Dual-Chamber Vacuum End Effector for Composite Preform Placement
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Solution Overview
Problem
Large preforms for composite parts face challenges in being securely placed and compacted onto complex, curved tooling surfaces due to peeling or shifting, which existing technologies fail to address effectively.
Innovation Solution
A vacuum system end effector with a dual-chambered base that applies negative pressure to both lift and compact objects, featuring a blocker door to control pressure distribution and vents to atmosphere, ensuring secure placement and compaction without premature compacting or shifting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single vacuum chamber is used to pick up and place preforms, then the device structure is simple, but the preform cannot be firmly compacted onto complex curved surfaces preventing peeling and shifting
Solution Approach 1:
The vacuum system is divided into two separate chambers: a first vacuum chamber for picking up the preform and a second vacuum chamber for compaction. This segmentation allows independent control of pickup and compaction functions, enabling reliable placement on complex surfaces without requiring a overly complex single-chamber design
Solution Approach 2:
The system uses dynamic control of vacuum application through the blocker door mechanism, which can selectively open or close the connection between chambers. This allows the system to transition between pickup mode (first chamber only) and compaction mode (second chamber only), providing adaptability for different operational phases
2Manufacturing precision
If vacuum is applied to both pickup and compaction regions simultaneously, then compaction occurs during pickup, but this causes unintended displacement and shifting of the preform
Solution Approach 1:
The pickup operation is completed first in the first vacuum chamber, securing the preform before any compaction action occurs. The blocker door remains closed during pickup, preventing premature vacuum application to the compaction region. Only after successful pickup does the system transition to compaction mode
Solution Approach 2:
The vacuum application is divided into periodic phases: first the pickup chamber operates independently to secure the preform, then the blocker door opens to enable the compaction chamber to operate for firm placement. This periodic activation ensures precise placement without displacement
3Productivity
If the vacuum system operates continuously without venting, then compaction is maintained, but the system cannot release vacuum for the next pickup cycle
Solution Approach 1:
The venting function is extracted as a separate feature through the blocker door mechanism that can open to atmosphere. This allows the compaction chamber to be vented independently when needed, enabling quick transition to the next pickup cycle without requiring complex centralized vacuum control systems
Solution Approach 2:
The system uses the blocker door to self-regulate vacuum application and release. When the blocker door opens, the compaction chamber automatically vents to atmosphere through the opening, providing automatic cycle reset without additional control mechanisms
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 vacuum system end effector effectively picks and places preforms onto complex surfaces, maintaining secure compaction and preventing unintended displacement, reducing rework and ensuring accurate placement of composite materials in aircraft manufacturing.
Implementation Method 1
A vacuum is applied to a first chamber of a base of a vacuum system end effector
Implementation Method 2
The vacuum is supplied from the second chamber to a second region of the manifold to compress the object
Data Source
AI summary
A vacuum system end effector and methods of use are presented. A method of picking and placing an object applies a negative pressure to a first chamber of a base of a vacuum system end effector. The negative pressure is supplied from the first chamber to a first region of a manifold to lift the object while venting a second chamber of the base to atmosphere. A barrier is moved away from an opening in the first chamber to supply negative pressure from the first chamber of the base to the second chamber of the base. A number of vents through the second chamber is blocked to cease venting to atmosphere. The negative pressure is supplied from the second chamber to a second region of the manifold to compress the object.