Automated Fiber Gun for Composite Placement Precision
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Solution Overview
Problem
Current methods for reinforcing composite components using fibers are labor-intensive and costly, particularly when aligning and positioning fibers in complex geometries like transition regions with high stress concentrations.
Innovation Solution
A fiber gun apparatus that automatically cuts, shapes, and positions fibers with high precision and speed, utilizing a mandrel with varying cross-sectional areas to change fiber shape and a robot for controlled movement, significantly reducing labor costs and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual methods are used to align and position fibers in complex geometries, then manufacturing precision can be achieved, but labor costs and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated fiber placement system that uses computer-controlled mechanisms to precisely position fibers. The system substitutes human labor with automated equipment including a robotic arm or positioning mechanism, a fiber delivery system, and control software, thereby achieving high precision fiber placement while dramatically reducing the time required for fiber alignment in complex geometries
Solution Approach 2:
The patent changes the operational parameters from manual control to automated control with precise positioning capabilities. The system uses programmable parameters for fiber placement location, angle, and sequence, allowing rapid adjustment and reproduction of complex fiber patterns without the time-consuming manual alignment process while maintaining manufacturing precision
2Productivity
If automated fiber placement systems are implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The patent designs the automated fiber placement system with multi-functional capabilities that justify the increased device complexity. The apparatus integrates fiber delivery, cutting, positioning, and placement functions into a single coordinated system, and can adapt to different fiber types, composite materials, and geometric configurations, thereby achieving high productivity through a versatile platform that handles multiple manufacturing tasks
Solution Approach 2:
The patent introduces a computer control system as an intermediary that coordinates the various components of the automated fiber placement system. This central control mechanism manages the complex interactions between the fiber delivery system, positioning mechanism, and placement head, simplifying the overall system operation while enabling high-speed automated fiber placement with precise control
3Ease of manufacture
If traditional fiber reinforcement methods are used, then manufacturing simplicity is maintained, but labor costs increase
Solution Approach 1:
The patent replaces manual fiber placement operations with automated systems that maintain ease of manufacture through centralized control. The automated system handles the complex tasks of fiber cutting, alignment, and placement, while the overall manufacturing process remains simple to operate through computer-controlled sequences, thereby eliminating labor-intensive operations without sacrificing process simplicity
Solution Approach 2:
The patent implements preliminary programming and setup of the automated fiber placement system, where fiber paths, cutting positions, and placement sequences are pre-defined through computer-aided design and manufacturing software. This preliminary action enables the system to automatically execute complex fiber reinforcement patterns at high speed without requiring complex real-time manual intervention, thus maintaining ease of manufacture while dramatically increasing productivity
Data Source
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AI summary
The present disclosure provides an apparatus that includes a fiber gun. In an embodiment, the apparatus may controllably cut one or more fibers into one or more fiber segments. In an embodiment, the apparatus may controllably shape one or more fibers into different shapes (e.g., from loops into substantially straight fibers). In an embodiment, the apparatus may controllably position the one or more fiber segments onto a supporting member (e.g., a composite component). For example, the apparatus may include a robot that may controllably move the fiber gun relative to a supporting member and align the fiber gun such that the one or more fiber segments are controllably positioned on the supporting member. The apparatus may further include a controller that at least partially controls operation of the apparatus.