Composite Forming End Effector With Movable Sweepers
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Solution Overview
Problem
Gantry formers have a limited work envelope and cannot accommodate more than a few degrees of tool tilting, while robots, although capable of orienting to unique angles, are not as rigid, necessitating an alternative method for forming composite material onto a mandrel.
Innovation Solution
A forming end effector with a frame, movable legs, and forming heads connected by actuators, featuring sweepers that can rotate and translate to form composite material onto a mandrel, allowing for efficient application and reaction of loads into the mandrel without a larger gantry system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a gantry former is used to form composite material onto a mandrel, then rigidity is improved, but the work envelope is limited and tool tilting capability is restricted to a few degrees
Solution Approach 1:
The system is divided into a stationary gantry structure that provides rigidity and a movable robotic end effector that provides flexibility. The robot can be repositioned to different locations and orientations within the work envelope while the gantry remains fixed, allowing both rigidity for forming and adaptability for different mandrel configurations.
Solution Approach 2:
The robotic end effector acts as an intermediary between the operator and the composite material forming process. It can be programmed to achieve precise orientations and angles that would be difficult or impossible to achieve with traditional gantry tools, while the gantry provides the rigid support structure needed for accurate force application.
2Adaptability or versatility
If a robot is used to form composite material onto a mandrel, then adaptability to unique angles is improved, but rigidity deteriorates
Solution Approach 1:
The invention merges the advantages of both gantry and robotic systems by combining a rigid gantry structure with a programmable robotic end effector. The gantry provides the necessary rigidity for applying forming forces, while the robot provides the adaptability to achieve unique angles and orientations through programmable motion and positioning.
Data Source
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AI summary
A forming end effector and methods of use are presented. Methods of forming a composite material onto a mandrel are presented. A forming end effector carrying the composite material is positioned over the mandrel. The forming end effector is connected to the mandrel. The composite material is swept onto the mandrel using sweepers of the forming end effector.