Compaction Device Pivoting Over Convex Radii
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Solution Overview
Problem
Existing methods for laminating composite tape over convex radius edges in fiber reinforced composite structures often result in voids or wrinkles due to the lifting of tape strips as the compaction device moves over the edge, compromising the quality of the laminate structure.
Innovation Solution
A method involving a compaction device that pivots around the trailing edge of the tape bandwidth as it moves over the convex radius edge, maintaining contact pressure by adjusting the tool center point to the trailing edge, preventing the tape strips from lifting and ensuring continuous compaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the compaction device moves over the convex radius edge at an angle to apply tape strips, then the tape strips can be placed on the substrate, but the trailing edge of the tape strips is lifted away from the substrate causing voids or wrinkles
Solution Approach 1:
The compaction device is made dynamically adjustable by allowing the tool center point to pivot around the trailing edge of the tape bandwidth. This dynamic adjustment enables the compaction device to adapt its position and maintain optimal contact pressure on the tape strips as they are being applied over the convex radius edge, preventing lifting and voids while maintaining manufacturing capability.
Solution Approach 2:
The position parameter of the tool center point is changed during operation. Instead of a fixed position, the tool center point pivots around the trailing edge of the tape bandwidth, changing its location to maintain proper compaction pressure on the tape strips as they are applied over the convex radius, thereby preventing voids and wrinkles.
2Device complexity
If the compaction device maintains fixed contact pressure, then the process is simple, but the tape strips lift off at convex radius edges creating defects
Solution Approach 1:
The compaction device transitions from a fixed-position system to a dynamic system where the tool center point can pivot around the trailing edge of the tape bandwidth. This dynamic capability allows the system to automatically adjust and maintain reliable contact pressure on tape strips as they are applied over convex radius edges, preventing defects without requiring complex external control mechanisms.
Solution Approach 2:
The compaction device utilizes the geometric relationship between the pivoting tool center point and the tape bandwidth to self-regulate contact pressure. As the tool center point pivots around the trailing edge, the system automatically maintains appropriate compaction pressure on the tape strips without requiring external sensing or control systems, thereby ensuring reliable laminate quality.
Data Source
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AI summary
A tape laminating machine (12) having a compaction roller (22) lays up composite tape (26) over a substrate having a convex radius (40). The compaction roller folds the tape as it moves over the convex radius, while simultaneously pivoting about a trailing edge of the tape to prevent the compaction roller from lifting off the tape laid just before the convex radius.