Fabric Handling Array Orientation for Damage-Free Composite Layup
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Solution Overview
Problem
Current methods for handling fabric materials in composite component manufacturing, such as aircraft components, are prone to errors due to manual handling, which can result in stretching, creasing, or damage, leading to increased production time and reduced accuracy.
Innovation Solution
A fabric handling apparatus with a layup table, mold, and a fabric handling array suspended above, featuring a plurality of attractors that can be oriented and adjusted to transfer fabric shapes from the layup table to the mold without deformation, using suction cups or electrostatic devices for precise positioning and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling methods are used to transfer fabric materials, then flexibility and ease of operation are maintained, but fabric deformation (stretching, creasing, damage) occurs and production time increases
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic system featuring a programmable arm and end effector. The robot performs pick-up, transfer, and placement operations automatically, eliminating human-induced fabric deformation while maintaining precise control over handling parameters to prevent damage and reduce production time
Solution Approach 2:
The system incorporates sensors and feedback mechanisms that enable the robotic handling system to self-adjust during fabric manipulation. The end effector automatically adapts its gripping force and positioning based on real-time feedback, ensuring reliable fabric handling without manual intervention while maintaining optimal handling parameters
2Productivity
If gripping tools are used to handle fabric materials, then transfer efficiency is improved, but fabric damage occurs at gripper locations
Solution Approach 1:
The patent employs an end effector with adjustable gripping parameters including variable suction force, adaptive grip pressure, and configurable contact points. By dynamically changing these parameters based on fabric type and thickness, the system achieves efficient transfer while preventing localized damage at gripper contact points
Solution Approach 2:
The end effector acts as an intermediary between the robotic system and the fabric, incorporating soft compliant elements and distributed contact points that spread the gripping force. This intermediate structure transfers the fabric efficiently while preventing concentration of stress that would cause damage at single gripper locations
3Productivity
If automated fabric handling systems are implemented, then production time is reduced, but system complexity increases
Solution Approach 1:
The robotic system is designed with a universal end effector that can handle multiple fabric types, sizes, and weights through programmable control. The same robotic arm and end effector configuration perform pick-up, transfer, orientation, and placement functions, reducing the need for multiple specialized devices while maintaining automated handling benefits
Solution Approach 2:
The system uses disposable or easily replaceable end effectors and gripper elements that can be quickly changed or recovered for maintenance. This approach allows complex automated handling functions to be implemented while simplifying long-term system management through easy replacement of wear-prone components
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 apparatus ensures accurate and reliable handling of fabric materials, reducing production time and improving the quality of composite components by preventing fabric deformation and damage during the handling process.
Implementation Method 1
A roller 48 is provided to pick up the fabric element, after being cut into the appropriate shape, using vacuum pressure.
Implementation Method 2
using suction cups or electrostatic devices for precise positioning and orientation
Data Source
AI summary
A fabric handling apparatus includes a layup table, a mold disposed adjacent to the layup table, and a fabric handling array suspended above the layup table and the mold. The fabric handling array is adapted to transfer at least one fabric shape from the layup table to the mold. The fabric handling array includes a plurality of attractors in an attractor array. An orientation of the fabric handling array is alterable with respect to at least one of the layup table and the mold so that the at least one fabric shape is positionable on the mold in a predetermined orientation.