Automated Acoustic Device Placement in Honeycomb Cores
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Solution Overview
Problem
Current methods for septumization of honeycomb cores in acoustic structures are time-consuming and labor-intensive, lacking efficiency and automation, which hinders the rapid and cost-effective production of acoustic devices for noise attenuation applications.
Innovation Solution
A fully automated system utilizing a manipulator with end effectors, digital controllers, and a material supply system to rapidly place and bond acoustic devices within cellular cores, employing laser cutting and thermal radiation for precise alignment and bonding, enabling high-speed and accurate placement of septums in honeycomb cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual septum pieces are inserted one-by-one into each honeycomb cell using automated robotic process, then placement precision is improved, but production speed deteriorates and labor intensity increases
Solution Approach 1:
Multiple placement tools are combined into a single end effector assembly, allowing simultaneous placement of multiple septum pieces across different honeycomb cells in one operation, thereby improving production speed while maintaining precision through automated control
Solution Approach 2:
Septum pieces are pre-positioned on the placement tools within the end effector before approaching the honeycomb core, allowing for rapid simultaneous deployment to multiple cells without individual handling, thus increasing productivity while maintaining placement accuracy
2Device complexity
If manual methods are used for septumization of honeycomb cores, then equipment complexity is reduced, but labor intensity increases and production efficiency deteriorates
Solution Approach 1:
The end effector assembly serves multiple functions including holding multiple septum pieces, positioning them accurately, and placing them simultaneously into multiple honeycomb cells, thereby achieving high productivity with a single multi-functional device rather than multiple simple tools
Solution Approach 2:
Manual mechanical operations are replaced with an automated robotic system controlled by a programmable controller, which uses sensors and automated positioning to achieve precise septum placement while dramatically improving production efficiency
3Ease of manufacture
If adhesive bonding process is simplified, then ease of manufacture is improved, but bonding reliability deteriorates
Solution Approach 1:
An adhesive layer is introduced as an intermediary between the septum pieces and honeycomb cell walls, providing reliable bonding while allowing for simple automated application processes through the end effector, thus achieving both ease of manufacture and bonding reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for rapid, precise, and cost-effective production of septumized acoustic structures, significantly improving the efficiency and automation of acoustic device placement within cellular cores, enhancing sound control capabilities.
Implementation Method 1
each of the acoustic device placement tools includes a vacuum pickup for holding an acoustic device on the mandrel
Implementation Method 2
employing laser cutting and thermal radiation for precise alignment and bonding
Implementation Method 3
employing laser cutting and thermal radiation for precise alignment and bonding
Data Source
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AI summary
A laser (62) cuts overlapping ribbons (58) of acoustic material (58) into acoustic devices (34). An automatically controlled manipulator (66) includes an end effector (60) having groups of placement tools (68) for simultaneously placing multiple acoustic devices (34) in a cellular core (32). The placement tools (68) include mandrels (104) provided with vacuum pickups for picking up and holding the acoustic devices (34) during transport to the core (32). A vision system aligns the placement tools (68) with the cells (42) of the core (32). The end effector (60) includes a thermal radiation (138) device for bonding the acoustic devices (34) to the core (32).