Bi-directional Lamination Head for Composite Layup
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Solution Overview
Problem
Conventional lamination heads for composite laminate manufacturing face inefficiencies due to excessive off-part movement, complex rotation requirements, and time-consuming tape threading processes, which increase production flow time and downtime.
Innovation Solution
A lamination head with bi-directional layup capability and self-threading capability, featuring a material supply drum, backing layer separation assembly, and directional control device that allows for seamless switching between directions without rotation, and automatic threading of tape through the use of a backing layer separation mechanism and collection drum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the lamination head moves back over the layup surface in the opposite direction to start a new course, then the lamination head can continue laying up composite laminates, but the off-part movement adds to production flow time
Solution Approach 1:
The patent inverts the conventional approach by enabling the lamination head to lay up material in both forward and reverse directions without requiring rotation. The head maintains continuous contact with the layup surface and dispenses tape bidirectionally, eliminating the time-consuming rotation and repositioning operations required in traditional unidirectional systems.
2Adaptability or versatility
If the lamination head is configured to rotate 180 degrees at the end of a course, then the lamination head can reverse direction to lay up the next course, but the rotation capability adds complexity to the lamination system
Solution Approach 1:
The patent extracts and eliminates the rotation mechanism from the lamination head system entirely. Instead of rotating the head to change direction, the system uses a bidirectional tape dispensing mechanism that can lay up material in both directions while the head remains in its original orientation, supported by a gantry system that provides the necessary movement capabilities.
Solution Approach 2:
The lamination head is designed with universal bidirectional tape dispensing capability, allowing it to lay up material in both forward and reverse directions without requiring rotation or reconfiguration. This multi-directional functionality is achieved through the head's internal mechanism rather than through rotation of the entire assembly.
3Ease of operation
If manual threading of the tape is performed after each material roll changeout, then the tape can be threaded through the lamination head components, but the threading process is time-consuming and increases lamination head downtime
Solution Approach 1:
The patent implements self-threading capability where the lamination head automatically threads the new tape from the material roll through its internal components and onto the backing layer collection drum without requiring manual intervention. This automated threading process significantly reduces downtime associated with material roll changeouts.
Solution Approach 2:
The system performs preliminary threading actions automatically as part of the material roll changeout process. The bidirectional layup capability and self-threading mechanism are预先 configured to enable rapid integration of new material rolls without requiring operators to manually thread the tape through complex head components.
4Adaptability or versatility
If the entire weight of the lamination head, material supply, and support cabling is rotated, then the lamination head can change direction, but the rotation requirement increases the complexity and weight handling requirements
Solution Approach 1:
Instead of rotating the heavy lamination head assembly to change direction, the patent inverts the approach by keeping the head stationary in orientation and enabling bidirectional tape dispensing through the head's internal mechanism. The gantry system handles the movement while the head maintains a fixed orientation, eliminating the need to rotate substantial weight.
Data Source
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AI summary
A lamination head having bi-directional layup capability has a material supply drum configured to support a material roll of backed material which is comprised of layup material backed by a backing layer. A backing layer separation assembly receives the backed material from the material supply drum and has a backing layer directional control device and first and second backing layer separation mechanisms. The backing layer directional control device in the first mode separation position is aligned with the first backing layer separation mechanism for separating the backing layer from the layup material as the lamination head moves along a first direction of travel. The backing layer directional control device in the second mode separation position is aligned with the second backing layer separation mechanism for separating the backing layer from the layup material as the lamination head moves along a second direction of travel.