Concurrent Lamination and Trimming Composite Manufacturing
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Solution Overview
Problem
Current methods for manufacturing composite laminates are limited by the serial application of single plies and the separate step of trimming, which restricts manufacturing rate and efficiency.
Innovation Solution
A manufacturing system with statically positioned lamination heads that dispense layup material onto a movable lamination surface, allowing sequential application and concurrent trimming of composite laminates as the surface moves through the station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If serial ply-by-ply lamination is used, then manufacturing precision and quality control are maintained, but productivity is limited
Solution Approach 1:
The lamination system is segmented into multiple independent lamination heads (first, second, third lamination heads) positioned at different locations. Each head can independently apply plies to the mandrel, allowing parallel processing of different sections of the composite laminate. This segmentation enables multiple plies to be applied simultaneously, significantly increasing productivity while maintaining the quality control of individual ply application.
Solution Approach 2:
The patent transitions from a single lamination head operating in one dimension (sequential passes) to multiple lamination heads operating in multiple spatial dimensions (end-to-end arrangement). The heads are positioned along the length of the mandrel, allowing plies to be applied at different longitudinal positions simultaneously. This dimensional expansion transforms the process from serial to parallel lamination, resolving the productivity limitation.
2Productivity
If trimming is performed as a separate post-processing step, then manufacturing precision is maintained, but productivity is reduced due to additional processing time
Solution Approach 1:
The patent merges the lamination and trimming operations into a single integrated process. Trimming devices are positioned within the lamination station to trim the composite laminate in-situ while the plies are being applied. This eliminates the need for separate post-processing trimming steps, reducing total manufacturing time and increasing productivity while maintaining trimming accuracy through the use of precision trimming devices.
Solution Approach 2:
The trimming operation is performed preliminarily during the lamination process itself, rather than as a subsequent step. The trimming devices cut the excess material from the laminate edges while the plies are still being applied, preparing the final dimensions before the laminate is fully cured. This preliminary action reduces overall process time while ensuring dimensional accuracy.
3Productivity
If multiple lamination heads are used to increase productivity, then manufacturing rate improves, but device complexity increases
Solution Approach 1:
Multiple lamination heads are designed with identical or similar functional capabilities, each capable of independently applying plies to the mandrel. This universality allows the system to maintain a standardized component design while achieving parallel processing. The heads can be interchangeably positioned along the mandrel length, and the control system manages them using similar protocols, reducing the complexity increase that would result from heterogeneous components.
Data Source
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AI summary
A manufacturing system includes a plurality of lamination heads statically positioned in end-to-end relation to each other and defining a lamination station, and configured to dispense a layup material along a dispensing direction. The manufacturing system also includes a lamination surface movable underneath the lamination station. The lamination heads are configured to sequentially apply the layup material onto the lamination surface and onto previously applied layup material as the lamination surface passes through the lamination station to thereby form a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by positions of the lamination heads relative to each other within the lamination station. The manufacturing system further includes one or more trimming devices configured to trim the composite laminate.