Elastic Shuttle Composite Ply Layup Wrinkle Prevention
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Solution Overview
Problem
The existing methods for fabricating composite structures through composite ply layup are labor-intensive and time-consuming, particularly when transporting and placing cut pieces on contoured forming tools, and are prone to wrinkling during the forming process.
Innovation Solution
A system and method utilizing a shuttle with a sheet of elastic material to pick up, transport, and compact composite plies on a forming tool, allowing for accurate placement and consolidation of plies with a desired shape, facilitated by a controller that uses sensed position information for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional labor-intensive methods are used to transport and place cut pieces on a forming tool, then flexibility in handling is maintained, but productivity is low and the process is time-consuming
Solution Approach 1:
A robotic arm with a specialized placement head serves as an intermediary between the cutting machine and the forming tool. The placement head includes a membrane structure that can selectively pick up, transport, and place composite plies onto the forming tool, automating the entire process while maintaining precision and flexibility
Solution Approach 2:
The manual mechanical process of picking, carrying, and placing plies is replaced with an automated robotic system. The robotic arm mechanically transports the placement head, while the membrane structure uses controlled deformation and suction to handle the plies, eliminating labor-intensive operations
2Manufacturing precision
If traditional methods are used to place plies on a contoured forming tool, then simplicity of the placement mechanism is maintained, but manufacturing precision is poor and plies cannot be accurately placed
Solution Approach 1:
The placement head incorporates a dynamic membrane structure that can be selectively deformed to match the contours of the forming tool. The membrane transitions from a flat state during transport to a contoured state during placement, enabling accurate adaptation to complex surfaces through controlled deformation rather than a fixed complex structure
Solution Approach 2:
The placement head uses a flexible membrane made of elastomeric material that can conform to the forming tool's contour. This thin film structure provides the necessary flexibility to adapt to complex geometries while maintaining a relatively simple overall device design, avoiding the need for rigid complex mechanisms
3Reliability
If multiple plies are formed using traditional methods, then ease of operation is maintained, but the process is prone to wrinkling during forming
Solution Approach 1:
The membrane in the placement head acts as an intermediary that directly contacts and controls the ply during placement and consolidation. By maintaining controlled contact through the membrane, the system ensures wrinkle-free consolidation without requiring complex additional forming equipment or manual manipulation
Solution Approach 2:
Manual manipulation and traditional mechanical consolidation methods are replaced with controlled suction and membrane deformation. The suction means creates negative pressure to hold and consolidate plies, while the deformable membrane applies controlled pressure, eliminating the need for labor-intensive wrinkle removal and ensuring reliable wrinkle-free consolidation
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
This approach automates the ply layup process, reducing labor and time while preventing wrinkling, enabling the efficient fabrication of composite structures with precise shape conformity to the forming tool.
Implementation Method 1
The shuttle includes a sheet of elastic material
Data Source
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AI summary
A method (1600) is provided for fabricating a composite ply layup with a desired shape. The method (1600) includes moving (1602) a shuttle (100) having a sheet (120) of elastic material into engagement with at least one composite ply (200) at a ply pickup station (310), and picking up (1604) the at least one composite ply (200) with the shuttle (100). The method (1600) also includes transporting (1606) the shuttle (100) and the at least one composite ply (200) from the ply pickup station (310) to a forming station (320), and moving (1608) the shuttle (100) and the at least one composite ply (200) into engagement with a forming tool (324) at the forming station (320) or any previously laid plies on the forming tool (324). The method (1600) further includes compacting (1610) the at least one composite ply (200) on the forming tool (324) or any previously laid plies on the forming tool (324) with the shuttle (100) to form the composite ply layup with the desired shape.