Compliant Nosepiece End Effector for Contoured Composite Forming

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Solution Overview

Problem

Conventional forming processes struggle to efficiently form large prepreg plies on highly contoured and complex tool surfaces, particularly in areas with sharp curvature, leading to issues like puckering or wrinkling.

Innovation Solution

An end effector equipped with multiple double-acting rotary actuators and a compliant nosepiece, which can be extended and retracted to apply multi-directional forces, allowing precise control over forming forces and conforming to tight radii and variable width surfaces, attached to a manipulator for precise movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional forming processes are used to form large prepreg plies on highly contoured surfaces, then the manufacturing process is simple, but the plies experience puckering or wrinkling and cannot conform to tight radii of curvatures

Engineering Contradiction:

Improveply conformance to contoured surfaceVSAvoidpuckering and wrinkling

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The nosepiece is divided into multiple independently actuated sections, each capable of applying forming forces at different magnitudes and directions. This segmentation allows localized control of forming forces to accommodate varying curvature requirements across the tool surface, preventing puckering and wrinkling while achieving precise ply conformance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system employs multiple double-acting rotary actuators that can dynamically adjust the position and orientation of nosepiece sections during the forming process. This dynamic adaptability enables the nosepiece to conform to tight radii of curvatures and variable width surfaces by real-time adjustment of forming forces in response to local geometric requirements.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If multiple individually controllable rotary actuators are used to control forming forces at different zones, then the forming precision is improved, but the device complexity increases

Engineering Contradiction:

Improvecontrolling forming forces at different zonesVSAvoidnumber of actuators and control systems

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Each rotary actuator serves multiple functions: it controls the position of a nosepiece section, applies forming forces, and can be locked in fixed positions when needed. The encoded readers on the actuators provide both position sensing and control capabilities. This multi-functionality reduces the need for separate control mechanisms for each zone, managing device complexity while maintaining precise forming control.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If the nosepiece is made compliant to better conform to tool surfaces, then the forming ability on contoured surfaces is improved, but the control precision of forming forces may be reduced

Engineering Contradiction:

Improveconformance to contoured surfacesVSAvoidcontrol of forming forces

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The nosepiece is constructed with compliant sections that can locally adapt to tool surface geometry while being driven by individually controlled actuators. Each section's compliance is optimized for its specific location on the tool, allowing the overall nosepiece to conform to complex contours while maintaining precise control of forming forces through the actuator system.

Inventive Principle:

Principle #3Local quality

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

Enables the formation of prepreg plies on highly contoured surfaces without puckering or wrinkling, allowing for local variation of forming forces and precise positioning, improving the efficiency and accuracy of the forming process.

Implementation Method 1

The end effector employs a plurality of double acting rotary actuators that are both extendable and retractable to closely control the position of a compliant nosepiece used to form the ply onto the tool

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

The end effector also includes rack and pinion drives coupling the actuators with the nosepiece. The use of multiple, individually controllable rotary actuators permits controlling forming forces at different levels and in individual zones along the nosepiece

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

The rotary actuators include encoded readers which sense position, enabling storage of nosepiece position, which in turn permits faster programming and process quality/repeatability

Methodology Applied

Scientific EffectPosition Sensing:

Data Source

PatentUS11014314B2End effector for forming prepreg plies on highly contoured surfaces

Publication Date: 2021.05.25 THE BOEING CO

AI summary

Apparatus including a robotically controlled end effector having a compliant nosepiece that forms plies of a material onto contoured surfaces of a tool. The end effector includes a plurality of individually controllable rotary actuators which respectively control the position and compliancy of individual sections of the nosepiece in order to better conform the plies the contoured tool surfaces.