Automated Tape Placement for Contoured Composite Structures
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Solution Overview
Problem
Existing methods for fabricating highly contoured, multi-leg composite structures are labor-intensive and inefficient for high-volume production, particularly when using automatic fiber placement machines, which struggle with complex structural features and tight radii, limiting their ability to produce structures like Z or J-cross sections.
Innovation Solution
A method utilizing unidirectional pre-impregnated composite tape and automated tape placement equipment to fabricate continuous composite structures with nearly unlimited ply orientation, maintaining polar fiber orientation and constant width tape segments, allowing for accurate feature placement and efficient production of structures like frames, spars, and ribs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hand layup techniques are used to fabricate highly contoured composite structures, then manufacturing flexibility and adaptability are maintained, but labor intensity increases and productivity decreases
Solution Approach 1:
The composite structure is divided into multiple plies or layers that can be independently fabricated and then assembled. This segmentation allows automated equipment to produce individual layers efficiently while maintaining the flexibility to create complex contoured shapes through the assembly of these standardized segments.
2Productivity
If automatic fiber placement machines are used to fabricate composite structures, then productivity and automation are improved, but the ability to produce highly contoured structures with tight radii and complex features deteriorates
Solution Approach 1:
The invention transitions from attempting to fabricate complex 3D contoured structures directly in one step to a two-dimensional approach where flat or simply curved plies are fabricated using automated equipment, then assembled into the final complex 3D shape. This dimensional transformation allows automated machinery to maintain its productivity advantage while achieving complex geometries through assembly rather than direct fabrication.
3Manufacturing precision
If AFP machines frequently start, stop, and change directions to accommodate complex structural features, then manufacturing precision may be maintained, but productivity and fabrication efficiency deteriorate
Solution Approach 1:
The complex structural features are pre-fabricated as separate plies or components using automated equipment under optimized conditions, then positioned and assembled into the final structure. This preliminary fabrication of individual elements allows each component to be manufactured with high precision without the need for frequent machine stopping and direction changes during the overall fabrication process, thereby maintaining both precision and productivity.
4Ease of manufacture
If AFP machines are used to fabricate structures with Z or J-cross sections, then some contoured shapes can be produced, but the ability to load material at inside corners deteriorates
Solution Approach 1:
Structures with challenging geometries like Z or J-cross sections are divided into multiple plies that can be independently fabricated and assembled. This segmentation allows material to be loaded and processed in manageable sections rather than attempting to continuously form complex corner regions, enabling the production of structures that would be difficult or impossible to fabricate with continuous AFP processes alone.
Data Source
AI summary
A contoured composite structure is fabricated by laying up a composite charge that includes at least one ply formed by uni-directional fiber pre-preg ply segments having substantially constant widths. The ply segments are placed in side-by-side, overlapping relationship with their longitudinal centerlines aligned in a polar orientation related to the contour of the structure. The charge is formed into the shape of the structure and cured.