Automated Composite Layup with Multi-Axis Dispenser and Roller
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual layup and compression of composite materials for parts like rotorcraft grips are time-consuming and prone to human error, making the process inefficient and labor-intensive.
Innovation Solution
A composite manufacturing system that uses multi-axis layup dispenser heads and rollers to automate the material layup and compression process, ensuring precise application of material layers and pressure, which can be cured and machined to form complex shapes efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual layup and compression of composite materials is used, then flexibility in material placement is maintained, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces manual mechanical layup operations with an automated multi-axis dispenser head that mechanically deposits material strips in precise patterns. The system uses computer-controlled robotic or automated positioning mechanisms to place composite material layers, eliminating manual labor while maintaining placement precision through programmed coordinate systems and multi-axis control.
Solution Approach 2:
The automated dispenser head system performs self-positioning and self-adjustment through computer-controlled feedback mechanisms. The system automatically tracks its position, adjusts material deposition parameters in real-time, and maintains consistent layer placement without human intervention, enabling continuous operation and higher productivity while preserving operational precision.
2Adaptability or versatility
If manual compression of composite materials is used, then adaptability to complex shapes is maintained, but the process becomes time-consuming and prone to human error
Solution Approach 1:
The patent employs dynamically adjustable compression mechanisms with multi-axis control that can adapt to complex part geometries. The compression system uses programmable motion control to adjust pressure application points, angles, and forces in real-time based on the specific part shape being manufactured, enabling the same system to handle diverse complex geometries efficiently without manual intervention.
Solution Approach 2:
The automated compression system incorporates sensors and feedback control mechanisms that monitor compression forces, material placement quality, and process parameters in real-time. This feedback enables automatic adjustment of compression parameters to maintain optimal conditions for complex shape formation, eliminating human error while preserving adaptability through programmable control algorithms.
3Device complexity
If manual layup and compression processes are used, then process simplicity is maintained, but manufacturing precision and consistency deteriorate due to human error
Solution Approach 1:
The patent replaces simple manual mechanical operations with a computer-controlled automated dispenser head that uses precision positioning systems. The system employs multi-axis robotic or automated mechanisms with computer numerical control (CNC) or similar precision control systems to place material strips with sub-millimeter accuracy, achieving high manufacturing precision through electronic control rather than complex mechanical manual operations.
4Productivity
If automated multi-axis layup dispenser heads are used, then productivity increases, but device complexity increases
Solution Approach 1:
The automated dispenser head system is designed as a universal multi-functional unit that combines material deposition, positioning, and initial compression functions in a single integrated system. The multi-axis dispenser head can handle various material types, part geometries, and manufacturing scenarios through programmable control, reducing the need for multiple separate machines and manual operations, thereby managing overall system complexity while maintaining high productivity.
Data Source
AI summary
A composite manufacturing system has a tool having a substantially planar first portion and a substantially planar second portion, a first carriage configured to carry a first roller that is configured to selectively apply pressure to the first portion, a second carriage configured to carry a second roller that is configured to selectively apply pressure to the second portion, and the first carriage and the second carriage are movable relative to the tool.