AFP Deposition Control for Spliced Tape Waste Reduction
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Solution Overview
Problem
Existing automated fiber placement (AFP) methods result in significant waste due to incomplete tape rolls, as unused tape material is either discarded or used for lower quality parts, and splicing alters mechanical properties, limiting the production of high-quality composite structures.
Innovation Solution
A computer-assisted method for controlling the deposition process in AFP devices that accounts for splicing regions by providing actual data on tape material positions and lengths, allowing for efficient use and placement of tape sections outside the composite structure, thereby reducing waste and maintaining quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If splicing is used to connect remaining short tapes, then tape material can be reused in AFP processes, but the mechanical properties of the tape and manufactured part are altered, limiting use to lower quality parts
Solution Approach 1:
The system performs preliminary detection of splicing regions in the tape material before deposition begins. By identifying splicing locations in advance and planning the deposition sequence accordingly, the system can route spliced sections to non-critical areas or exclude them from the final product, thereby preserving mechanical properties while enabling tape reuse
Solution Approach 2:
The system incorporates feedback mechanisms that detect splicing regions during tape material processing and use this information to dynamically adjust the deposition sequence. This closed-loop approach ensures that spliced sections are strategically placed in non-critical areas, maintaining structural integrity while maximizing material utilization
2Strength
If remaining tape material is discarded or used for lower grade parts, then mechanical properties are maintained, but considerable amounts of waste are generated
Solution Approach 1:
The system converts the previously harmful effect of splicing (which limited tape reuse) into a beneficial opportunity for waste reduction. By detecting splicing regions and intelligently routing them to non-critical areas through optimized deposition sequencing, the system transforms spliced tape material from unusable waste into reusable resource, thereby reducing waste while maintaining structural quality
3Productivity
If splicing regions are present in the tape material, then tape can be continuously supplied, but splicing regions must be avoided in the composite structure requiring additional process steps
Solution Approach 1:
The system performs preliminary detection and mapping of splicing regions before the deposition process begins. By pre-planning the deposition sequence to account for splicing locations, the system eliminates the need for complex real-time interventions, manual inspections, or post-processing steps, thereby maintaining continuous productivity while simplifying the manufacturing process
Data Source
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AI summary
The present invention provides a computer-assisted method for controlling a deposition process in an automated fiber placement (AFP) device (100) for forming a composite structure (108) from a pre-impregnated fibre containing tape material by deposition tape sections (110) of different lengths by means of a placement head (107) according to a deposition sequence, wherein the tape sections (110) are provided by cutting a tape material (104) and having at least one slicing region (101), a computing device (112), an automated fibre placement (100) device for executing the method and a composite structure (108) manufactured using the method.