Automated Fiber Placement Merge Zone Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automated fiber placement machines face difficulties in applying tows over complex contours, leading to inconsistencies such as gaps and overlaps in composite laminate structures, particularly in aircraft components like spars and stringers.
Innovation Solution
A method and system where tows are laid up in non-parallel sections that converge at merge zones, optimized for complex contours, using a tow placement system controlled by a computer system to ensure precise overlap and gap management, reducing inconsistencies through staggered merge zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated fiber placement machines are used to apply tows over complex contours, then productivity and automation are improved, but manufacturing precision deteriorates due to gaps and overlaps
Solution Approach 1:
The patent divides a single ply into multiple sections that are laid up separately and then merged. Each section can be independently controlled by the AFP machine, allowing optimized path planning for each segment to avoid gaps and overlaps while maintaining automation. The merge zones are carefully designed to ensure proper alignment and bonding between sections.
Solution Approach 2:
The patent employs dynamic path planning that adapts to complex contours in real-time. The AFP machine adjusts tow paths, speeds, and merge zone locations dynamically based on the specific geometry being formed. This dynamic control allows the automated system to maintain high precision on varying radii and complex shapes without sacrificing productivity.
2Adaptability or versatility
If tows are applied along curved paths to form nonlinear features, then adaptability to complex shapes is improved, but manufacturing precision deteriorates due to difficulties in applying tows over curves
Solution Approach 1:
The patent segments the layup path into multiple sections with designated merge zones. Each section can be optimized for its specific curvature characteristics, allowing the AFP machine to maintain better control and precision on tight radii. The segmentation enables independent path optimization for each segment while maintaining overall adaptability to complex geometries.
Solution Approach 2:
The patent introduces merge zones as intermediary regions where tow sections converge and are joined. These merge zones act as transition areas that mediate between different curved paths, allowing the system to handle complex contours by breaking down continuous curved paths into manageable segments that can be properly aligned and bonded.
3Manufacturing precision
If merge zones are used to join tow sections, then manufacturing precision is improved by reducing gaps and overlaps, but device complexity increases due to need for controlled convergence
Solution Approach 1:
The patent performs preliminary planning of merge zone locations and tow paths before the actual layup process. The control system pre-calculates optimal merge zone positions, convergence angles, and path intersections to ensure precise alignment. This preliminary action simplifies the real-time control requirements during manufacturing while maintaining high precision in tow end alignment.
Solution Approach 2:
The patent incorporates feedback mechanisms where the control system monitors the actual positions and orientations of tow sections as they approach merge zones. Real-time feedback allows dynamic adjustments to path trajectories and convergence points, ensuring precise alignment while managing the complexity of controlled convergence through adaptive control algorithms.
Data Source
AI summary
A method and apparatus for forming a composite object. A first plurality of tows is laid up over a tool according to a first path. A second plurality of tows is laid up over the tool according to a second path. A first portion of the first plurality of tows runs non-parallel to a second portion of the second plurality of tows. First ends of the first portion of the first plurality of tows and second ends of the second portion of the second plurality of tows meet at a merge zone along the tool to form a ply of a composite laminate.