Adaptive Fiber Spool Assembly for Complex Composite Layup
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Solution Overview
Problem
Existing fiber composite component manufacturing technologies, such as Automated Fiber Placement (AFP), face challenges in efficiently laying fibers on complex and uneven tool geometries, requiring large systems and multiple robots, which can be inefficient and wasteful, especially for large components like aircraft fuselage parts.
Innovation Solution
A laying unit with a housing containing laterally spaced, independently movable fiber spools that can be unwound and tilted to accommodate uneven tool surfaces, allowing for adaptive fiber placement with reduced material usage and improved precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of rails and depositing robots are used to lay fibers on complex tool geometries, then the ability to cover uneven surfaces is improved, but the device complexity and system size increase significantly
Solution Approach 1:
The fiber spool assembly is segmented into multiple independently movable spools (at least three spools with different radial positions) that can be individually adjusted. This segmentation allows each spool to adapt to different sections of the tool geometry without requiring a complex multi-robot system, thereby reducing overall device complexity while maintaining adaptability to uneven surfaces.
Solution Approach 2:
The fiber spools are designed with dynamic adjustment capabilities, allowing them to move independently in radial and axial directions. This dynamic configuration enables the spools to adapt to varying tool geometries during the fiber laying process, providing the necessary versatility without increasing device complexity through additional robots or rails.
2Adaptability or versatility
If fiber spools are fixed in position within the housing, then the device complexity is reduced, but the ability to adapt to uneven tool surfaces is lost
Solution Approach 1:
The fiber spool assembly is segmented into multiple independently movable spools (at least three spools with different radial positions) that can be individually adjusted. This segmentation allows each spool to adapt to different sections of the tool geometry without requiring a complex multi-robot system, thereby reducing overall device complexity while maintaining adaptability to uneven surfaces.
Solution Approach 2:
The invention combines multiple fiber spools with different radial positions into a single integrated assembly that can be mounted on the laying unit. This merging of multiple spools into one adjustable unit provides adaptability to uneven surfaces without requiring separate mounting mechanisms for each spool, thus minimizing the increase in device complexity.
3Manufacturing precision
If multiple fiber spools with different radial positions are used, then the precision of fiber placement on complex surfaces is improved, but the housing size and device complexity increase
Solution Approach 1:
The fiber spools are designed with dynamic adjustment capabilities, allowing them to move independently in radial and axial directions. This dynamic configuration enables the spools to adapt to varying tool geometries during the fiber laying process, providing the necessary versatility without increasing device complexity through additional robots or rails.
Solution Approach 2:
The housing is designed as a universal mounting structure that can accommodate fiber spools at different radial positions and allow their independent movement. This multi-functional housing design enables precise fiber placement on various tool geometries without requiring multiple specialized housings, thereby minimizing the overall housing size while maintaining precision.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~4B
AI summary
The present invention provides a layup unit for manufacturing a fiber composite component, comprising: a housing; and a plurality of fiber spools which are designed to be unwound when the layup unit is moved, wherein the fiber spools are movably mounted within the housing. The invention further provides a method for manufacturing a fiber composite component with a layup unit in which the fiber spools are laterally spaced apart from one another.