Adjustable Intermediate Mandrel Support for Composite Lamination
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Solution Overview
Problem
The construction of mandrels in composite material lamination processes often results in mandrel sag, leading to ply migration and undesirable structural qualities, especially in high-performance applications like thin helicopter blades, due to insufficient support and deflection during the lamination process.
Innovation Solution
A mandrel support system that includes a rotatable mandrel with adjustable intermediate supports, allowing for dynamic height adjustment and continuous 360-degree rotation without interrupting the lamination process, thereby reducing mandrel deflection and maintaining a constant surface area contact to minimize ply migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If intermediate supports are used to prevent mandrel sag, then mandrel stability is improved, but the complexity of the support system increases
Solution Approach 1:
The intermediate support system employs adjustable height mechanisms that allow the support distance to be dynamically modified during the lamination process. This enables the system to adapt to changing mandrel deflection conditions while maintaining stability, rather than requiring a complex fixed multi-point support system.
Solution Approach 2:
The system changes the support distance parameter during operation to optimize mandrel support. By adjusting the vertical distance between the intermediate support and the mandrel axis, the system maintains mandrel stability without requiring complex structural arrangements.
2Productivity
If the mandrel is rotated continuously for 360 degrees, then lamination efficiency is improved, but maintaining consistent support contact becomes more difficult
Solution Approach 1:
The intermediate support system is designed with adjustable height capabilities that allow it to dynamically adapt during mandrel rotation. This ensures consistent support contact is maintained throughout the 360-degree rotation, enabling continuous lamination without interrupting for support adjustments.
Solution Approach 2:
The system enables continuous mandrel rotation and uninterrupted lamination by maintaining consistent intermediate support contact throughout the rotation. The adjustable support distance ensures the mandrel remains properly supported during the entire 360-degree cycle, allowing the lamination process to proceed without interruption.
3Adaptability or versatility
If the support distance is increased to accommodate thicker composite material, then adaptability to different composite thicknesses is improved, but mandrel stability during rotation may worsen
Solution Approach 1:
The intermediate support distance is made dynamically adjustable rather than fixed. This allows the support distance to be optimized for each specific composite thickness being laminated, maintaining mandrel stability while accommodating variations in composite material thickness.
Solution Approach 2:
The system modifies the support distance parameter to match the composite thickness being applied. By adjusting this parameter, the system maintains optimal mandrel support and stability for each lamination step, whether the composite layer is thin or thick.
Data Source
AI summary
A system includes a mandrel having an exterior surface configured to receive composite material, a first end, and a second end opposite the first end, an end support coupled to the first end of the mandrel such that the mandrel is rotatable about an axis of rotation, and an intermediate support configured to support the mandrel between the first end and the second end such that at least a portion of the exterior surface is exposed while the mandrel is supported by the intermediate support, a vertical distance between the intermediate support and the axis of rotation defining a support distance, and the intermediate support being adjustable between a first position having a first support distance and a second position having a second support distance greater than the first support distance.