Automated CFRT Tape Reconfiguration via Edge Welding
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Solution Overview
Problem
Current manufacturing processes for continuous fiber reinforced thermoplastic (CFRT) tapes are inefficient and labor-intensive, limiting high-volume production capabilities and leading to worker safety issues, inconsistent quality, and a lack of automation in downstream conversion processes.
Innovation Solution
A programmable, computer-controlled machine system for automatically unwinding, cutting, orienting, edge-welding, and tensioning CFRT tapes to reconfigure them into new forms, utilizing configurable tensioning mechanisms, control systems, and force-feedback mechanisms to ensure precise alignment and quality control, enabling continuous and high-throughput production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual practices and machines are used for CFRT tape manufacturing, then flexibility and adaptability are maintained, but productivity and production volume are limited
Solution Approach 1:
The patent replaces manual mechanical handling with an automated machine system that includes programmable logic controllers, automated feed mechanisms, and computer-controlled positioning systems. This substitution enables high-volume production while maintaining precision through electronic control rather than manual operation.
Solution Approach 2:
The machine system is designed to automatically perform multiple operations including feeding, positioning, welding, and winding of CFRT tape without continuous human intervention. The system self-regulates through feedback mechanisms and programmable control sequences, enabling sustained high-speed production.
2Reliability
If manual handling of CFRT tape is used, then operational flexibility is maintained, but worker safety and consistency are compromised
Solution Approach 1:
The system incorporates feedback mechanisms including force-feedback from the tape feed and positioning systems, and quality monitoring during the welding process. This feedback enables real-time adjustments to maintain consistent quality and detect issues before they affect product reliability.
Solution Approach 2:
Manual operations are replaced with automated control systems that eliminate human variability in handling and processing. The programmable logic controller ensures identical operational parameters are applied consistently across all production batches, guaranteeing quality uniformity.
3Productivity
If high-volume production is implemented with automated systems, then productivity increases, but system complexity increases
Solution Approach 1:
The machine system is designed as a multi-functional integrated unit that performs feeding, positioning, welding, and winding operations within a single automated platform. This consolidation reduces the need for multiple separate machines and simplifies the overall production system while maintaining high throughput.
Solution Approach 2:
Multiple discrete operations are merged into a continuous automated process flow. The feed mechanism, positioning system, welding apparatus, and winding device are integrated and coordinated through programmable control, eliminating transfer steps and reducing system complexity despite high production volume requirements.
4Strength
If continuous fiber reinforced thermoplastic tape is used, then mechanical properties are superior, but processing difficulty increases
Solution Approach 1:
The system controls critical processing parameters including temperature, pressure, and welding duration to optimize the joining of continuous fiber reinforced thermoplastic tape. By precisely controlling these parameters, the system maintains the superior mechanical properties of the continuous fibers while enabling reliable automated processing and welding.
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 system enables the production of high-quality, reconfigured CFRT tapes with improved mechanical strength and consistency, facilitating higher-volume manufacturing while enhancing worker safety and reducing production time, thereby addressing the bottlenecks in existing manual and low-volume methods.
Implementation Method 1
a welder having a configurable position to weld the first intermediate cut section of material to the second intermediate cut section of material
Implementation Method 2
edge-welding... CFRT tapes to reconfigure them into new forms
Data Source
AI summary
A system to re-configure an input material into an output material includes an input material feeder reconfigurable to accept and feed an input material, an output material spooler, the input material feeder re-configurable relative to the material cutter to cut the input material at a re-configurable cut angle to produce a first intermediate cut section of material, a positioning and alignment system to position and align a leading edge of the first intermediate cut section of material with a trailing edge of a second intermediate cut section of material, a welder having a configurable position to weld the first intermediate cut section of material to the second intermediate cut section of material, and a control system comprising logic to set at least intensity of the welder, a contact pressure of the welder, temperature of the weld-table surface, and a tension applied by the output material spooler.