Composite Positioning Flippers for Precise Automated Charge Transfer
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Solution Overview
Problem
Current methods for manufacturing composite structures, such as aircraft stringers, are slow and costly due to manual lay-up and crane handling, necessitating a more efficient and automated composite handling system.
Innovation Solution
A composite transfer cell with a delivery system, tool, and a composite transfer system comprising independently movable flipper arms that rotate and lift composite charges from a conveyor to a tool, using vertical and rotary motors, and pneumatic and mechanical connectors to facilitate precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual lay-up and crane handling are used, then flexibility and simplicity are maintained, but productivity is low and costs are high
Solution Approach 1:
The composite handling system is divided into multiple independent flipper arms that can operate separately yet cooperatively. Each flipper arm is independently controllable, allowing the system to handle different composite charge sizes and configurations efficiently, thereby improving productivity without requiring an overly complex monolithic structure.
Solution Approach 2:
The flipper arm mechanism serves multiple functions: lifting composite charges from the delivery system, rotating them to desired orientations, positioning them precisely on the tool, and supporting various composite charge configurations. This multi-functionality improves productivity while avoiding the need for separate specialized equipment for each operation.
2Manufacturing precision
If automated composite positioning system is implemented, then productivity and precision are improved, but device complexity increases
Solution Approach 1:
The flipper arms are designed with dynamic movement capabilities, allowing independent vertical movement and rotation. This dynamic configuration enables precise positioning of composite charges by adjusting each arm's position and angle, achieving high manufacturing precision through controlled motion rather than complex fixed positioning mechanisms.
Solution Approach 2:
The flipper arms act as intermediary elements between the delivery system and the tool. They provide a flexible intermediate platform that can adapt to different positioning requirements, simplifying the overall system by using these versatile intermediaries rather than direct complex positioning mechanisms between the delivery system and tool.
3Adaptability or versatility
If multiple independently movable flipper arms are used, then composite handling flexibility and precision are improved, but device complexity increases
Solution Approach 1:
The system uses multiple segmented flipper arms that can be independently controlled. Each arm operates as an independent unit with its own motors and control systems, allowing flexible adaptation to different composite charge configurations while maintaining manageable system complexity through modular design.
Solution Approach 2:
The flipper arms can change multiple parameters simultaneously: vertical position, rotation angle, and orientation. This ability to change parameters independently for each arm provides high adaptability for handling different composite charges, while the standardized control mechanism for each parameter keeps the overall system complexity manageable.
Data Source
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AI summary
A composite transfer cell and associated components and methods are presented. The composite transfer cell comprises a delivery system on a first side of the composite transfer cell; a tool on a second side of the composite transfer cell; and a composite transfer system between the first side and the second side of the composite transfer cell, the composite transfer system comprising a plurality of flipper arms independently movable in a vertical direction and rotatingly movable to lift and place a composite charge from the delivery system to the tool.