Composite Tape Lamination Head with Rotating Guillotine Cutters
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Solution Overview
Problem
Existing automated fiber placement machines face difficulties in laying down long, narrow composite structures such as spars and stringers without wrinkling and are inefficient in laying down non-zero oriented tape courses, leading to material waste and reduced lay-down rates.
Innovation Solution
A method and apparatus using narrow width tape with guillotine type tape cutters that can rotate to different angles, combined with adjustable tape control modules to minimize gaps and tension, allowing for efficient lamination and cutting of zero and non-zero degree tape courses, reducing waste and improving lay-down rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If automated fiber placement machines use high operational flexibility for adding, dropping off, or cutting tape strips independently, then adaptability is improved, but difficulty in laying down long zero degree tape courses without wrinkling increases
Solution Approach 1:
The patent applies dynamics by making the tape control modules laterally adjustable during operation. The modules can move independently along the beam to maintain optimal positioning and tension control throughout the lamination process, enabling the system to adapt to varying tape lengths and orientations while maintaining wrinkle-free application on long zero degree courses
2Productivity
If automated machines perform rapid start-stop movements for short non-zero tape courses, then productivity is improved, but material waste increases
Solution Approach 1:
The patent replaces traditional mechanical cutting systems with guillotine-type cutters that can rapidly and precisely cut tape at any position during the layup process. This substitution enables efficient handling of short non-zero tape courses by allowing rapid cutting without excessive material waste, as the cutters can precisely trim tape to the required length rather than requiring large excess lengths for positioning
3Productivity
If wide tape is used for lamination, then productivity is improved, but material waste increases for long narrow parts
Solution Approach 1:
The patent applies segmentation by using multiple narrow tape control modules instead of a single wide tape system. Each module handles a narrow strip of tape that can be precisely positioned and laid down sequentially or in parallel, matching the width of long narrow parts like spars and stringers. This segmentation reduces material waste by eliminating the need to use excess wide tape material while maintaining high productivity through coordinated operation of multiple modules
Data Source
AI summary
Composite tape is laminated onto a substrate using a gantry to move a tape laminating head along the length of the substrate. The laminating head is mounted for movement along a beam on the gantry that extends across the width of the substrate. The direction of lamination may be altered by changing the angular orientation of the beam.