Fiber Placement Head Structure to Prevent Tow Wrap
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fiber placement machines face inefficiencies due to fiber tow wraps during the application process, requiring time-consuming disassembly to correct tape misplacement, which affects machine productivity.
Innovation Solution
A fiber placement head with powered wheels and elongated fingers that conform to the wheel surface to prevent fiber wraps, combined with modular lane modules for easy maintenance and service, including removable cutting subassemblies to minimize resin interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional fiber placement head is used, then the structure is simple, but the fiber tow wrap causes misplacement of reinforcement and reduces manufacturing precision
Solution Approach 1:
The placement head is divided into multiple independently controllable nozzles arranged in an array. Each nozzle can be individually positioned and controlled to place fibers precisely, allowing the system to overcome the wrap issue through segmented placement rather than relying on a single complex wrapping mechanism.
Solution Approach 2:
The nozzles are designed to be movable and repositionable along the placement path. This dynamic capability allows the system to adapt to fiber tow wrap variations and maintain precise fiber placement by adjusting nozzle positions in real-time during the placement process.
2Productivity
If fiber placement is performed manually or with simple equipment, then the device complexity is low, but the productivity is reduced and labor intensity is high
Solution Approach 1:
Multiple nozzles are combined into a single integrated placement head assembly that can simultaneously place fibers along an entire section of the mold. This merging of multiple placement functions into one unit dramatically increases productivity while the modular design keeps the complexity manageable.
Solution Approach 2:
The system incorporates feedback mechanisms where sensors detect fiber placement quality and the system automatically adjusts nozzle positioning and fiber delivery parameters. This self-regulating capability maintains high productivity without requiring complex manual intervention.
3Manufacturing precision
If the fiber placement head is designed with multiple nozzles, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The nozzle array design allows the same basic nozzle unit to perform multiple functions: fiber delivery, positioning, and adjustment. This universal design reduces the variety of components needed and simplifies the overall system despite having multiple nozzles, as each unit is identical and can be independently controlled.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A fiber placement head for applying a plurality of composite tape segments on a mold including one or more powered wheels that are configured to engage and move composite tape; and one or more elongated fingers that closely conform to or abut an outer surface of the powered wheel(s) such that a portion of the elongated finger(s) forms at least a portion of a lane path.