Automated Composite Ply Formation System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for forming large and complex composite structures are inefficient due to manual labor requirements and limitations in automated processes, leading to issues like tow-related distortions, structural wrinkles, and increased material usage.
Innovation Solution
A system and method for automated ply-by-ply formation of composite structures, utilizing a network of sub-systems for lamination, transfer, forming, and film removal, which enables synchronized parallel processing and reduces manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If automated drape forming process is used, then labor time is reduced, but manufacturing precision deteriorates due to tow-related distortions and structural wrinkles
Solution Approach 1:
The patent divides the composite structure into multiple discrete plies that are formed and cured separately. Each ply is individually laid, formed, and cured before adding the next layer. This segmentation prevents tow distortion and wrinkling that occur in conventional automated processes by treating each layer as an independent unit with controlled formation conditions.
Solution Approach 2:
The patent performs preliminary formation of each individual ply on a forming tool before curing. The ply is pre-formed to the desired contour while still flexible, then cured in that formed state. This preliminary action ensures proper fiber alignment and eliminates the need for post-formation adjustments, maintaining structural quality.
2Manufacturing precision
If conventional manual layup is used, then manufacturing precision is maintained, but productivity decreases due to time-consuming manual labor
Solution Approach 1:
The system uses automated material handling and layup equipment that operates with minimal human intervention. The composite plies are automatically transported, positioned, and laid on the forming tool by robotic or automated mechanisms. This self-service capability maintains precision while dramatically increasing productivity compared to manual layup.
3Productivity
If automated ply-by-ply formation is used, then productivity is increased, but device complexity increases due to multiple coordinated subsystems
Solution Approach 1:
The patent employs a multi-functional integrated system where a single automated platform performs multiple operations: material handling, ply laying, forming, and curing coordination. This universal system consolidates what would otherwise require separate manual operations, increasing productivity while managing complexity through integration rather than proliferation of independent devices.
Solution Approach 2:
The system uses an intermediary forming tool that serves as a mediator between the automated layup process and the final cured structure. The forming tool receives plies in a planar state, transforms them to the desired contour, and maintains that shape during curing. This intermediary simplifies the overall process by decoupling the layup operation from the formation operation.
4Productivity
If thick laminates are formed using automated processes, then productivity is improved, but manufacturing precision deteriorates due to difficulty in forming complex shapes
Solution Approach 1:
The patent forms thick laminates by stacking multiple individually formed plies rather than attempting to form the entire thick laminate at once. Each thin ply is independently formed to the correct shape, then stacked to build the final thick structure. This segmentation maintains shape accuracy while enabling production of thick sections that would be impossible to form in a single automated operation.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A system for fabricating a composite structure includes a ply carrier including a ply support surface configured to support at least one composite ply. The system includes a carrier transfer device configured to convey the ply carrier. The system includes a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier. The system includes a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool. The system includes a forming system configured to form the at least one composite ply over the at least a portion of the forming surface of the forming tool.