Fiber Composite Layup Orientation Unit for Mass Reduction

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Solution Overview

Problem

Existing methods for producing fiber composite workpieces face challenges in reducing moving masses and minimizing shutdown periods of laying units, leading to inefficiencies and increased costs.

Innovation Solution

The method involves changing the spatial orientation of the base unit relative to the retaining means upstream of the application station using an orientation unit, which is part of the conveyor device, allowing for full automation and reducing the mass to be moved, thereby eliminating the need for complex robot-guided movement actuator mechanisms and enabling a static process zone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a laying table movable in rotational and translational manner is used, then different laying directions can be achieved, but the moving mass increases and plant dynamics are limited

Engineering Contradiction:

Improvelaying direction variationVSAvoidmoving mass

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

Instead of moving the laying table to achieve different laying directions, the invention inverts the approach by keeping the laying table stationary and moving the application station with the laying heads. This transfers the motion from the heavy table to the lighter application station, resolving the contradiction between adaptability and moving mass.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention introduces dynamic positioning capabilities to the application station through robot-guided movement actuator mechanisms, allowing the laying heads to be precisely positioned at different locations and orientations. This dynamic system replaces the need for a large movable table, achieving both versatility and reduced moving mass.

Inventive Principle:

Principle #15Dynamics

2Extent of automation

If robot-guided movement actuator mechanisms are used, then automation is improved, but device complexity increases

Engineering Contradiction:

Improveautomation levelVSAvoidmechanism complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The robot-guided movement actuator mechanisms serve multiple functions: they position the laying heads in the longitudinal direction, adjust lateral positions, and control rotational orientations. This multi-functionality reduces the need for separate mechanisms for each degree of freedom, achieving high automation without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If the laying table is moved in transverse direction, then different laying angles are achieved, but laying speed is limited by acceleration of large masses

Engineering Contradiction:

Improvelaying angleVSAvoidlaying speed

Core Design Contradiction:

Adaptability or versatilityVSSpeed

Solution Approach 1:

The invention inverts the motion strategy by keeping the heavy laying table stationary and moving only the lighter application station to achieve different laying angles. This dramatically reduces the mass that needs to be accelerated, enabling higher laying speeds while maintaining angular versatility.

Inventive Principle:

Principle #13The other way round (Inversion)

4Adaptability or versatility

If a movable laying table is used, then spatially changing process zone is created, but safety devices and quality assurance devices become difficult to provide

Engineering Contradiction:

Improveprocess zone configurationVSAvoidsafety and quality assurance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The invention creates a static process zone by keeping the laying table stationary and moving the application station instead. This stationary configuration allows safety devices and quality assurance devices to be easily installed and positioned, improving reliability while maintaining the needed process flexibility.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11731377B2Method and device for producing workpieces comprising fiber composite material

Publication Date: 2023.08.22 AZL AACHEN GMBH

AI summary

In a method for producing workpieces comprising fibre composite material, in which a base unit (5) held by retaining means (97) of a conveying device is guided by at least one application station (2, 14, 17, 20, 23, 27, 29,2, 14, 17, 20, 23, 27, 29, 39-41, 67-72) and, in order to form the workpieces at the application station (2, 14, 17, 20, 23, 27, 29,2, 14, 17, 20, 23, 27, 29, 39-41, 67-72) or at least at one of the application stations (2, 14, 17, 20, 23, 27, 29,2, 14, 17, 20, 23, 27, 29, 39-41, 67-72), during a translational movement of the base unit (5) through the application station (2, 14, 17, 20, 23, 27, 29,2, 14, 17, 20, 23, 27, 29, 39-41, 67-72) in question at least one strip (6) belonging to the fibre composite material is placed on the base unit (5), it is proposed that the spatial orientation of the base unit (5) is altered by means of at least one rotation relative to the retaining means (97) before the application station (2, 14, 17, 20, 23, 27, 29,2, 14, 17, 20, 23, 27, 29, 39-41, 67-72) or before at least one of the application stations (2, 14, 17, 20, 23, 27, 29,2, 14, 17, 20, 23, 27, 29, 39-41, 67-72) in the conveying direction. The invention furthermore relates to an apparatus suitable therefor.