Composite Laying Device with Rotary Spools for Complex 3D Shapes
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Solution Overview
Problem
Current technologies are limited in producing composite products with complex 3D shapes that can withstand complex loads, necessitating the use of metal reinforcements in vehicles like tailgates, as existing devices are not capable of efficiently laying up composite materials for such applications.
Innovation Solution
A device featuring individual unwinding spools of fibrous rovings arranged around a composite product on rotary disc rings with independent drives and a program-controlled main manipulator, allowing for variable orientation and density of layers, enabling the production of complex 3D composite reinforcements with precise control over the internal structure and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional laying up devices are used for simple shapes, then production of straight or slightly curved rods/tubes is achieved, but complex 3D shaped closed composite products cannot be produced
Solution Approach 1:
The device employs a programmable robotic manipulator that can dynamically adjust its movement path, orientation, and laying parameters to accommodate complex 3D shapes. The robotic system transitions from static, fixed-path mechanisms to dynamic, programmable motion control, enabling production of tailored composite reinforcements for complex geometries like vehicle tailgates
Solution Approach 2:
The invention changes the laying parameters including fiber orientation angles, layer density, and winding patterns through programmable control. This allows adaptation to complex 3D shapes by varying these parameters during the laying process, transforming the device from producing simple cylindrical shapes to complex closed structures with variable cross-sections
2Strength
If metal reinforcements are used for complex loads, then structural strength is achieved, but weight reduction benefits of composite materials are lost
Solution Approach 1:
The device applies local quality by varying the fiber orientation, layer density, and material composition at different locations within the composite structure. This allows optimization of strength precisely where complex loads act, while maintaining lower weight overall compared to uniform metal reinforcement. The programmable system adjusts laying parameters locally to match the stress distribution pattern
Solution Approach 2:
The invention utilizes composite materials with continuous fibrous reinforcement arranged in tailored configurations to achieve metal-level strength. By controlling fiber orientation and layering through the programmable laying device, composite materials can withstand complex multidirectional loads previously requiring metal, while maintaining the inherent weight advantages of composites
3Manufacturing precision
If manual or simple automated laying up is used, then production speed is maintained, but manufacturing precision for complex shapes deteriorates
Solution Approach 1:
The invention replaces manual or simple automated mechanical laying systems with a programmable robotic manipulator equipped with sensors and control algorithms. This substitution enables precise control of fiber placement coordinates, orientation angles, and layer sequences while maintaining high production speeds through automated operation and optimized path planning
Solution Approach 2:
The device incorporates feedback mechanisms through programmable control systems that monitor and adjust laying parameters in real-time. This feedback enables correction of positioning deviations, maintenance of precise fiber placement accuracy, and adaptation to variations in the workpiece geometry, all while sustaining high production rates through automated closed-loop control
Data Source
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AI summary
Device for laying up a composite product with fibrous rovings made from glass, carbon, aramid and other similar filaments, designed especially for production of composite reinforcements or supporting elements such as the reinforcement of tailgates of personal vehicles, consists of individual unwinding spools (2) of fibrous rovings (21) rotatably arranged around the composite product (1). The unwinding spools (2) are installed on the set of the rotary disc rings (3) which are mounted on a common fixed ring frame (4) and equipped with independent drives (5) with pre-programmed control of direction and speed of their rotation wherein the composite product (1) is during the laying up procedure alternately fixed to individual carrier grippers (8) of at least one program-controlled manipulator (9). In each rotary disc ring (3) as well as in fixed ring frame (4) at least one lateral passage (6) is created for entry and exit of the composite product (1) between the unwinding spools (2).