Composite Slab Edge Gripping for Low-Swarf Compression Molding
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Solution Overview
Problem
Traditional gripping systems for pre-consolidated slabs of composite material in thermoforming processes result in high swarf generation, require manual intervention, and are not suitable for automated production lines, leading to increased costs and reduced efficiency.
Innovation Solution
A gripping system with releasable gripping members that frictionally engage the peripheral edge of the slab and automatically adjust to different profiles, allowing for automated handling and minimal swarf generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional gripping systems with fixed arms and hooks are used, then the slabs can be held in position, but high swarf is generated and manual intervention is required
Solution Approach 1:
The patent replaces the traditional mechanical hook-and-ear gripping system with a suction-based gripping system. The suction grippers use vacuum pressure to hold the slab directly on the support structure, eliminating the need for mechanical hooks and lateral ears. This substitution enables automated operation while minimizing material removal since no ears need to be drilled or removed.
Solution Approach 2:
The invention extracts and eliminates the lateral ears from the slab design entirely. Instead of requiring ears for hook attachment, the slab is gripped directly through its main surface using suction. This extraction of the ear component completely removes the source of swarf generation associated with ear drilling and removal.
2Productivity
If traditional gripping systems are used, then the slabs can be positioned, but manual intervention is required which reduces productivity
Solution Approach 1:
The suction grippers are designed to automatically engage with the slab when it is placed on the support structure. The vacuum system self-activates to create holding force without requiring manual positioning or adjustment of hooks. This self-service capability enables fully automated operation and increases production speed.
Solution Approach 2:
By replacing the manual hook-attachment system with an automated suction system, the patent enables robotic or automated line integration. The suction grippers can be controlled through automated systems to engage and release slabs, eliminating the need for manual intervention and thereby increasing productivity.
3Ease of manufacture
If lateral ears are drilled for hook attachment, then the slabs can be gripped, but swarf is generated that increases costs
Solution Approach 1:
The invention completely removes the lateral ear feature from the slab design. Instead of drilling holes in ears for hook attachment, the suction grippers engage the slab through its main surface. This extraction eliminates the entire ear-drilling-swarf-removal cycle, reducing material loss and simplifying the manufacturing process.
Solution Approach 2:
The patent substitutes the mechanical hook-attachment-to-ear system with a suction-based direct-surface gripping system. This substitution eliminates the need for ear drilling and subsequent ear removal, thereby eliminating the associated swarf generation while maintaining gripping effectiveness.
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
Enables automatic and versatile gripping of composite material slabs, reducing swarf, minimizing thermal impact, and integrating seamlessly into automated production systems, thereby lowering production costs and times.
Implementation Method 1
an elastic resting element 25 configured to receive in abutment a first surface 29 of the peripheral edge 9 of the slab 2 and elastically deformable between a first undeformed operative position (figures 3 and 4A), set in absence of external stresses, and a second deformed operative position (figure 4C), which is spaced apart from the first operative position along a direction parallel to the loading direction (A)
Implementation Method 2
gripping members 4 carried by the support structure 3 and configured to retain the slab 2 in a predetermined position for compression molding
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A gripping system (1) comprising: a support structure (3) defining a cavity (5) intended to receive a slab (2) of composite material to be compression molded; and at least two releasable gripping members (4), carried by the support structure (3) and configured to retain the slab (2) in a predetermined position for molding; each gripping member (4) comprises: an elastic resting element (25) adapted to receive a peripheral edge (9) of the slab (2); and jaw (27) facing the elastic resting element (25) along a loading direction (A) of the slab (2) and having a head portion (28) adapted to cooperate, in use, with the aforementioned peripheral edge (9), on the opposite side with respect to the elastic resting element (25); the jaw (27) is movable between a stable equilibrium operative position, in which it protrudes into the cavity (5), and an unstable equilibrium operative position, in which it is set aside from the cavity (5) and allows the slab (2) to move along the loading direction (A); a constraint element (41) is also provided to inhibit the movement of the jaw (27) to the unstable equilibrium operative position in a moving direction (E) of the slab (2) contrary to the loading direction (A).