Composite Placement Creel With Quick-Release Coupler
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Solution Overview
Problem
The existing technologies for laying up composite materials with different tow widths are cost-prohibitive due to the need for multiple machines and time-consuming rethreading processes, making it impractical to efficiently switch between various tow sizes on a single positioner.
Innovation Solution
A multi-axis positioner with an integrated composite placement head and creel featuring a cube-shaped creel with tow feed spools on four sides, where the spools' unwind rotation axis is perpendicular to the head centerline, combined with a quick release coupler for rapid attachment and a fiber delivery system that optimizes compaction device functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple machines are used to lay up different widths of tow on the same part, then the ability to handle various tow sizes is improved, but the cost becomes prohibitive
Solution Approach 1:
The creel assembly is designed to be universally applicable for laying up different widths of tow on the same part. By making the creel assembly multi-functional through the ability to quickly swap spools and adjust the fiber delivery system, the system can handle various tow sizes without requiring multiple dedicated machines, thereby reducing cost while maintaining versatility
2Ease of manufacture
If the same positioner with different heads is used for different sizes of tow, then the cost is reduced, but rethreading the machine and head takes significant time
Solution Approach 1:
The creel assembly is pre-configured with spools mounted on four sides of a cube-shaped creel, with the fiber delivery system pre-arranged to deliver tows to the compaction device. This preliminary arrangement of components allows for rapid changeover between different tow sizes without time-consuming rethreading operations, as the system is already prepared for quick spool replacement and tow delivery
Solution Approach 2:
The system incorporates dynamic adjustability in the fiber delivery system, allowing it to be reconfigured for different tow sizes. The ability to dynamically adjust the delivery mechanism and quickly swap spools enables the system to adapt to different production requirements without lengthy setup times, maintaining cost-effectiveness while reducing time loss
3Productivity
If tow feed spools are arranged on four sides of the cube with rotation axis perpendicular to head centerline, then the compaction device ability to apply tows is optimized, but the device complexity increases
Solution Approach 1:
The spools are arranged asymmetrically on the four sides of the cube-shaped creel, with their unwind rotation axes positioned perpendicular to the head centerline. This asymmetric configuration optimizes the fiber delivery path to the compaction device, improving the ability to apply tows efficiently. The asymmetric design, while increasing structural complexity, is justified by the significant productivity gain in tow application
Data Source
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AI summary
A device for fabricating a composite structure comprises a multi-axis positioner and an attached end effector comprising an integrated head (16) and creel (18). The head (16) has a clamp, cut and restart mechanism (30) and a compaction roller (31) with a rotary axis (43). The creel (18) has a prismatic shape with a coupling device on the top of the creel (18) for attachment to the multi axis positioner and a centerline (35) which passes through the center of the creel (18) and intersects the axis of rotation (43) of the compaction roller (31). A composite placement head (16) is attached to the bottom of the creel (18). A plurality of composite material supply spools (33) are mounted on the sides of the creel (18) and face outward from the creel (18). A plurality of rollers (42) are mounted on the outside surface of the creel (18) for directing the composite material (40) from the supply spools (33) to the fiber placement head (16).