Composite Preform Variable Profile Production via Edge Lifting
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Solution Overview
Problem
There is no practical automated or semi-automated process for integrating unidirectional (UD) fibre layers between multi-axial fibre layers in fibre-reinforced composite preforms, especially when the profile has a variable height or width, requiring complex and time-consuming manual procedures.
Innovation Solution
A method and apparatus for producing a composite preform with a variable profile height or width by positioning the edge region of the preform out of the primary plane, allowing for the insertion of additional fibre layers, such as UD fibre layers, between multi-axial fibre layers, using guide members and forming members to adjust and set the profile dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual procedures are used to integrate UD fibre layers between multi-axial fibre layers, then manufacturing precision can be achieved, but productivity decreases and labor complexity increases
Solution Approach 1:
The apparatus is configured to automatically position and integrate UD fibre layers between multi-axial fibre layers before the composite preform is fully formed. The guide members and forming members are pre-positioned to receive and guide the UD fibre layers, enabling automated integration without requiring manual intervention during the forming process.
Solution Approach 2:
The manual mechanical process of individually shaping and integrating UD fibre layers is replaced with an automated apparatus that uses guide members to position UD fibre layers and forming members to integrate them between multi-axial fibre layers. This substitution of manual mechanical operations with automated mechanical systems resolves the contradiction between precision and productivity.
2Productivity
If automated processes are implemented to integrate UD fibre layers, then productivity improves, but device complexity increases
Solution Approach 1:
The apparatus is divided into functional segments: guide members for positioning UD fibre layers, forming members for integrating them between multi-axial fibre layers, and a control system. This segmentation allows each component to perform a specific function independently, reducing overall system complexity while maintaining automation capabilities.
Solution Approach 2:
The guide members and forming members are designed to handle multiple operations within the same apparatus. The guide members both position and guide the UD fibre layers, while the forming members both shape the composite preform and integrate the UD fibre layers. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity.
3Adaptability or versatility
If variable profile height or width is produced, then adaptability improves, but manufacturing precision becomes more difficult to maintain
Solution Approach 1:
The apparatus incorporates adjustable guide members and forming members that can dynamically adapt to different profile heights and widths. The guide members can be positioned at different locations to accommodate varying UD fibre layer positions, and the forming members can be adjusted to create different profile dimensions. This dynamic adjustability maintains manufacturing precision across variable profiles.
Solution Approach 2:
The apparatus controls profile dimensions by changing positional parameters of the guide members and forming members. By adjusting the position and configuration of these members, the system can produce variable profile heights and widths while maintaining precise control over the final dimensions. This parameter-based control allows adaptability without sacrificing precision.
Data Source
AI summary
A method of producing a composite preform having a profile with variable profile height or width is provided. The method includes: providing a plurality of first fiber layers overlapping or upon one another in or substantially parallel to a primary plane; inserting a second fiber layer via a guide member between two of the first fiber layers at an edge region of the preform profile, such that the second fiber layer extends substantially parallel to the first fiber layers; and positioning the edge region of the preform profile, and thus respective edge regions of the first fiber layers, out of the primary plane to set or determine a dimension of the preform profile in the primary plane.