Automated Fiber Placement Device for Composite Strip Deposition
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Solution Overview
Problem
Conventional Automated Fiber Placement (AFP) methods are limited in applying Ceramic Matrix Composite (CMC) and Polymer Matrix Composite (PMC) materials due to their unavailability in large spools, making it infeasible to place these materials onto tool surfaces using conventional AFP machines.
Innovation Solution
A device comprising a housing, motor, driving component, guide chute, layup roller, and cartridge configured to discharge thin strips of material onto a tool surface, allowing for precise placement and adaptation to complex geometries, reducing material waste and improving material utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional AFP methods are used with large spools, then automation is achieved, but material availability is limited to spool-packaged materials only
Solution Approach 1:
The material supply system is segmented from large spools to individual strip cartridges. Each cartridge holds a limited length of material and can be independently replaced, enabling the system to handle materials that cannot be packaged in large spools while maintaining automated operation.
Solution Approach 2:
The system dynamically switches between different cartridge types and material configurations based on the specific manufacturing requirements. The automated manipulator adapts its operation to accommodate various cartridge formats, strip widths, and material properties, providing versatility while maintaining automation.
2Adaptability or versatility
If thin strips are used for complex geometries, then adaptability improves, but material placement precision becomes more challenging
Solution Approach 1:
The system incorporates feedback mechanisms including sensors that monitor strip position, tension, and alignment during placement. This real-time feedback enables the automated manipulator to make precise adjustments, ensuring accurate material placement even when working with thin strips on complex geometries.
Solution Approach 2:
The system replaces manual placement mechanics with automated robotic manipulation controlled by computer vision and positioning systems. This substitution enables precise control of thin strip placement on complex surfaces that would be difficult to achieve manually while maintaining the adaptability needed for varying geometries.
3Productivity
If manual labor is reduced through automation, then productivity increases, but device complexity increases
Solution Approach 1:
The automated manipulator is designed as a universal system that can handle multiple cartridge types, material widths, and geometric configurations through programmable control. This multi-functionality consolidates what would otherwise require multiple specialized devices, increasing productivity while limiting the growth of device complexity through standardized architecture.
Data Source
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AI summary
A device (100) for the placement of material (121) on a surface (117) includes a housing (104), a motor (110) coupled to the housing (104), and a driving component (106) coupled to the housing (104) and powered by the motor (110). The device (100) further includes at least one guide chute (111, 112) defining a guide channel (160, 164) with the driving component (106). The device (100) further includes a layup roller (114) coupled to the housing (104) adjacent the guide channel (160, 164). The layup roller (114) includes a roller surface (166) and the guide channel (160, 164) is configured to discharge a quantity of material (121) to the roller surface (166). The layup roller (114) is configured to deposit the material (121) onto the surface (117).