Composite End Effector Roller Synchronization

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Solution Overview

Problem

Existing end effectors for constructing composite members face issues with tension loss in tow materials due to compaction roller movement, leading to quality degradation and despooling problems, particularly in accommodating misalignments and surface variations during the fabrication process.

Innovation Solution

The end effector design includes a compaction roller and redirect roller that translate together along a compaction axis, with the tow fed at a substantially right angle to the compaction axis, maintaining constant tension and eliminating the need for complex bi-directional spools and rewind apparatus by constraining the redirect and compaction rollers from relative translation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the compaction roller is made movable toward and away from the end effector to accommodate misalignments and surface variations, then the adaptability is improved, but the tension in the tows is reduced causing rewinding and despooling problems

Engineering Contradiction:

Improveaccommodation of misalignments and surface variationsVSAvoidtow tension maintenance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The compaction roller is made movable along the compaction axis to dynamically adapt to surface variations and misalignments during the lay-up process, while the system maintains tow tension through the constrained translation mechanism of the roller assembly

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If the compaction roller moves independently to accommodate workpiece variations, then the ease of operation is improved, but the device complexity increases due to the need for bi-directional spools and rewind apparatus

Engineering Contradiction:

Improveaccommodation of misalignmentsVSAvoidbi-directional spools and rewind apparatus

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The redirect roller and compaction roller are merged into a constrained translation assembly that moves together along the compaction axis, eliminating the need for independent bi-directional spools and rewind apparatus while maintaining ease of operation for accommodating misalignments

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If the compaction roller moves to accommodate surface variations, then the manufacturing precision is improved, but the loss of substance increases due to tow rewinding and despooling

Engineering Contradiction:

Improvequality of lay-upVSAvoidtow material loss

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The potential harm of roller movement causing tow slack is converted into a benefit by the constrained translation mechanism, which allows the roller to move to accommodate surface variations while maintaining constant tow tension through the coordinated movement of the redirect and compaction rollers, preventing material loss

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS8256484B2End effector for constructing composite members

Publication Date: 2012.09.04 THE BOEING CO

AI summary

An end effector constructing composite members, in which a compaction roller and redirect rollers translate synchronously along the compaction axis. Additionally, the end effector includes an advantageous arrangement of spools and rollers that directs tow to the redirect rollers at substantially a right angle. Movement of the compaction roller along the compaction axis induces little, if any, changes in tow tension. The substantially constant tow tension advantageously reduces rewinding of the tow supply spools, which can degrade the quality of the lay up and contribute to despooling problems.