Hinge Clamps for Composite Charge Forming Tension
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Solution Overview
Problem
Existing composite forming systems fail to accurately hold a composite charge in position relative to a forming mandrel during the transition from a flat to an angled configuration, while maintaining continuous lengthwise tension and ensuring easy removal for high production rates.
Innovation Solution
A clamping system utilizing upstream and downstream hinge clamps that fold the composite charge about a hinge axis, allowing continuous tension application and maintaining center alignment, with a blanket assembly translating along the mandrel to secure the charge in position and facilitate easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the composite charge is held in position during forming, then positioning accuracy is improved, but the system complexity increases due to additional clamping mechanisms
Solution Approach 1:
The hinge clamp is integrated into the blanket assembly, with the clamp mechanism nested within the blanket structure. The clamp arm pivots within the blanket assembly framework, allowing the clamping function to be embedded within the existing forming system rather than adding completely separate clamping devices.
Solution Approach 2:
The blanket assembly serves multiple functions: it provides thermal insulation, applies compressive force to the composite charge, and incorporates the hinge clamp mechanism for positioning. This multi-functionality reduces the need for separate dedicated clamping systems, thereby limiting complexity increase.
2Manufacturing precision
If continuous lengthwise tension is applied to prevent wrinkles, then forming quality is improved, but the device complexity increases due to tension application mechanisms
Solution Approach 1:
The hinge clamp mechanism automatically generates and maintains tension on the composite charge through its folding action. As the clamp arm pivots during the forming process, it naturally applies and maintains lengthwise tension without requiring external actuators or complex tension control systems.
Solution Approach 2:
The hinge clamp transitions from a static clamping position to a dynamic folding motion, continuously adjusting the tension applied to the composite charge throughout the forming process. This dynamic action ensures continuous tension without requiring complex active control mechanisms.
3Stability of the object's composition
If the composite charge is securely held during forming, then positioning stability is improved, but removal difficulty increases
Solution Approach 1:
The hinge clamp operates in periodic cycles: it engages and secures the composite charge at the beginning of forming, maintains clamping throughout the forming process, and then releases for removal. This periodic engagement and disengagement allows stable holding during forming while enabling easy removal when needed.
Solution Approach 2:
The hinge clamp transitions between static clamped positions and dynamic release motion. The pivotal hinge mechanism allows the clamp arm to be firmly held in the clamped position during forming, then easily pivoted to the released position for quick removal, providing both stability during operation and ease of removal.
4Manufacturing precision
If the composite charge transitions from flat to angled configuration, then forming accuracy is improved, but the risk of wrinkle formation increases
Solution Approach 1:
The hinge clamp applies preliminary tension to the composite charge before the forming process begins and maintains this tension throughout the transition from flat to angled configuration. This pre-applied and continuous tension prevents the material from buckling or wrinkling as it is formed into the angled shape.
Solution Approach 2:
The hinge clamp acts as an intermediary element between the composite charge and the forming mandrel, mediating the transition from flat to angled configuration. By maintaining continuous tension through this intermediary clamping mechanism, the system enables accurate forming while preventing wrinkle formation that would otherwise occur during the configuration transition.
Data Source
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AI summary
A clamping system for securing a composite charge in position relative to a forming mandrel includes an upstream hinge clamp and a downstream hinge clamp for clamping opposing ends of the composite charge in respective position relative to a mandrel upstream end and a mandrel downstream end during forming of the composite charge onto the forming mandrel. Each one of the hinge clamps is configured to fold a corresponding end of the composite charge from a generally approximately flat configuration to an angled configuration during forming of the composite charge onto the forming mandrel. At least one of the hinge axes is oriented approximately parallel to a folding axis located proximate an intersection of a mandrel top portion with at least one of opposing mandrel side surfaces.