Adaptable Winding Tools for Fiber-Matrix Composite Ducts
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Solution Overview
Problem
The complex and varying design of air ducts made from fiber-matrix composite materials poses challenges in manufacturing, leading to inefficiencies and high costs.
Innovation Solution
A manufacturing tool with an adaptable form for winding applications, comprising a support structure, adjustable manipulators, and a variable outer deposit surface, allowing for dynamic shape adjustment through pressurizable reservoirs or electroactive structures, enabling the production of duct components with varying shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fixed-mold tools are used for manufacturing fiber-matrix composite ducts, then manufacturing precision can be maintained for specific shapes, but device complexity increases and adaptability decreases when producing different duct shapes and sizes
Solution Approach 1:
The patent applies the dynamics principle by implementing an adjustable support structure with movable support elements that can be positioned at different locations and heights. This dynamic configuration allows a single tool to adapt to various duct shapes and sizes without requiring multiple fixed molds, thereby improving tool adaptability while maintaining manageable complexity through systematic adjustability rather than complete redesign for each duct variant
Solution Approach 2:
The patent implements universality by designing a single manufacturing tool capable of producing multiple duct configurations through its adjustable support structure. The tool can accommodate different duct geometries, sizes, and cross-sectional shapes by reconfiguring the support elements, eliminating the need for multiple specialized tools and reducing overall device complexity while maintaining manufacturing precision across different product variants
2Loss of substance
If multiple fixed molds are used for different duct shapes, then manufacturing precision is maintained for each specific shape, but loss of substance increases due to waste material from unused molds
Solution Approach 1:
The patent applies discarding and recovering by using a single reusable tool with adjustable support elements instead of multiple disposable or specialized fixed molds. The support structure can be reconfigured and reused for different duct productions, minimizing waste material generation while maintaining the ability to produce various duct shapes and sizes efficiently
3Adaptability or versatility
If adjustable manipulators are added to create an adaptable manufacturing tool, then tool versatility improves for different duct shapes, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the support structure into multiple independent, adjustable support elements that can be individually positioned and configured. This modular approach allows the tool to achieve high versatility for different duct shapes while keeping each individual component relatively simple, thereby managing overall device complexity through systematic segmentation rather than requiring a completely complex integrated system
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
Facilitates efficient and cost-effective manufacturing of fiber-matrix composite ducts by allowing a single tool to be reused for different shapes, reducing waste, and enabling tool development flexibility during the manufacturing process.
Implementation Method 1
a change of a pressure of a fluid inside the reservoir results in a change of a form of the reservoir which leads to change of the contour of the outer deposit surface
Implementation Method 2
a change of an applied electric current results in a change of a form of the electroactive structures which leads to change of the contour of the outer deposit surface
Implementation Method 3
A change of an applied electric current results in a change of an extension of the piezoelectric structures
Implementation Method 4
A change of an applied electric current and temperature results in change of a shape of the form shape memory material parts
Data Source
AI summary
A manufacturing tool with an adaptable form for winding applications of fiber-matrix composites to generate duct components from fiber-matrix composites includes a support structure, outer deposit surface and adjustable manipulators. The support structure has at least two support connectors and is configured to be mounted to bearings of a winding manufacturing system by the support connectors. The outer deposit surface is configured for material deposit support and to provide a variable circumferential contour for laying down fiber material in a winding process. The adjustable manipulators are between the outer deposit surface and the support structure to adjustably support the outer deposit surface on the support structure. The adjustable manipulators are configured to adjust a distance between the outer deposit surface and the support structure to provide different adjustable outer shapes of the manufacturing tool.