Hydraulic Composite Separator Mandrel Removal
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Solution Overview
Problem
The existing methods for removing composite parts from layup mandrels are inefficient, often requiring excessive manual force and time, with some instances taking up to sixteen hours, and previous mechanical solutions can be unsafe due to stored energy causing clamps to be forced off the assembly.
Innovation Solution
An apparatus and method utilizing a gripper system with an actuation system to apply force between grippers positioned on either side of the composite part, allowing for controlled separation of the layup mandrel from the composite part by moving the mandrel away from the part using actuators, which can apply up to 1150 pounds of force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human strength is used to pull the layup mandrels from the composite part, then the separation can be achieved, but excessive force (over 1000 pounds) and time (up to sixteen hours) are required
Solution Approach 1:
The patent replaces manual mechanical pulling with a controlled mechanical separation system. The system uses a spreading mechanism with movable supports that gradually increase the distance between them, applying controlled force to separate the mandrel from the composite part. This substitution eliminates the need for excessive manual force and reduces separation time from up to sixteen hours to a controlled mechanical process.
Solution Approach 2:
The patent employs hydraulic actuators to power the spreading mechanism. The hydraulic system provides controlled, progressive force to move the supports apart and separate the mandrel from the composite part. This hydraulic actuation enables precise control over the separation force and speed, improving productivity while reducing the uncontrolled excessive forces associated with manual pulling.
2Force
If clamps and assembly are used to pry the layup mandrel from the composite part, then separation force can be applied, but the stored energy from clamping force causes the clamps to be forced off the assembly
Solution Approach 1:
The patent uses a dynamic spreading mechanism where the movable supports gradually increase their distance from each other during the separation process. This progressive movement allows controlled application of separation force without creating sudden energy release. The system adapts to the resistance encountered during separation, maintaining force application while preventing the catastrophic failure that occurs with static clamping systems.
Solution Approach 2:
The patent introduces movable supports as intermediary elements between the hydraulic actuators and the composite part/mandrel assembly. These supports distribute and control the force application, acting as a mediator that prevents direct, uncontrolled force transmission. The intermediaries enable gradual separation while maintaining system safety by preventing sudden energy release.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and efficient removal of composite parts from layup mandrels without damaging the parts, reducing the time and labor required for separation and ensuring safety by controlling the application of force.
Implementation Method 1
An actuator is coupled to the layup mandrel and applies force to a transfer block. The actuator includes a piston that moves in a first direction to contact the transfer block, whereupon the layup mandrel is caused to move in a second, opposite direction away from the composite part.
Data Source
AI summary
A method and apparatus for applying a force to an assembly comprising a layup mandrel and a composite part. The apparatus comprises a first gripper and a second gripper. The second gripper is spaced apart from the first gripper so as to define a space between the first and second grippers, the space configured to receive the assembly. An actuation system is positioned between the first and second grippers adjacent the space, the actuation system configured to separate the layup mandrel from the composite part by applying force.