head 6 approaches the laying mold 1. The laying head 6 and air cylinder 7, which are attached to the arm tip 5T of the robot arm 5, are positioned directly above or below the laying mold 1. In other words, the laying head 6 and air cylinder 7 are positioned in a direction that coincides with the direction of gravity acting on the laying mold 1.

[0038] With the above arrangement, the stroke direction of the floating operation of the laying head 6 also coincides with the direction of gravity acting on the lamination mold 1. Therefore, the laying head 6 can be stroked accurately following the deflection of the lamination mold 1 due to gravity. Note that the stroke direction and the direction of gravity do not need to strictly coincide, and may be in an approximate relationship with a slight directional deviation. The laying head 6 and the air cylinder 7 may be disposed directly above or slightly offset from directly below the lamination mold 1. Furthermore, in the case of compensating for the deflection deformation of the lamination mold 1 due to the pressing force PR of the laying head 6 shown in FIG. 4, the stroke direction of the laying head 6 is not limited to the direction of gravity.

[0039] The lamination mold 1 has a lamination area for laminating the prepreg tape 82 on at least one of its upper and lower surfaces in the direction of gravity. Specifically, when the lamination head 6 is positioned directly above the lamination mold 1, a region of a constant width in the circumferential direction on the upper surface of the lamination mold 1 becomes the lamination area 1A where the prepreg tape 82 is laminated. When the lamination head 6 is positioned directly below the lamination mold 1, a region of a constant width in the circumferential direction on the lower surface of the lamination mold 1 becomes the lamination area 1B where the prepreg tape 82 is laminated. When laminating the prepreg tape 82, the control device 9 controls the six operating axes of the robot arm 5 so that the lamination head 6 is positioned at a position where it can stroke the lamination areas 1A and 1B in the direction of gravity. The pressing force of the compaction roller 61 against the lamination areas 1A and 1B may be adjusted by the air cylinder 7.

[0040] The central drawing in Figure 6 shows a state in which the laying head 6 and air cylinder 7 are positioned directly above the laying mold 1, which is deflecting due to gravity, and the prepreg tape 82 is being laid. The laying mold 1 is deflected by gravity into a downwardly convex bow shape centered on its center of gravity. In other words, the area near the center of gravity hangs down the lowest. Both ends of the laying mold 1 are held by the work positioner 3, so there is no change in the height position.

[0041] In this case, the air cylinder 7 performs the plus stroke shown in FIG. 6. That is, the cylinder 71 is lowered so that the compaction roller 61 protrudes beyond the reference position Sd. The height position of the arm tip 5T remains unchanged. The amount of protrusion of the compaction roller 61 is greatest near the center of gravity of the lamination mold 1, and the amount of protrusion decreases toward the axial end. This plus stroke allows the compaction roller 61 to be pressed with a constant pressure against the concave upper lamination area 1A of the lamination mold 1. Therefore, the prepreg tape 82 can be accurately laminated onto the lamination area 1A regardless of the deflection of the lamination mold 1.

[0042] The right side of Figure 6 shows the state in which the laying head 6 and air cylinder 7 are positioned directly below the lamination mold 1, which is deflected due to gravity, and the prepreg tape 82 is being laid. In this case, the air cylinder 7 performs the negative stroke shown in Figure 6. That is, the cylinder 71 is raised so that the compaction roller 61 retreats from the reference position Sd. The height position of the arm tip 5T remains unchanged. The amount of retreat of the compaction roller 61 is greatest near the center of gravity of the lamination mold 1 and decreases toward the axial end. This negative stroke allows the compaction roller 61 to be pressed with a constant pressure against the convex lower lamination area 1B of the lamination mold 1. Therefore, the prepreg tape 82 can be accurately laid in the lamination area 1B regardless of the deflection of the lamination mold 1.

[0043] As described above, according to the processing method of the present disclosure, the prepreg tape 82 is laminated onto the lamination mold 1 by a floating operation that strokes the lamination head 6 in the direction of gravity in response to the deflection of the lamination mold 1 caused by gravity. Because the deflection direction and stroke direction of the lamination mold 1 are the same, the compaction roller 61 can easily follow the deflection of the lamination mold 1. Furthermore, the stroke of the air cylinder 7 accommodates the unevenness of the lamination mold 1 without changing the height position of the arm tip 5T. Therefore, there is no need to make corrections to the position control of the robot arm 5 itself, which makes it possible to suppress the complexity of the control logic of the robot arm 5.

[0044] [Adjusting the Pitch Angle of the Lamination Head] In the above embodiment, an example was shown in which the lamination head 6 was disposed directly above or directly below the lamination mold 1. That is, an example was shown in which the pitch angle at which the lamination head 6 faces the surface of the lamination mold 1 is 90°. Below, an example will be shown in which the pitch angle of the lamination head 6 is set arbitrarily.

[0045] FIG. 7 shows a sheet laminating apparatus 4A equipped with a function for adjusting the pitch angle P (deg) of the laminating head 6. The sheet laminating apparatus 4A for manufacturing a sheet laminate includes a robot arm 5, a laminating head 6, a robot controller 91, and an operation unit 92. The laminating head 6 laminates a sheet-like material, such as the prepreg tape 82 exemplified above, onto the laminating mold surface 1S. The laminating head 6 is attached to the arm tip 5T of the robot arm 5 via an air cylinder 7. The laminating head 6 has a compaction roller 61 at its tip that rotates and presses the prepreg tape 82 when attaching the prepreg tape 82 to the laminating mold 1. The robot arm 5 has a joint consisting of six motion axes, which changes the position and orientation of the laminating head 6 relative to the laminating mold surface 1S.

[0046] The robot controller 91 controls the operation of the robot arm 5. The robot arm 5 and robot controller 91 function as an adjustment mechanism that adjusts the pitch angle P of the laying head 6. The operation unit 92 accepts input of adjustment information for the pitch angle P from the user. The robot controller 91 adjusts the joint angle of the robot arm 5 so that the laying head 6 faces the laying mold surface 1S at the desired pitch angle P input to the operation unit 92. Furthermore, the robot controller 91 causes the laying head 6, whose orientation is set at the adjusted pitch angle P, to perform the laying operation of laying the prepreg tape 82 on the laying mold surface 1S.

[0047] In an environment where the sheet laying device 4A is actually installed, there are often some structures or other devices within the movable range of the robot arm 5. In particular, as illustrated in FIG. 7, there are many cases where an obstacle OB exists above the robot arm 5. In this case, as illustrated in FIG. 1, if the pitch angle P of the laying head 6 is set to 90°, the robot arm 5 and the prepreg tape 82 guided by the guide roller 83 are likely to interfere with the obstacle OB. Therefore, it is desirable to set the pitch angle P to an angle that can avoid interference between the robot arm 5, guide roller 83, and prepreg tape 82 and the obstacle OB.

[0048] The pitch angle P is defined as follows in the example of FIG. 7 . The pitch angle P is the angle between a line L1 in the stroke direction that floats the laying head 6 when laminating a sheet-like material onto the lamination mold, and a tangent line Ta to the lamination mold surface 1S. The line L1 is a line that runs along the stroke direction of the laying head 6 when viewed from the direction of the roller rotation axis 61R of the compaction roller 61. The lamination mold surface 1S is the surface of the lamination mold 1 itself, or the surface of the prepreg tape 82 that has previously been laminated onto the lamination mold 1. In other words, the surface of the lamination mold 1 closest to the compaction roller 61 is the lamination mold surface 1S. The tangent line Ta is a line that runs along this lamination mold surface 1S.

[0049] FIG. 8 is a diagram showing another example of a sheet stacking device 4B equipped with a function for adjusting the pitch angle P of the stacking head 6. The sheet stacking device 4B includes a robot arm 5A, a stacking head 6, and functional units equivalent to the robot controller 91 and operation unit 92 illustrated in FIG. 7. The robot arm 5A is a multi-joint arm having six motion axes. The robot arm 5A is equipped with the stacking head 6 as an end effector, but is not equipped with the air cylinder 7 for floating the stacking head 6.

[0050] In the example of FIG. 8 , the pitch angle P is defined as follows: The pitch angle P is the angle between a line L2 set at the tip of the robot arm 5A and a tangent line Ta to the laminating mold surface 1S. The line L2 is a line connecting an arbitrary reference point SP and the roller rotation axis 61R, which is the rotation center of the compaction roller 61. The reference point SP is a point set at an arbitrary position at the tip of the robot arm 5A. For example, the reference point SP may be set on the arm axis in the tip region of the sixth arm 56 of the robot arm 5A. The definition of the tangent line Ta is the same as in the example of FIG. 7 . The pitch angle P can be defined in various ways so as to specify the relative angle of the laminating head 6 with respect to the tangent line Ta to the laminating mold surface 1S.

[0051] [Summary of the Disclosure] The specific embodiments described above include disclosures having the following configurations.

[0052] A processing method according to a first aspect of the present disclosure includes supporting a stacking mold having a rotation axis so that it can rotate around the axis, and stacking a sheet-like material onto the stacking mold using a stacking head that allows a floating operation of stroking the stacking head in a direction intersecting the rotation axis, while stacking the sheet-like material onto the stacking mold using the stacking head.

[0053] According to the first aspect, even if the lamination mold has concave or convex portions due to warping or the like, the lamination head can be pressed against the lamination mold with a constant pressure by the action of the stroke of the lamination head caused by the floating operation. In other words, the lamination head changes its position in the stroke direction according to the unevenness of the lamination mold, so the pressing force of the lamination head against the lamination mold can be kept constant without control using a pressure sensor or the like. Therefore, the influence of warping of the lamination mold is suppressed, making it easier to accurately laminate the sheet-like member in the required position on the lamination mold.

[0054] A processing method according to a second aspect is the processing method according to the first aspect, wherein the floating operation is an operation of stroking the stacking head in a direction that coincides with or is close to the direction of gravity acting on the stacking mold.

[0055] According to the second aspect, the laying head can be stroked in accordance with the deflection of the laying mold due to gravity, which makes it easier to lay the sheet-like members on the laying mold more accurately.

[0056] A processing method according to a third aspect is the processing method according to the first or second aspect, wherein an air cylinder capable of adjusting the pressing force of the lamination head against the lamination mold is used as the mechanism for performing the floating operation.

[0057] According to the third aspect, the laying head can be easily stroked by injecting and discharging air into the air cylinder. In addition, since the operating medium is air, there is an advantage that the surrounding area is less likely to be contaminated compared to hydraulic cylinders.

[0058] The processing method of the fourth aspect is the processing method of the first to third aspects, and uses a work positioner as a device for supporting the stacked mold, which supports the end of the stacked mold in the direction of the rotation axis and rotates the stacked mold around the rotation axis.

[0059] According to the fourth aspect, the use of a work positioner allows the stacked mold to be stably supported and rotated around its axis. However, since the work positioner supports the stacked mold at its end, the stacked mold tends to bend easily due to gravity. Therefore, there are great advantages to applying the present disclosure.

[0060] A processing method according to a fifth aspect is the processing method according to any one of the first to fourth aspects, wherein the laminating head is attached to a tip of a robot arm so as to be capable of floating.

[0061] According to the fifth aspect, by operating the robot arm, it becomes possible to easily and freely position the lamination head at a desired location.

[0062] The processing method of the sixth aspect is the processing method of the first to fifth aspects, wherein the stacking mold has a stacking area for stacking the sheet-like material on at least one of the upper surface in the direction of gravity and the lower surface in the direction of gravity, the stacking head is attached to the tip of the robot arm so as to be capable of floating movement, and the robot arm is operated so that the stacking head strokes against the stacking area along the direction of gravity.

[0063] According to the sixth aspect, the laying head attached to the robot arm can be stroked in accordance with the deflection of the laying mold due to gravity, which makes it easier to lay the sheet-like members on the laying mold more accurately.

[0064] A processing method according to a seventh aspect is the processing method according to the fifth or sixth aspect, wherein the robot arm is moved in the extending direction of the rotation axis while the lamination head is caused to laminate sheet-like members.

[0065] According to the seventh aspect, the robot arm can be moved in the direction of the rotation axis of the stacking mold, so that sheet-like members can be stacked on the stacking mold in a variety of ways.

[0066] In an eighth aspect of the present invention, in the processing method of the first to seventh aspects, when the sheet-like member is attached to the lamination mold by the lamination head, the sheet-like member is pressed by a roller member.

[0067] According to the eighth aspect, the sheet-like members can be attached to the lamination mold with the assistance of the roller members, thereby stabilizing the stacked state of the sheet-like members.

[0068] A processing method according to a ninth aspect is the processing method according to any one of the first to eighth aspects, wherein a tape-like prepreg is used as the sheet-like member.

[0069] According to the ninth aspect, a molded part made of a prepreg laminate can be produced by the processing method of the present disclosure.

[0070] A method for manufacturing a laminate according to a tenth aspect includes preparing a processing device including a stacking head that stacks sheet-like materials onto a stacking mold, a robot arm that changes the position and posture of the stacking head relative to the stacking mold, an adjustment mechanism that adjusts the pitch angle of the stacking head facing the stacking mold, an operation unit that accepts input of adjustment information for the pitch angle, and a controller that controls the robot arm based on the adjustment information for the pitch angle input from the operation unit; inputting the adjustment information for the pitch angle from the operation unit; and manufacturing a laminate using the processing device.

[0071] According to the tenth aspect, the relative position of the robot arm with respect to the stacking mold can be optimized. For example, the pitch angle P of the stacking head can be set so that the robot arm causing the stacking head to perform the stacking operation does not interfere with surrounding obstacles.

[0072] A method for manufacturing a laminate according to an eleventh aspect is the method according to the tenth aspect, wherein the lamination head further includes a roller member that rotates and presses the sheet-like member when attaching the sheet-like member to the lamination mold, and the pitch angle of the lamination head facing the lamination mold is the angle formed by a line connecting a reference point set at an arbitrary position at the tip of the robot arm and the center of rotation of the roller member when viewed from the direction of the rotation axis of the roller member, and a tangent to the surface of the lamination mold at a position on the surface of the lamination mold closest to the roller member when viewed from the direction of the rotation axis of the roller member.

[0073] According to the eleventh aspect, the pitch angle of the laminating head can be appropriately set using a line connecting a reference point arbitrarily set at the tip of the robot arm and the center of rotation of the roller member.

[0074] A method for manufacturing a laminate according to a twelfth aspect is the method according to the tenth aspect, wherein the sheet stacking device further includes a floating mechanism for stroking the stacking head, the stacking head is attached to the tip of the robot arm via the floating mechanism, and the stacking head further includes a roller member for rotating and pressing the sheet-like member when attaching the sheet-like member to the stacking mold, and the pitch angle of the stacking head facing the stacking mold is the angle formed by the stroke direction of the stacking head by the floating mechanism when viewed from the direction of the rotational axis of the roller member, and the tangent to the surface of the stacking mold at the position of the surface of the stacking mold closest to the roller member when viewed from the direction of the rotational axis of the roller member when the sheet-like member is stacked on the stacking mold.

[0075] According to the twelfth aspect, the pitch angle of the laminating head can be appropriately set using a line connecting a reference point arbitrarily set at the tip of the robot arm and the center of rotation of the roller member.

[0076] A method for manufacturing a laminate according to a thirteenth aspect is the method according to any one of the tenth to twelfth aspects, wherein the adjustment mechanism adjusts the pitch angle by adjusting a joint angle of the robot arm.

[0077] According to the thirteenth aspect, the pitch angle of the laminating head can be adjusted by utilizing the joint angle movement mechanism of an existing robot arm.

[0078] A method for manufacturing a laminate according to a fourteenth aspect is the method according to any one of the tenth to thirteenth aspects, wherein the floating mechanism is an air cylinder capable of adjusting the pressing force of the lamination head against the lamination mold.

[0079] According to the fourteenth aspect, even if the laminated mold is bent, the pressing force of the laminated head against the laminated mold can be maintained constant by the operation of the floating mechanism.

Claims

1. A processing method in which a lamination mold having a rotation axis is supported so that it can rotate around the axis, and a lamination head that laminates a sheet-like material onto the lamination mold is allowed to perform a floating operation by stroking the lamination head in a direction intersecting the rotation axis, and the lamination head laminates the sheet-like material onto the lamination mold.

2. A processing method according to claim 1, wherein the floating operation is an operation of stroking the stacking head in a direction that coincides with or approximates the direction of gravity acting on the stacking mold.

3. A processing method according to claim 1, wherein an air cylinder capable of adjusting the pressing force of the lamination head against the lamination mold is used as the mechanism for performing the floating operation.

4. A processing method according to claim 1, wherein the device for supporting the laminated mold is a work positioner that supports the end of the laminated mold in the direction of the rotation axis while rotating the laminated mold around the rotation axis.

5. A processing method according to any one of claims 1 to 4, wherein the laminating head is attached to the tip of a robot arm so as to enable the floating operation.

6. A processing method according to claim 2, wherein the lamination mold has a lamination area for laminating the sheet-like material on at least one of the upper surface in the direction of gravity and the lower surface in the direction of gravity, the lamination head is attached to the tip of a robot arm so as to enable the floating operation, and the robot arm is operated so that the lamination head strokes against the lamination area along the direction of gravity.

7. A processing method according to claim 5, wherein the robot arm is moved in the direction of extension of the rotation axis while the lamination head is caused to laminate sheet-like members.

8. A processing method according to claim 5, wherein when the sheet-like member is attached to the lamination mold by the lamination head, the sheet-like member is pressed by a roller member.

9. The processing method according to claim 1, wherein a tape-like prepreg is used as the sheet-like member.

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