Integrated Composite Manufacturing Device for In-Situ Forming
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Solution Overview
Problem
The existing manufacturing processes for composite materials in the aeronautical industry are inefficient and costly due to the need for manual handling and separate operations for laying, cutting, and hot-forming, especially when dealing with complex shapes and large numbers of layers.
Innovation Solution
A device and process that integrates laying, cutting, and hot-forming operations on a single system with dual tables, an automatic laying head, a cutting head, and a forming membrane, allowing for vacuum and heat application, enabling in-situ lamination, cutting, and forming without manual handling, and capable of producing two parallel pieces simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate manual operations are used for laying, cutting, and hot-forming, then flexibility and adaptability are maintained, but manufacturing cost increases and productivity decreases
Solution Approach 1:
The patent merges three separate manufacturing operations (laying, cutting, and hot-forming) into a single integrated device. The laying head deposits composite layers directly onto the table, the cutting head trims excess material in-situ, and the hot-forming tool applies heat and pressure to form the final shape, all without manual handling or removal of the workpiece.
Solution Approach 2:
The table serves multiple functions: it acts as the support surface for laying operations, the base for cutting operations, and the heating platen for hot-forming operations. This multi-functional design eliminates the need for separate equipment for each manufacturing step.
2Adaptability or versatility
If manual handling is used for adapting preimpregnated courses to curves, then adaptability to complex shapes is achieved, but operation complexity and time increase significantly
Solution Approach 1:
The patent replaces manual mechanical manipulation with an automated hot-forming system. The forming membrane, when heated, applies controlled pressure and thermal energy to automatically adapt the composite layers to complex curved surfaces, eliminating the need for manual pressing and deformation.
Solution Approach 2:
The patent changes the physical parameters of the composite material by applying heat during the hot-forming stage. This thermal energy softens the preimpregnated material, making it pliable and adaptable to complex shapes without requiring manual deformation efforts.
3Productivity
If multiple separate operations are performed with handling between steps, then process control is maintained, but loss of time and productivity occur
Solution Approach 1:
The patent ensures continuous processing by performing laying, cutting, and hot-forming operations sequentially on the same workpiece without removal or handling. The automated heads move between operations while the workpiece remains in position, eliminating idle time and handling delays.
4Ease of manufacture
If integrated in-situ processing is implemented, then productivity and cost efficiency improve, but device complexity increases
Solution Approach 1:
The patent divides the integrated device into three independent functional modules: the laying head with its automated deposition system, the cutting head with trimming capabilities, and the hot-forming tool with heating and pressing mechanisms. This segmentation allows each module to be optimized independently while working together in sequence.
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 integrated approach reduces costs and complexity by enabling continuous processing of composite materials, improving handling and forming efficiency, and allowing for the production of complex shapes without manual intervention, thereby streamlining the manufacturing of composite pieces.
Implementation Method 1
They have in their insides means for generating a vacuum in a closed space on it
Implementation Method 2
They can include means for providing heat to their upper surface
Data Source
Figure 1a
Figure 1b
Figure 2a~2b
AI summary
A device for manufacturing pieces of composite material by means of laying, cutting and hot forming operations comprising two same tables (11, 13) configurable with a planar upper surface (41) or with an upper surface (43) with the shape of the piece to be manufactured and means for generating a vacuum in the closed space on it; an automatic laying head (15) supported by means (19) allowing its displacement on said tables (11, 13) and a cutting head (17) associated to the same; and a tool (21), also displaceable on said tables (11,13) including a forming membrane (25) and heating means (27). The invention also comprises a process for manufacturing pieces of composite material by means of laying, cutting and hot forming operations carried out on a same device.