EOAT Roller Gripper for Precise Prepreg Ply Tensioning
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Solution Overview
Problem
The handling of pre-impregnated composite plies in automated layup routines is challenging due to their flexibility and tackiness, leading to difficulties in maintaining precise tensioning and conforming to mold contours, which can result in final parts with undesired properties such as reduced tensile and shear strength.
Innovation Solution
An end-of-arm tool (EOAT) with a mechanical gripper arrangement featuring rollers and torque regulators that apply compressive force and adjustable rotational resistance to securely grip and tension pre-preg plies, allowing for precise control and repositioning without damaging the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual hand layup is used to tension and adhere pre-preg plies, then the laminator can manually control the tensioning process, but the process becomes time-consuming and difficult to maintain consistent tensioning across multiple iterations
Solution Approach 1:
The patent replaces the manual mechanical hand layup process with an automated robotic system. The robotic arm equipped with a specialized end-of-arm tool (EOAT) featuring roller members and torque regulators automatically performs the tensioning and layup operations, eliminating manual intervention while maintaining precise tension control through programmed motion sequences and regulated torque application.
Solution Approach 2:
The robotic system is programmed with automated control sequences that enable it to independently perform the complete layup process. The system self-regulates the tensioning force through torque regulators on the roller members, automatically positions the pre-preg plies, and executes the adhesion process without requiring manual intervention for each iteration, thereby maintaining consistent tensioning while improving productivity.
2Reliability
If high compressive force is applied by the gripper to securely grip the tacky pre-preg ply, then the material is held firmly, but the excessive force may damage the fibers or deform the material
Solution Approach 1:
The patent distributes the gripping force across multiple roller members that contact different portions of the pre-preg ply. This local distribution of force ensures secure grip through cumulative friction while preventing concentrated stress points that could damage fibers or deform the material. The torque regulators on each roller member independently control the local compressive force to optimize grip security while minimizing harmful effects.
3Reliability
If the roller members are locked to prevent rotation for secure gripping, then the pre-preg ply is held firmly, but the roller members cannot rotate to allow repositioning or release of the material
Solution Approach 1:
The patent implements a dynamic gripping system where the roller members can transition between locked and unlocked states. During the gripping and tensioning phases, the torque regulators lock the rollers to provide stable, non-slip grip on the tacky pre-preg material. When repositioning or release is required, the system unlocks the rollers, allowing them to rotate freely and enable smooth material handling without damage, thus providing both grip stability and repositioning versatility.
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 EOAT effectively maintains secure grip and tension on pre-preg plies, preventing slipping and ensuring proper conforming to mold contours, thereby improving the quality and properties of the final composite parts by minimizing fiber damage and maintaining consistent tensioning.
Implementation Method 1
each of the first and second roller members to engage opposite surfaces of the pre-impregnated composite ply and supply a normal force to grip the pre-impregnated composite ply
Data Source
AI summary
An end of arm tool (EOAT) for use during manufacture of parts using one or more pre-impregnated composite plies is disclosed. In an embodiment, the EOAT includes a mechanical gripper arrangement with first and second fingers configured to supply a compressive force to grip a pre-impregnated composite ply therebetween. At least one of the first and second fingers include a roller member to engage opposite surfaces of the pre-preg ply and supply a compressive gripping force. The roller member on either or both the first and second fingers preferably include a torque regulator to selectively adjust an associated roller member's resistance to rotation via supply of a rotational torque resistance.