Single-Sided Sewing Head for Stable Composite Stringer Stitching
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Solution Overview
Problem
Existing sewing technologies for composite materials face issues such as material displacement during stitching, complex programming, needle breakage, and increased processing time due to the need for additional support materials, leading to inefficiencies in the production of composite parts.
Innovation Solution
A single-sided sewing head with adjustable needle angles and real-time thickness compensation, utilizing a polymer reinforcement to stabilize the stringer during stitching, and a catcher needle sleeve to prevent fiber damage, along with dual stitching paths for enhanced speed and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polymer reinforcement is added to stabilize composite materials during stitching, then material displacement is reduced and stitching quality is improved, but device complexity and processing time increase
Solution Approach 1:
The polymer reinforcement is placed in advance between the composite laminate layers before the stitching process begins. This preliminary placement provides immediate structural support to the flexible composite materials, preventing material displacement and needle breakage during the stitching operation without requiring complex real-time adjustments.
Solution Approach 2:
The polymer reinforcement acts as an intermediary element between the stitching needle and the composite laminate. It provides a stable pathway for the needle to penetrate through the flexible composite layers, reducing direct interaction between the needle and the unstable composite material, thereby preventing material displacement and improving stitching consistency.
2Manufacturing precision
If polymer reinforcement is used to support composite materials during stitching, then material displacement is reduced, but processing time increases
Solution Approach 1:
The polymer reinforcement is positioned in advance before stitching begins, eliminating the need for complex real-time adjustments or additional support materials during the stitching process. This preliminary preparation reduces material displacement issues that would otherwise require time-consuming corrections.
Solution Approach 2:
The polymer reinforcement changes the physical parameters of the composite structure by providing rigid support within the flexible laminate layers. This parameter change stabilizes the material during stitching, reducing displacement and the need for rework, thereby offsetting the initial placement time.
3Device complexity
If traditional stitching methods are used on flexible composite materials, then processing is simpler, but needle breakage and material displacement occur frequently
Solution Approach 1:
The polymer reinforcement serves as a mediator between the stitching needle and the flexible composite laminate. It creates a stable pathway for needle penetration, reducing direct contact between the needle and the unstable composite material, thereby minimizing needle breakage without requiring complex equipment modifications.
Solution Approach 2:
By placing the polymer reinforcement before stitching, the system prepares a stable structure in advance that guides the needle through the composite layers. This preliminary action prevents the needle from encountering unexpected material deformations or resistance that would cause breakage, maintaining simplicity while improving reliability.
4Manufacturing precision
If additional support materials are added during stitching, then stitching consistency is improved, but processing time and complexity increase
Solution Approach 1:
The polymer reinforcement is placed in advance before stitching begins, providing consistent support throughout the entire stitching process. This eliminates the need for additional support materials to be added during stitching, as the preliminary reinforcement already ensures uniform material stability and needle penetration throughout the operation.
Data Source
AI summary
A composite sewn part for use in a subsequent curing process, including: a first composite laminate; at least one stringer secured to the first composite laminate by stitches, the at least one stringer including a first stringer portion comprising a composite laminate and a second stringer portion comprising a composite laminate, which are sewn together to provide the at least one stringer, the first stringer portion having a flange portion that is sewn to the first composite laminate and a web that extends upwardly from the flange portion and the second stringer portion having a flange portion that is sewn to the first composite laminate and a web that extends upwardly from the flange portion of the second stringer portion; and a polymer reinforcement located between the first stringer portion and the second stringer portion or between the first composite laminate and the first stringer portion and the second stringer portion.