AFP Deposition Control Around Tape Splice Regions
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Solution Overview
Problem
Existing automated fiber placement (AFP) methods result in significant waste due to incomplete tape rolls, and splicing these rolls to extend their use alters the mechanical properties of the tape and manufactured parts, limiting their use to lower quality applications.
Innovation Solution
A computer-assisted method for controlling the deposition process in AFP devices to efficiently use tape material with splicing regions by adjusting the deposition sequence to avoid splicing regions in the composite structure, using sensors and measurement technology to detect and adjust for splicing positions, and integrating this data into the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If tape rolls are spliced to extend their use, then material utilization is improved, but the mechanical properties of the tape and manufactured parts deteriorate
Solution Approach 1:
The patent extracts and removes the splicing regions from the tape material before deposition. Sensors detect splicing positions and the system automatically adjusts the deposition sequence to exclude these regions, thereby utilizing the remaining tape material for high-quality composite structures without compromising mechanical properties
Solution Approach 2:
The patent applies different handling to different regions of the tape material. Splicing regions are identified and excluded from critical areas, while non-spliced regions are used for high-quality deposition. This local differentiation allows maximum material utilization while preserving the quality of the final product
2Loss of substance
If splicing regions are included in the composite structure, then material utilization is improved, but the quality of the composite structure deteriorates
Solution Approach 1:
The system performs preliminary detection of splicing regions using sensors before the deposition process begins. The deposition sequence is then pre-adjusted to avoid these regions, ensuring that only high-quality tape sections are deposited into the composite structure while maximizing material utilization
3Loss of substance
If tape rolls are not fully emptied, then material waste is reduced, but the productivity of the AFP process deteriorates
Solution Approach 1:
The patent recovers and reuses remaining tape material from partially emptied rolls by splicing it back into the deposition sequence. The system identifies when a roll is partially used and integrates the remaining tape sections into subsequent composite structure production, thereby eliminating waste and maintaining productivity
Data Source
AI summary
A computer-assisted method for controlling a deposition process in an automated fiber placement (AFP) device for forming a composite structure from a pre-impregnated fiber containing tape material by deposition of tape sections of different lengths by a placement head according to a deposition sequence, wherein the tape sections are provided by cutting a tape material and having at least one slicing region, a computing device, an automated fiber placement device for executing the method and a composite structure manufactured using the method.