Dual-Mode Composite End Effector for Fast Adhesion Switching
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Solution Overview
Problem
Existing pick and place end effectors for composite materials are inefficient due to the need to switch between different types, which is time-consuming and space-prohibitive, especially in automated layup processes, and they often cause deformation or require multiple robots/gantries.
Innovation Solution
A single end effector using both vacuum and electrostatic mechanisms, where vacuum pogos can hold an electrostatic membrane to switch between vacuum and electrostatic adhesion, allowing for efficient handling of different composite materials and forming curvatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different end effectors are used for different types of composite material, then the end effector can handle various materials effectively, but removing and connecting different end effectors is time-consuming
Solution Approach 1:
The end effector is designed with a universal base structure that can accommodate both vacuum pogos and electrostatic membranes through a single interchangeable component system. The base end effector includes a mounting structure that accepts either vacuum pogos directly or electrostatic membranes, allowing one end effector to perform multiple functions for different composite materials without requiring complete replacement of the entire end effector assembly.
Solution Approach 2:
The end effector is divided into modular components: a base end effector structure, interchangeable vacuum pogo assemblies, and separate electrostatic membrane components. This segmentation allows the vacuum pogos and electrostatic membranes to be independently attached and detached from the base structure, enabling quick switching between different material handling modes without moving the entire end effector assembly.
2Adaptability or versatility
If multiple robots or gantries are used to handle different composite materials, then each material can be handled optimally, but space requirements and system complexity increase
Solution Approach 1:
A single robot or gantry is equipped with a universal end effector system that can switch between vacuum pogo mode and electrostatic membrane mode. This eliminates the need for multiple separate robots or gantries, as one system can handle all types of composite materials through the interchangeable components attached to the same positioning and movement mechanism.
Solution Approach 2:
The vacuum pogo system and electrostatic membrane system are merged into a single integrated end effector assembly that can be attached to one robot or gantry. The base structure provides common mounting interfaces for both vacuum pogos and electrostatic membranes, combining what would traditionally require separate systems into one unified platform.
3Adaptability or versatility
If vacuum pogos are used to hold electrostatic membranes, then switching between vacuum and electrostatic adhesion is enabled, but additional components are required
Solution Approach 1:
The vacuum pogo system serves a dual purpose: it can directly hold composite materials using vacuum adhesion, or it can hold electrostatic membranes using the same vacuum gripping mechanism. This merging of functions allows the vacuum pogos to enable switching between adhesion types without requiring separate holding mechanisms for each mode.
Solution Approach 2:
The electrostatic membrane acts as an intermediary component between the vacuum pogo system and the composite material. When electrostatic mode is needed, the membrane is attached to the vacuum pogos and contacts the composite material, providing electrostatic adhesion while the vacuum pogos maintain mechanical support and positioning.
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 dual-mechanism end effector reduces downtime and space requirements by allowing seamless switching between vacuum and electrostatic adhesion, enhancing efficiency and flexibility in handling various composite materials and forming complex shapes.
Implementation Method 1
a vacuum end effector with a plurality of vacuum pogos configured to pick and place a composite preform in contact with the plurality of vacuum pogos
Implementation Method 2
an electrostatic membrane configured to be removably held by the plurality of vacuum pogos and pick and place a single ply composite material while the electrostatic membrane is held by the plurality of vacuum pogos
Data Source
AI summary
An end effector configured to lift composite material through two different mechanisms and methods of picking and placing composite material are presented. The end effector comprises a vacuum end effector with a plurality of vacuum pogos configured to pick and place a composite preform in contact with the plurality of vacuum pogos, and an electrostatic membrane configured to be removably held by the plurality of vacuum pogos and pick and place a single ply composite material while the electrostatic membrane is held by the plurality of vacuum pogos.