Bi-Stable Valve Control for Selective Composite Ply Adhesion
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Solution Overview
Problem
Existing systems for handling composite plies in aerospace manufacturing face challenges due to the lack of stiffness in non-fiber directions of unidirectional fiber materials, difficulty in controlling ply adhesion, and the need for high valve densities to efficiently pick up and place plies.
Innovation Solution
An automated bi-stable valve system with multiple valves controlled by a single mechanism, allowing for precise control of adhesion zones and enabling higher valve densities, is introduced. This system includes a bi-stable valve mechanism and a control system with a traversable bridge apparatus and valve switch mechanism to selectively control the bi-stable valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional pneumatic valves are used to control adhesion zones, then valve control capability is provided, but the system becomes bulky and heavy, reducing valve density
Solution Approach 1:
The patent replaces traditional pneumatic valves with a magnetic field-based valve mechanism. Magnets are positioned behind a ferromagnetic plate to generate magnetic fields that actuate valves without requiring bulky pneumatic components. This substitution enables higher valve density while reducing system weight and size.
Solution Approach 2:
The patent combines multiple valve control functions into a single integrated system. The ferromagnetic plate serves as both a structural component and a control medium, with magnets positioned behind it to simultaneously control multiple adhesion zones. This merging of functions reduces the overall system complexity and weight.
2Ease of operation
If multiple individually controlled pneumatic valves are used, then adhesion zone control is achieved, but the system requires bulky valve blocks and complex plumbing
Solution Approach 1:
The patent replaces complex pneumatic valve blocks and plumbing with a simplified magnetic field control system. Electromagnets or permanent magnets positioned behind a ferromagnetic plate can independently control multiple adhesion zones without requiring separate pneumatic lines for each valve, significantly reducing system complexity.
Solution Approach 2:
The ferromagnetic plate serves multiple functions: it provides structural support, acts as a magnetic flux conduit, and enables independent control of multiple adhesion zones through strategically positioned magnets. This multi-functionality eliminates the need for separate valve blocks and plumbing infrastructure.
3Use of energy by moving object
If area vacuum grippers with passive check valves are used, then vacuum flow is unrestricted, but discrete control of adhesion zones is lost
Solution Approach 1:
The patent divides the vacuum gripper surface into multiple independently controllable adhesion zones, each with its own valve controlled by a magnet positioned behind the ferromagnetic plate. This segmentation allows selective activation of specific zones while maintaining efficient vacuum flow through each active zone, unlike area vacuum grippers that treat the entire surface as a single zone.
Solution Approach 2:
The patent implements dynamic control of adhesion zones through magnetically actuated valves that can be independently opened or closed. This dynamic capability allows the system to adaptively control which zones are active based on the specific handling requirements, providing selectivity that passive check valves cannot achieve.
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 bi-stable valve system provides precise control over ply adhesion, allowing for efficient picking up and placement of composite plies without disturbing adjacent plies or waste material, while achieving higher valve densities and reducing the size, mass, and weight of the valve system.
Implementation Method 1
a magnetic field sufficient to push the floating magnet from the first stable position to the second stable position
Implementation Method 2
a vacuum system configured to pull air flow through the bi-stable valve mechanism
Data Source
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AI summary
There is provided an automated bi-stable valve system (10). The system (10) includes a bi-stable valve mechanism (76) with bi-stable valves (78). Each of the bi-stable valves (78) is configured to switch between a valve closed state (80) and a valve open state (82). The system (10) includes a control system (85) coupled to the bi-stable valve mechanism (76) and configured to operably control the bi-stable valve mechanism (76). The control system (84) includes, (i) at least one traversable bridge apparatus (86), and (ii) a valve switch mechanism (88) attached to the traversable bridge apparatus (86), and movable, via the traversable bridge apparatus (86), over the bi-stable valves (78). The valve switch mechanism (88) is configured to switch the bi-stable valve(s) (78) between the valve closed state (80) and the valve open state (82), to allow for selective control of one or more adhesion areas (68) on the bi-stable valve mechanism (76). The adhesion zone(s) (68) correspond to adhesion area(s) (68) on a surface (70) of a material (40) to be selectively picked up and placed.