Composite Forming Feature for Automated Complex-Shape Ply Compaction
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Solution Overview
Problem
Conventional methods for forming composite structures, particularly large and complex ones, are inefficient and labor-intensive, often requiring manual labor due to challenges in forming composite material to intricate contours, leading to time consumption and potential inconsistencies.
Innovation Solution
A composite forming apparatus and system that includes an end effector with a forming feature and a positioning member, which facilitates automated compaction and deformation of composite plies over a forming tool, ensuring uniform application of force and conforming to complex geometries through a positioning member that controls the position and orientation of the forming feature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual layup of fiber plies is used, then flexibility and adaptability to complex shapes are improved, but time consumption and labor intensity increase significantly
Solution Approach 1:
The forming feature is designed to automatically conform to the forming tool surface without manual intervention. The positioning member enables the forming feature to self-position and self-adjust as it moves across the composite ply, allowing the system to perform the formation operation autonomously based on the programmed motion path, thereby eliminating manual layup time while maintaining shape accuracy
Solution Approach 2:
The patent replaces the manual mechanical layup process with an automated forming feature that uses controlled mechanical motion. The end effector moves the forming feature along a predetermined path, substituting human hands and eyes with an automated positioning and motion control system that achieves the same conforming action more efficiently
2Extent of automation
If drape forming process is used, then automation is improved, but effectiveness on thick laminates and complex shapes deteriorates
Solution Approach 1:
The forming operation is divided into multiple discrete steps: positioning the forming feature, moving it across the composite ply in controlled segments, and adjusting its position relative to the forming tool. This segmentation allows the automated system to handle thick laminates and complex shapes by breaking down the formation process into manageable phases, each optimized for specific geometric requirements
Solution Approach 2:
The forming feature is designed with dynamic positioning capability through the positioning member, allowing it to adjust its location and orientation in real-time during the formation process. This dynamic adjustment enables the automated system to adapt to varying ply thicknesses and complex surface geometries, maintaining reliability across different workpiece configurations
3Force
If compactor is used to compress composite charge, then compaction is improved, but supplemental manual formation is still required for contoured surfaces
Solution Approach 1:
The patent merges the compaction function with the forming function into a single integrated operation. The forming feature simultaneously applies compaction force and geometric formation in one action, eliminating the need for separate compaction and manual formation steps. This combined operation is achieved through the coordinated movement of the end effector, forming feature, and positioning member across the composite ply
4Productivity
If automated forming feature is used, then productivity is improved, but control precision for uniform force application must be maintained
Solution Approach 1:
The positioning member provides feedback control for the forming feature's position and orientation. As the end effector moves the forming feature across the composite ply, the positioning member monitors and adjusts the forming feature's location to ensure uniform force application and precise conforming to the forming tool surface, maintaining manufacturing precision throughout the automated operation
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
The apparatus and system enable automated fabrication of composite laminates with reduced processing time, labor, and costs, minimizing inconsistencies and buckling, while effectively forming large and complex composite structures.
Implementation Method 1
forming the at least one ply of composite material over the forming surface of the forming tool with the forming feature
Implementation Method 2
facilitates a position between the forming feature and the composite ply to promote uniform application of compaction force over the forming surface
Data Source
Figure 1
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Figure 3A
AI summary
A composite forming apparatus includes an end effector and a forming feature that is coupled to the end effector. The end effector moves the forming feature relative to a forming tool to form a composite ply over a forming surface of the forming tool or over previously formed composite material on the forming surface of the forming tool. The composite forming apparatus further includes a positioning member engaged with the forming feature. The engagement between the positioning member and the forming feature facilitates a position between the forming feature and the composite ply to promote uniform application of compaction force over the forming surface of the forming tool.