Compaction Roller Pivoting for Composite Tape Convex Radius Layup
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Solution Overview
Problem
Existing methods for laminating composite tape over convex radius edges in composite laminate structures often result in voids or wrinkles due to the lifting of tape strips as the compaction device moves over the edge, especially when fiber orientations and tangent lines create angles that differ slightly, affecting the quality of the completed structure.
Innovation Solution
A method involving a compaction roller with an angularly offset axis of rotation and a pivoting mechanism around the trailing edge of the tape bandwidth, which maintains contact and prevents lifting by folding the tape as it moves around the convex radius edge, ensuring consistent compaction pressure across the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the compaction device moves over the convex radius edge at an angle to compact the tape strips, then the tape strips are compacted against 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 transitions from a fixed linear motion to a dynamic pivoting motion. The device pivots about a point on its trailing edge as it moves along the convex radius edge, allowing the compaction force to remain consistently applied to the tape strips without lifting the trailing edge. This dynamic adjustment of the compaction path eliminates the harmful lifting effect while maintaining effective compaction.
2Device complexity
If the compaction device follows a standard linear path over the convex radius edge, then the device structure is simple, but the tape strips lift away causing quality defects
Solution Approach 1:
The compaction device incorporates a pivoting mechanism that allows it to dynamically adjust its motion path. As the device moves along the convex radius edge, it pivots about a point on its trailing edge, creating a curved compaction path that follows the geometry of the radius edge. This dynamic motion control maintains consistent contact between the compaction device and tape strips, preventing quality defects.
3Adaptability or versatility
If tape strips are applied at an angle over the convex radius edge, then fiber orientation requirements are met, but the angle between fibers and tangent lines causes lifting during compaction
Solution Approach 1:
The compaction device pivots about a point on its trailing edge as it moves along the convex radius edge, dynamically adjusting the compaction path to match the angle of tape application. This pivoting motion ensures that the compaction force remains aligned with the tape strips regardless of the fiber orientation angle, preventing lifting while maintaining the required fiber orientation capabilities.
Data Source
AI summary
A tape laminating machine having a compaction roller lays up composite tape over a substrate having a convex radius. 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.