Composite Layup End Effector with Roller Conforming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual layup of composite materials for forming composite structures is inefficient, leading to inconsistent production rates, labor-intensive processes, and a high likelihood of errors due to skill variations among human operators, resulting in undesired rework and discarded out-of-tolerance parts.
Innovation Solution
A method and apparatus utilizing an end effector with flexible flanges, a vacuum system, and a roller system to accurately place and conform composite materials onto a tool, enabling automated and precise layup of multilayer materials, which reduces human error and increases efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual layup by human operator is used, then flexibility in handling complex shapes is maintained, but productivity is low and manufacturing precision is inconsistent
Solution Approach 1:
The end effector is divided into separate functional modules: a vacuum system for holding the composite material, flexible flanges for adaptation, and a roller system for conforming and compacting. This segmentation allows each component to perform its specific function efficiently while maintaining overall system manageability.
Solution Approach 2:
The roller system changes the physical state of the flexible flanges from a relaxed configuration to a conformed configuration by applying mechanical force through the rollers. This parameter change enables the flanges to adapt to complex tool shapes while maintaining vacuum sealing capability.
2Manufacturing precision
If manual layup by human operator is used, then adaptability to different tool shapes is maintained, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The end effector system performs the layup operation autonomously without requiring operator skill intervention. The vacuum system automatically holds the material, the roller system automatically conforms it to the tool shape, and the entire process is controlled by programming rather than human dexterity.
Solution Approach 2:
The flexible flanges change their configuration parameters (shape, curvature, contact pressure) automatically in response to the tool geometry through the roller system, eliminating the need for operator skill while maintaining high placement accuracy.
3Productivity
If manual layup is used, then flexibility in handling materials is maintained, but loss of time and productivity increase
Solution Approach 1:
The vacuum holding function and the mechanical conforming function are merged into a single integrated end effector system that operates simultaneously. The vacuum system holds the material while the roller system conforms it, eliminating the sequential operations required in manual layup.
Solution Approach 2:
The end effector maintains continuous contact with the composite material throughout the conforming process, with the vacuum system continuously holding the material in place while the roller system applies conforming force. This continuous action eliminates idle time and accelerates the layup process.
4Manufacturing precision
If manual layup is used, then adaptability to material types is maintained, but manufacturing precision and quality control deteriorate
Solution Approach 1:
The roller system applies controlled mechanical force that changes the configuration of the flexible flanges to match the tool shape. This parameter change is precisely controllable through the linkage mechanism, ensuring accurate layer alignment regardless of material type.
Solution Approach 2:
The manual mechanical manipulation by the operator is replaced with a programmable mechanical system. The roller system's movement and the vacuum system's pressure can be precisely controlled through programming, achieving high alignment accuracy that is consistent and reproducible.
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 solution enables faster, more accurate placement and compaction of composite materials, reducing rework and discarded parts by automating the layup process and minimizing the impact of operator skill variations.
Implementation Method 1
The vacuum system holds a piece of a composite material during operation of the vacuum system against the flexible flanges
Implementation Method 2
The roller system is moveable to conform to a shape of a tool such that the roller system bends the flexible flanges to substantially conform to the shape of the tool
Data Source
AI summary
A method for placing a piece of a composite material. The piece of the composite material is picked up from a source using an end effector. The piece is moved to a tool using the end effector. The piece is placed on the tool using the end effector. The piece is conformed to a shape of the tool using a roller system in the end effector, in which the roller system is moveable to conform the piece to a shape of the tool.