CFRP End Effector with Pivoting Bernoulli Cups
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Solution Overview
Problem
In the fabrication of Carbon Fiber Reinforced Polymer (CFRP), existing end effector technologies face challenges in preventing wrinkles and damaging delicate carbon fiber plies during the layup process, as they struggle to apply conforming forces without causing warping or damage.
Innovation Solution
The use of multiple Bernoulli cups and a suction cup in a robot end effector allows the ply to float horizontally and pivot, enabling it to conform to a mandrel surface without generating wrinkles, by utilizing pneumatic lines for pressure control and allowing vertical translation and pivoting of the Bernoulli cups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional end effectors apply force to conform the ply to the mandrel, then the ply is shaped to the desired form, but the ply may warp or get damaged due to excessive force
Solution Approach 1:
The end effector is divided into multiple independent suction cups instead of a single rigid gripping mechanism. Each suction cup can independently apply force to different regions of the ply, allowing distributed force application that conforms the ply to the mandrel without concentrating stress that would cause damage or warping
Solution Approach 2:
The suction cups utilize negative pressure (vacuum) as the controlling parameter to hold and conform the ply. By adjusting the pressure level, the system can apply sufficient force for shaping while maintaining control to prevent excessive force that would damage the delicate carbon fiber ply
2Stability of the object's composition
If the end effector holds the ply firmly during transport, then the ply is securely positioned, but the ply may develop wrinkles during the shaping process
Solution Approach 1:
The suction cups are designed to be movable relative to each other and to the mandrel surface. During transport, they hold the ply firmly in a stable configuration. During shaping, the suction cups can move and adjust their positions independently, allowing the ply to conform to the mandrel without developing wrinkles from rigid constraint
Solution Approach 2:
Multiple independent suction cups allow different regions of the ply to be held with different degrees of firmness. This segmented approach enables the ply to maintain stability during transport while allowing localized adjustments during shaping to prevent wrinkle formation
3Device complexity
If a single rigid end effector is used to handle the ply, then the device structure is simple, but it cannot adapt to complex mandrel surfaces without causing damage
Solution Approach 1:
The end effector consists of multiple independent suction cups instead of a single rigid structure. Each suction cup can independently position and conform to different regions of complex mandrel surfaces, providing the adaptability needed for complex geometries while maintaining relatively simple individual cup structures
Solution Approach 2:
The suction cups are designed with degrees of freedom that allow them to move and adjust their positions dynamically. This enables the end effector to adapt to complex mandrel surfaces by allowing each cup to find its optimal position, achieving versatility without requiring an overly complex predetermined mechanical structure
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 solution effectively prevents wrinkles and damage by ensuring the ply is held securely without warping, allowing for precise shaping and positioning of the carbon fiber plies during the CFRP fabrication process, enhancing the quality and cost-effectiveness of the end effector technology.
Implementation Method 1
a pneumatic line applying negatively pressurized gas to an interior of the suction cup
Implementation Method 2
a pneumatic line applying positively pressurized gas to the Bernoulli cup
Implementation Method 3
a bearing that enables the Bernoulli cup to pivot about an end of the shaft to conform with a surface
Data Source
AI summary
Systems and methods are provided for carrying plies of material. One embodiment is an apparatus that includes an end effector of a robot. The apparatus includes a frame, and a fixed cup assembly that is attached to the frame. The fixed cup assembly includes a suction cup for holding a ply, a pneumatic line, and a shaft that is coupled with the suction cup and that houses the pneumatic line, the shaft enabling the suction cup to translate vertically. The apparatus also includes floating cup assemblies. Each floating cup assembly includes a Bernoulli cup, a pneumatic line applying positively pressurized gas to the Bernoulli cup, a shaft that is coupled with the Bernoulli cup and that houses the pneumatic line, the shaft enabling the Bernoulli cup to translate vertically, and a bearing that enables the Bernoulli cup to pivot about an end of the shaft to conform with a surface.