Composite Structure Shaping with Sequential Automated Manipulators
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Solution Overview
Problem
Existing composite manufacturing techniques are labor-intensive and time-consuming, requiring special handling to prevent defects during the transfer and placement of composite materials, especially for structures with complex contours and geometries.
Innovation Solution
A method and system utilizing automated manipulators to hold and shape uncured composite members from an initial to a final contour by sequentially forming unformed portions while maintaining unformed portions in the initial contour, applying tension and heat as needed, and using a place tool to define the final shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated manipulators are used to shape composite members, then productivity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The composite member is divided into multiple unformed portions that are sequentially shaped along its length. Multiple manipulators are positioned at different locations to independently shape different portions, enabling parallel processing and improving productivity while managing system complexity through modular architecture
Solution Approach 2:
The place tool is pre-configured with the final contour geometry before the composite member is positioned. This preliminary setup allows the automated manipulators to directly form the final shape without requiring complex real-time calculations or adjustments during the shaping process
2Manufacturing precision
If sequential shaping of unformed portions is performed while holding remaining portions, then manufacturing precision is improved, but duration of action increases
Solution Approach 1:
While one manipulator is shaping a portion of the composite member, other manipulators simultaneously shape different portions. The process maintains continuous useful action across the entire member by eliminating idle time between shaping operations through parallel processing of multiple unformed portions
Solution Approach 2:
The system dynamically coordinates multiple manipulators to adapt their positioning and shaping sequences based on the specific geometry and length of the composite member. This dynamic adjustment allows optimization of the shaping process for different part configurations, balancing precision requirements with production time
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the likelihood of defects and enhances efficiency by automating the shaping process, allowing for precise formation of complex composite structures with reduced labor and time requirements.
Implementation Method 1
synchronizing motion of the automated manipulators to form a final contour along the length of the composite member
Implementation Method 2
The operations include applying heat to the composite member while forming the final contour along the length of the composite member
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A method for shaping a composite structure includes steps of: (1) holding a composite member in an initial contour along a length of the composite member; and (2) forming a final contour along the length of the composite member by: (3) sequentially shaping formed portions of the composite member while holding unformed portions of the composite member in the initial contour to form portions of the final contour; and (4) sequentially shaping the unformed portions of the composite member to form other portions of the final contour.