Fiber Layer Positioning on Molds Using Path-Based Lateral Alignment
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Solution Overview
Problem
Existing methods for positioning fiber layers on molds for manufacturing fiber composite components, such as stiffening elements for aircraft, are time-consuming and imprecise, especially when dealing with non-flat surfaces and low transverse stiffness of uncured laminates, making it difficult to achieve accurate lateral positioning without slippage.
Innovation Solution
A positioning device comprising a motion device, path position detection, and material layer positioning, which allows for precise lateral alignment of material layers on molds with varying widths and shapes, using centering devices, grippers, and actuators to adjust positions based on detected path positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement and positioning methods are used, then flexibility and simplicity are maintained, but positioning precision and time efficiency deteriorate
Solution Approach 1:
The patent replaces manual measurement and mechanical positioning with an automated optical detection system. A sensor device detects the longitudinal position of the laminate automatically, and a positioning device with actuators adjusts the lateral position based on detected path position, eliminating time-consuming manual operations while achieving high precision positioning.
Solution Approach 2:
The positioning system performs self-positioning through automatic detection and adjustment. The sensor device continuously monitors the laminate position, and the control system automatically commands the positioning device to correct any deviations, enabling the system to self-correct without manual intervention.
2Reliability
If positioning pins or pressure-sensitive tapes are used to prevent slippage, then positioning stability improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent replaces mechanical fixation methods like positioning pins and pressure-sensitive tapes with an automated positioning system using sensors and actuators. This electronic control system maintains positioning stability through continuous detection and adjustment without requiring additional mechanical fixing aids, thereby reducing overall device complexity.
Solution Approach 2:
The patent introduces a control system as an intermediary between detection and positioning actions. The control system processes sensor data and commands the positioning device, creating a coordinated system that achieves stable positioning through intelligent control rather than complex mechanical structures.
3Measurement precision
If holes are drilled in laminates for pinning, then positioning accuracy improves, but laminate integrity and manufacturing complexity worsen
Solution Approach 1:
The patent performs preliminary positioning through automatic detection before the laminate is fully processed. The sensor device detects the longitudinal position early in the process, and the positioning device adjusts lateral position accordingly, eliminating the need for subsequent hole-drilling operations and preserving laminate integrity.
Solution Approach 2:
The patent replaces the mechanical hole-drilling and pinning process with an automated optical detection and electronic positioning system. This substitution maintains high positioning accuracy while completely avoiding damage to the laminate structure and simplifying the manufacturing process.
4Area of stationary object
If the laminate covers the entire mold base, then complete coverage is achieved, but lateral positioning becomes more difficult without stops
Solution Approach 1:
The patent implements a feedback control system where the sensor device continuously monitors the laminate's longitudinal position, and the control system uses this feedback to automatically adjust the lateral positioning. This closed-loop control enables precise lateral positioning even when the laminate covers the entire mold base without traditional stops.
Solution Approach 2:
The patent replaces mechanical stops with an automated sensor-based positioning system. The sensor device detects position information, and the positioning device with actuators adjusts lateral position accordingly, enabling precise positioning across the entire mold base area without requiring physical boundary stops.
Data Source
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AI summary
For the precise lateral continuous positioning of material layers on a mold tool, the invention provides a positioning device (50) for positioning a material layer (26) on a mold tool (30) during the production of a fiber composite component, comprising: a positioning device (56) for positioning the positioning device (50) relative to a surface of the mold tool (30), a movement device (58) for moving the positioning device (50) along a predetermined movement path (60) along the mold tool (30), a path position detection device (62) for detecting the current path position of the positioning device (50) on the movement path (60), and a material layer positioning device (64) for positioning the material layer (26) in a direction transverse to the direction of movement depending on the current path position detected by the path position detection device (62).