Automated Tape Laying Head for Composite Preforms
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Solution Overview
Problem
Manual drape-forming operations in composite material manufacturing are limited by low deposition rates and susceptibility to fiber wrinkling and misalignment, leading to defects in the final part, especially when producing large, complex panels like aircraft wing panels.
Innovation Solution
An automated device with a manipulator and tape laying head equipped with a drum for fabric suction, heating, and tension control, along with a shape-adaptable roller and hot air nozzles, ensures precise alignment, tension, and thermal activation of resin for uniform adhesion, enabling high-speed deposition of fibrous layers without wrinkling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated tape laying is implemented, then deposition rate increases, but control of fabric tension and alignment becomes more difficult
Solution Approach 1:
The patent introduces a drum with suction orifices as an intermediary device between the automated tape laying system and the fabric. This drum mediates the deposition process by using controlled suction to grip and tension the fabric during automated placement, ensuring precise alignment while maintaining high deposition rates. The suction mechanism acts as a bridge that enables automated handling without sacrificing fabric control.
Solution Approach 2:
The patent employs pneumatic suction through the drum's orifices to control fabric tension and positioning during automated deposition. By using controlled vacuum pressure, the system maintains precise fabric alignment and tension automatically, resolving the contradiction between high-speed automated deposition and precision fabric control.
2Productivity
If high deposition rates are achieved, then productivity increases, but fiber wrinkling and misalignment defects increase
Solution Approach 1:
The patent applies preliminary heating to the fabric before deposition using heating means associated with the drum. This pre-heating activates the resin dusting on the fabric in advance, creating tackiness that prevents fiber wrinkling and misalignment during high-speed automated deposition. By preparing the fabric beforehand, the system maintains reliability even at high deposition rates.
Solution Approach 2:
The controlled pneumatic suction through the drum maintains fabric tension uniformly during high-speed deposition, preventing fiber wrinkling and misalignment defects while enabling high productivity.
3Manufacturing precision
If manual drape-forming is used, then fabric alignment and tension control are maintained, but deposition rate is limited
Solution Approach 1:
The patent enables the fabric to self-tension through the suction drum mechanism during automated deposition. The suction grip and release system allows the fabric to maintain its own tension and alignment automatically, eliminating the need for manual handling while achieving high deposition rates with maintained precision.
4Strength
If resin dusting is applied to non-tacky fabric, then layer adhesion is enabled, but fabric alignment control becomes difficult
Solution Approach 1:
The patent applies preliminary heating to activate the resin dusting on the fabric before deposition. This pre-activation creates tackiness at the optimal moment, enabling layer adhesion while the suction drum maintains precise fabric alignment during the deposition process. The timing of resin activation is controlled to coincide with fabric placement.
Solution Approach 2:
The patent changes the temperature parameter of the fabric through heating means, transforming the resin from non-tacky to tacky state. This parameter change enables adhesion while the suction mechanism maintains alignment control throughout the process.
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
The automated system significantly increases deposition rates while maintaining the versatility of manual methods, reducing defects and improving the mechanical characteristics of the final composite parts by ensuring precise alignment and tension control during the drape-forming process.
Implementation Method 1
a drum comprising at least one suction orifice leading to its surface and able to individually grasp a length of fabric on a mounting outside the tool and the tape laying head
Implementation Method 2
means of heating the length of fabric... Brought to a so-called activation temperature, the resin becomes fluid and glues the layers to each other
Implementation Method 3
a roller separate from the drum and means to pre-adjust its shape, able to compact the length of fabric deposited on the preform
Data Source
AI summary
The invention relates to an automated device for implementing a drape-forming step to form a laminated fibrous preform, which is then impregnated with resin to produce a part made of composite material. The invention relates more particularly to the production of preforms for manufacturing parts such as panels, in particular very thick panels, that extend basically in two dimensions. The device of the invention comprises a manipulator able to move and orient in space a tape laying head, said tape laying head comprising: a drum comprising a suction orifice leading to its surface and able to individually grasp a length of fabric on a mounting outside the tool and the tape laying head; means designed to subsequently place this length of fabric on the preform comprising means of compacting; and means of heating the length of fabric.