Fiber Placement Head With Transverse Feed for Complex Blade Roots

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Solution Overview

Problem

Conventional automated fiber placement methods face challenges in manufacturing large aeronautical parts with complex geometries, such as propellers, due to bulkiness issues at the neck area, which can lead to machine head interference and require shape modifications that compromise functionality.

Innovation Solution

An application head with a rotatable roller and a feed device for fibers oriented transversely to the roller's axis, allowing deposition of fibers at various angles, including a pre-application roller for enhanced kinematic freedom and simultaneous or sequential deposition of strips and ribbons, optimizing fiber orientation and mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional automated fiber placement methods are used with fibers oriented parallel to the roller movement, then the deposition process is simple, but the machine head becomes bulky and interferes with complex geometries like neck areas

Engineering Contradiction:

Improvedeposition process simplicityVSAvoidmachine head bulkiness

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The patent inverts the conventional fiber orientation approach: instead of orienting fibers parallel to the roller movement direction, the fibers are oriented transversely (perpendicularly) to the roller axis. This inversion allows the application head to access complex geometries like neck areas without bulkiness interference while maintaining effective fiber deposition

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces a new dimensional approach by orienting fibers in the transverse direction (perpendicular to roller axis) rather than only in the longitudinal direction (parallel to movement). This adds a new dimension to fiber placement capability, enabling access to previously unreachable areas of complex parts

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If the head moves along the longitudinal axis to deposit fibers, then conventional deposition is achieved, but the head risks touching the neck area of the part

Engineering Contradiction:

Improvedeposition efficiencyVSAvoidhead interference avoidance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs asymmetric fiber orientation where fibers are placed at specific angles (0°, 45°, 90°) relative to the roller axis rather than uniformly parallel to movement. This asymmetric placement strategy enables the head to navigate around complex geometries like neck areas while maintaining deposition efficiency and avoiding interference

Inventive Principle:

Principle #4Asymmetry

3Ease of manufacture

If fibers are deposited only parallel to the movement direction, then the application process is straightforward, but complex geometries like tulip roots cannot be manufactured

Engineering Contradiction:

Improveapplication process simplicityVSAvoidgeometry compatibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent implements a dynamic fiber placement system that can adapt fiber orientation angles (0°, 45°, 90°) relative to the roller axis based on the local geometry requirements. This dynamic adjustment capability allows the same application head to manufacture diverse complex geometries including tulip roots, blades, and propellers while maintaining manufacturing simplicity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The application head achieves multi-functionality by incorporating transverse fiber orientation capability, enabling it to handle both simple and complex geometries (blades, propellers, tulip roots) with a single device, eliminating the need for specialized equipment for different part types

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables efficient manufacturing of complex parts like blade roots with optimized mechanical properties and reduced draping time, ensuring continuous mechanical strength and adaptability to varied shapes without head interference.

Implementation Method 1

an application roller that is designed to apply fibers to a shaping tool which application roller is rotatably movable on its axis for applying fibers to the shaping tool

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12466139B2Application head for automatically applying fibres

Publication Date: 2025.11.11 SAFRAN SA

AI summary

Application head for automated fiber placement, which application head includes at least: an application roller that is designed to apply fibers to a shaping tool which application roller is rotatably movable on its axis for applying fibers to the shaping tool, and a feed device includes a winding of a strip of fibers having a predefined orientation, the strip of fibers being configured to be transferred by unwinding from the feed device onto the application roller with at least one portion of the fibers of the strip being oriented such that they are not perpendicular to the axis of the roller.