Non-Planar Composite Tape Laying Trajectory Optimization
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Solution Overview
Problem
Determining trajectories for tapes in the 0º direction on non-planar surfaces using Automated Tape Laying machines is challenging due to excessive gaps and wrinkle formation, especially in complex geometries like aircraft wing skins, where existing methods like geodesic curves do not ensure adequate gap control and wrinkle prevention.
Innovation Solution
The method involves determining modified geodesic trajectories with a minimum radius of curvature of 400mm and a maximum gap of 3.5mm between tapes, projected onto a horizontal plane and then intersected with a vertical plane to ensure proper laying on the surface, avoiding wrinkles and excessive gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If geodesic trajectories are used for tape laying on non-planar surfaces, then the tapes follow the surface contour, but excessive gaps appear between adjacent tapes
Solution Approach 1:
The patent modifies the geodesic trajectory parameters by introducing a offset distance interval between adjacent tapes. Instead of using pure geodesic curves, the method adjusts the spacing parameter to maintain gaps within acceptable limits (between 0 and a predetermined maximum value) while preserving the surface-following capability of geodesic paths.
2Manufacturing precision
If natural path segments with non-natural angles are used to reduce gaps, then gap control improves, but wrinkles are produced on the tapes
Solution Approach 1:
The patent carefully controls the angle parameter between adjacent trajectory segments. By limiting the non-natural angle to specific ranges and introducing offset distances, the method achieves gap control without creating excessive bending stresses that would cause wrinkles. The parameter optimization balances gap reduction with wrinkle prevention.
3Manufacturing precision
If complex trajectory calculations are performed to avoid gaps and wrinkles, then manufacturing precision improves, but computational complexity increases
Solution Approach 1:
The patent divides the complex trajectory calculation into manageable segments. Instead of computing the entire path as one complex geodesic curve, the method breaks it down into multiple natural path segments with controlled angles and offset distances. This segmentation simplifies the computational burden while maintaining manufacturing precision through localized parameter control.
4Object-generated harmful factors
If minimum radius of curvature constraints are applied to trajectories, then wrinkle formation is prevented, but the ability to follow complex surface geometry is reduced
Solution Approach 1:
The patent introduces a minimum radius of curvature parameter as a constraint on the trajectory design. By enforcing this parameter, the method prevents excessive bending of tapes that would cause wrinkles. The offset distance and angle control work together to maintain surface conformity while respecting the minimum curvature radius requirement, achieving a balance between wrinkle prevention and geometric adaptation.
Data Source
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AI summary
A method for laying-up the tapes (21, 23, 25) of a prepeg composite material in the 0º direction of a non-planar composite component on a suitable mould using an ATL machine comprising steps of: a) determining the trajectories of said tapes as modified trajectories of geodesic trajectories complying with the following conditions in their projections in an horizontal plane: that the radius of curvature R2 of their curved segments is bigger than a predetermined value Rmin; that the gap G2p between two contiguous tapes is comprised between 0 and a predetermined value Gmax; b) providing said modified trajectories to said ATL machine. A non-planar composite component such as an skin of an aircraft wing having the tapes in the 0° direction following trajectories complying with said conditions is also disclosed.