Automated Tape Placement for Layered Composite Structures
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Solution Overview
Problem
The manufacture of layered composite structures, including radius fillers, is time-consuming and labor-intensive, often resulting in damage during handling, necessitating the automation of their construction.
Innovation Solution
Apparatuses and methods are developed to create layered tape composite structures using a frame that translates relative to a layup surface, with modules for placing and combining tapes to form a desired cross-sectional profile, allowing for the automated placement and compaction of tapes to fill voids and form composite structures efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual assembly methods are used to create layered composite structures, then flexibility in handling and adjustment is maintained, but the manufacturing process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated robotic system that uses programmable control to place composite tapes. The robotic arm with end effector automatically positions and deposits tapes according to predetermined paths, eliminating manual labor while maintaining precision through digital control systems.
Solution Approach 2:
The system incorporates automatic tape dispensing and placement capabilities where the robotic system serves itself by automatically retrieving tapes from storage, positioning them on the workpiece, and advancing to the next placement location without human intervention. The predetermined paths enable the system to autonomously complete the entire layup process.
2Adaptability or versatility
If manual assembly methods are used to create layered composite structures, then adaptability to design changes is maintained, but the process results in damage during handling and increased labor requirements
Solution Approach 1:
The patent replaces manual handling operations with automated robotic manipulation. The robotic end effector gently deposits tapes in a controlled manner, eliminating the rough handling that occurs during manual assembly. The automated system provides consistent, damage-free placement while maintaining adaptability through programmable paths and parameters.
Solution Approach 2:
The system uses predetermined digital paths and models to replicate the exact composite structure design. By storing the layup pattern as digital data, the system can reproduce complex geometries with high precision and consistency, eliminating variations and errors associated with manual copying or measurement.
3Productivity
If automated tape placement is implemented, then manufacturing time and labor are reduced, but the device complexity increases
Solution Approach 1:
The robotic system is designed with multi-functionality, where a single robotic arm with interchangeable end effectors can perform multiple operations including tape dispensing, positioning, and placement. This universal approach consolidates what would otherwise require multiple specialized devices, reducing overall system complexity while maintaining high productivity.
Solution Approach 2:
The patent introduces a controller as an intermediary between the robotic system and the tape placement process. The controller manages the complex coordination of robot motion, tape dispensing, and path following through software programming, thereby simplifying the operational complexity by centralizing control logic in a programmable interface rather than requiring complex mechanical linkages.
4Manufacturing precision
If automated tape placement with predetermined paths is used, then manufacturing precision is improved, but the ease of operation for complex geometries decreases
Solution Approach 1:
The system uses digital copying of the desired composite structure geometry into predetermined paths. By creating a digital model or importing CAD data, the complex geometry is represented as programmable coordinates and trajectories. This allows the robotic system to accurately reproduce complex shapes without requiring manual programming of each point, thereby maintaining ease of operation while achieving high precision.
Solution Approach 2:
The system enables easy adaptation to different geometries by changing programming parameters such as path coordinates, tape orientation angles, and placement speeds. Rather than reprogramming the entire system for each new geometry, operators can modify key parameters to accommodate design variations, maintaining both precision and operational simplicity.
Data Source
AI summary
Apparatuses for creating layered tape composite structures include a frame, a source of first tape, and a first tape placement module configured to receive first tape and place the first tape on a layup surface as the frame translates along the layup surface. Some apparatuses further include a source of second tape, and a second tape placement module configured to receive second tape and place the second tape on the first tape as the frame moves along the layup surface. Methods for creating layered tape composite structures include supplying a first tape, and placing the first tape on a layup surface. Some methods further include supplying a second tape, and placing the second tape on the first tape on the layup surface.