Helix Feed Application Device for Lightweight Flexible Tape Lay-Up
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Solution Overview
Problem
Existing application devices face challenges in applying tape material to a workpiece precisely and efficiently while minimizing weight and space requirements, especially when using a robot arm, and existing systems for feeding material to lay-up machines are complex and limit path geometry.
Innovation Solution
An application device with a base unit, application unit, and deflection unit, where the application unit is fixedly coupled to the base unit and the deflection unit is pivotally coupled about an axis, allowing the tape to be applied in one piece without manual intervention and along paths with free geometry, using input guide elements and deflection rollers to guide the tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the entire tape material is provided directly on the application device, then the tape can be applied in one piece without manual intervention, but the weight increases and precision decreases
Solution Approach 1:
The system divides the tape supply into two segments: a large tape roll remains stationary on the floor, while only the application device with minimal tape is moved by the robot arm. This segmentation allows automated application without transporting the entire tape weight.
Solution Approach 2:
A floor-mounted tape dispenser acts as an intermediary between the tape supply and the application device. It feeds tape to the moving application device through a guide element, enabling the robot to apply tape without carrying the heavy tape roll.
2Extent of automation
If the entire tape material is provided directly on the application device, then continuous application is possible, but the space required increases
Solution Approach 1:
The bulk of the tape supply is extracted from the moving application device and placed in a stationary floor-mounted dispenser. This removes the space-consuming tape storage from the robot's workspace while maintaining continuous application capability.
3Weight of moving object
If a tape dispenser is located on the floor, then weight is reduced, but the geometry of paths is severely limited
Solution Approach 1:
The deflection unit is designed to be pivotable about the axis, allowing dynamic adjustment of the tape feed direction. This enables the application device to follow complex paths while the stationary dispenser remains in one location, combining weight reduction with path flexibility.
4Quantity of substance
If multiple material drives are used to feed material, then material supply is ensured, but the complexity and size of the feed system increases
Solution Approach 1:
The complex multi-drive feed system is replaced by extracting the tape supply function to a simple stationary dispenser on the floor. The application device receives tape through a single guide element, dramatically simplifying the feed system while ensuring continuous material supply.
5Device complexity
If the deflection unit is fixed, then the structure is simple, but the tape cannot wrap around to provide sufficient length
Solution Approach 1:
The deflection unit is made pivotable about the axis, allowing it to dynamically adjust its position as the application device moves. This enables the tape to wrap around the deflection unit, providing sufficient tape length for complex paths without requiring a complex fixed structure.
Data Source
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AI summary
The invention relates to an application device (17), comprising: - a base unit (25), which has, at a first end (31), a connecting apparatus (35) for a production system (1) and which extends along an axis (37) from the first end (31) to a second end (33) remote from the connecting apparatus (35); - an application unit (27), which is designed to apply a tape (23), preferably adhesive tape, to a workpiece (19), the application unit (27) being fixedly coupled to the base unit (25) at the second end (33) of the base unit (25); and - a deflecting unit (29), which is coupled to the base unit (25) for pivoting about the axis (37); wherein: the application unit (27) has a first input guide element (41), by means of which the tape (23) can be fed to the application unit (27); the defecting unit (29) is designed such that the tape (23) can wrap around the deflecting unit (29) so that, when the tape is guided by means of the deflecting unit from an axial receiving position (71), at which the tape comes into contact with the deflecting unit (29), to an axial discharging position (73), at which the tape is released from the deflecting unit (29), the axial receiving position (71) is spaced apart from the axial discharging position (73) in the axial direction of the axis (37); and the first input guide element (41) of the application unit (27) is spaced apart from the axial receiving position (71) in the axial direction of the axis (37).