Automated Composite Forming Apparatus with Stomp Foot
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for forming large and complex composite structures require extensive manual labor, leading to inefficiencies and inconsistencies due to the time-consuming and laborious process of laying composite fiber plies over shaped forming tools.
Innovation Solution
A forming apparatus and system that includes a frame with a carriage and end effectors, allowing for automated ply-by-ply formation and compaction of composite materials over a forming tool, utilizing a stomp foot and inflatable bladders to apply pressure and conform to complex geometries, reducing manual labor and inconsistencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual layup of fiber plies is used, then complex contoured parts can be formed, but the process is time-consuming and laborious
Solution Approach 1:
The forming apparatus divides the composite structure formation into discrete ply-by-ply operations, with each ply being independently placed and formed by automated robotic arms. This segmentation enables precise control over each layer while maintaining high productivity through automation.
Solution Approach 2:
The patent replaces manual mechanical layup operations with automated robotic systems that use computer-controlled positioning and automated fiber placement technology. This substitution dramatically increases productivity while maintaining the ability to form complex geometries through programmable motion paths.
2Extent of automation
If automated drape forming with vacuum bag is used, then labor is reduced, but the method achieves limited success on thick laminates or structures with complex shapes
Solution Approach 1:
The forming apparatus employs dynamically adjustable tooling and forming presses that can adapt to varying laminate thicknesses and complex geometries. The system includes movable forming tools and adjustable pressure application points that respond to real-time feedback about the workpiece geometry.
Solution Approach 2:
The patent implements localized forming zones with independent pressure and temperature control for different regions of the composite structure. This allows optimization of forming parameters for specific areas, enabling successful formation of thick laminates and complex shapes that require different conditions in different locations.
3Extent of automation
If compactor is used to compress composite charge, then automation is improved, but supplemental manual formation is still required for contoured tool surfaces
Solution Approach 1:
The forming apparatus integrates multiple functions into a single automated system, combining compression, contouring, and finishing operations. The forming tools are designed to perform both compression and surface contouring, eliminating the need for separate manual formation steps.
Solution Approach 2:
The system incorporates self-adjusting forming tools that automatically conform to the desired tool surface geometry through programmed motion and adaptive positioning. The apparatus performs its own contouring operations without requiring supplemental manual intervention, achieving complete automation of the formation process.
4Ease of operation
If manual layup is used, then labor flexibility is maintained, but inconsistencies occur in the formation process
Solution Approach 1:
The forming apparatus incorporates sensors and monitoring systems that provide real-time feedback on ply placement accuracy, pressure distribution, and forming quality. This feedback is used to automatically adjust process parameters, ensuring consistent formation quality while maintaining operational flexibility through programmable control.
Solution Approach 2:
The patent replaces manual operations with automated robotic systems that execute precise, repeatable motion paths programmed with high-precision positioning data. This substitution eliminates human variability and ensures consistent formation quality across all produced parts.
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 system enables faster, more accurate, and consistent formation of large and complex composite structures by automating the ply-by-ply process, reducing processing time, labor costs, and minimizing buckling or wrinkling of plies.
Implementation Method 1
deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus
Implementation Method 2
A first end effector is movably connected to the carriage and a second end effector movably connected to the carriage. The first end effector and second end effector are laterally opposed to each other
Data Source
AI summary
A forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage and a second end effector movably connected to the carriage. The first end effector and second end effector are laterally opposed to each other along the longitudinal axis and the stomp foot is located between the first end effector and the second end effector.