Adaptive Ply Manipulation Tool for Composite Handling
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Solution Overview
Problem
The manual handling and stacking of composite plies in manufacturing processes are labor-intensive and time-consuming, leading to increased costs and potential health concerns, and existing automated solutions struggle to adapt to various ply shapes and sizes without damaging the material.
Innovation Solution
An automated ply manipulation system comprising a robotic arm with a ply manipulation tool featuring adjustable grippers and clamping elements, controlled by a processor to adapt to different ply shapes and sizes, ensuring efficient removal and storage without displacing the remaining material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated apparatus is used to remove composite plies from sheet, then productivity and labor safety are improved, but the apparatus must adapt to various ply shapes and sizes which increases device complexity
Solution Approach 1:
The gripper assembly incorporates movable components including a jaw assembly that can pivot and adjust its position relative to the shuttle. The jaw assembly includes a jaw member that can move between different positions to accommodate various ply shapes and sizes, allowing the automated apparatus to handle diverse composite materials without requiring multiple specialized grippers.
Solution Approach 2:
The ply manipulation tool is divided into distinct functional components: a shuttle that moves along the robotic arm, a jaw assembly that can pivot independently, and individual jaw members that can adjust their positions. This segmentation allows each component to be optimized for its specific function while collectively providing adaptability to various ply configurations.
2Manufacturing precision
If automated apparatus removes composite plies without displacement, then manufacturing precision is improved, but the apparatus complexity increases
Solution Approach 1:
The system incorporates a processor that receives information about the ply configuration and controls the robotic arm and gripper assembly accordingly. The processor coordinates the movement of the shuttle along the robotic arm and the positioning of the jaw assembly to ensure precise ply removal and placement without displacing adjacent plies.
Solution Approach 2:
The gripper assembly is designed to perform multiple functions: gripping the ply to be removed, holding adjacent plies in place, and releasing the ply at the target location. The jaw assembly can pivot and the jaw members can adjust their positions to accommodate different ply shapes and sizes, providing universal applicability across various composite material configurations.
3Ease of operation
If manual ply handling is performed, then ease of operation is maintained, but productivity decreases and health concerns arise
Solution Approach 1:
The automated system is designed to operate with minimal human intervention. The robotic arm positions the shuttle, the jaw assembly automatically grips and manipulates the ply, and the processor coordinates the entire sequence. This self-service capability maintains operational simplicity while dramatically increasing productivity compared to manual handling.
4Reliability
If tension is maintained on large composite plies during removal, then ply integrity is preserved, but the apparatus complexity increases
Solution Approach 1:
The jaw assembly is designed with dynamic tension control capability. The jaw members can apply controlled force to maintain tension on large composite plies during removal, preventing damage while accommodating the specific requirements of each ply size and shape through adjustable positioning and force application.
Data Source
AI summary
Various adaptive apparatus and systems for automated handling of components such as composite plies are provided. In one embodiment, a ply manipulation system is provided that comprises an automated machine having an arm, and a ply manipulation tool attached to the arm of the automated machine. The ply manipulation tool includes a first shuttle including a first gripper, a second shuttle including a second gripper, and an actuator. The ply manipulation system further comprises a processor that automatically controls the actuator to move the first and second shuttles linearly with respect to one another to adapt the first and second grippers to a ply shape. In another embodiment, the first and second shuttles include one or more clamping elements moveable to a position to be deployed outside a perimeter of the ply. Methods for removing a ply from a sheet of material using a ply manipulation tool also are provided.