Composite Laminate Tape Rework for Automated Defect Replacement
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Solution Overview
Problem
The existing manufacturing process of fibre reinforced plastic parts requires manual rework for defects detected during or after tape laying, which is inefficient and lacks full automation.
Innovation Solution
An automated tape placement machine with a reworking system that detects defects during the laying process, continues laying until a predetermined length, catches and cuts the defective tape, and lays a replacement tape, enabling full automation of the rework process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual rework is used to remove defective tape, then the defect can be corrected, but the process efficiency decreases and labor costs increase
Solution Approach 1:
The system enables automated self-service rework by equipping the tape placement machine with defect detection capabilities and automated removal mechanisms. When a defect is detected, the system automatically stops, identifies the defective tape location, and removes it without requiring manual intervention, thus maintaining high reliability while improving productivity
Solution Approach 2:
Manual mechanical rework operations are replaced by an automated system that uses sensors to detect defects and mechanical arms or cutting devices to remove defective tape. This substitution eliminates manual labor while maintaining precise defect correction, resolving the contradiction between reliability and productivity
2Productivity
If automated tape placement is used, then productivity increases, but the ability to handle defects automatically decreases
Solution Approach 1:
The tape placement machine is enhanced with multi-functionality to perform both high-speed automated tape laying and automated defect detection and removal. The system integrates sensors, decision-making algorithms, and removal mechanisms, allowing it to automatically handle both production and quality control tasks without reducing productivity
Solution Approach 2:
The system implements real-time feedback through sensors that continuously monitor the tape laying process and detect defects. When a defect is detected, the system automatically adjusts by stopping the laying process, identifying the defect location, and removing the defective tape, thereby maintaining both high productivity and full automation capability
3Ease of operation
If defective tape is removed manually, then labor flexibility is maintained, but lead time increases
Solution Approach 1:
The automated system maintains continuous operation by detecting defects in real-time and immediately removing defective tape without interrupting the overall production flow. The automated removal process occurs seamlessly during or immediately after the laying operation, eliminating the time loss associated with manual rework while maintaining operational flexibility through programmable control
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
The solution automates the rework process, improving laminate quality, reducing lead time, and saving labor, while ensuring seamless integration with the existing manufacturing workflow.
Implementation Method 1
The actual position is determined from signals derived from a sensing system sensing attributes of each sheet as the sheet is applied
Data Source
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AI summary
Method for reworking a composite laminate (1) comprising a plurality of tapes (2), the method comprising the following steps: - detecting the occurrence of a defect (3) on a tape (4) of composite material while the tape (4) is being laid up, - continuing the lay-up of the defective tape (4) until a tape (4) length which surpasses a manufacturing length (L) of the tape (4), - catching the part of the defective tape (4) that surpasses the manufacturing length (L) of the tape (4), - cutting the defective tape (4) in the part of the defective tape (4) that surpasses the manufacturing length (L) of the tape (4), - removing from the laminate (1) the caught defective tape (4) by the catching system, and - laying-up a replacement tape (2) in the place of the removed defective tape (4).