Interchangeable Composite Lay-up Heads on 6-Axis Gantry
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Solution Overview
Problem
Current composite lamination systems require moving large, partially completed articles between machines to switch between laying up composite contour tape and fiber towpreg, which is cumbersome, time-consuming, and reduces accuracy.
Innovation Solution
A 6-axis gantry composite lamination system with live docking stations and interchangeable heads, where none of the six motion axes reside with the heads, allowing for quick and efficient switching between tape laying and fiber placement heads without redundant axis hardware, enabling simultaneous lay-up of both composite CTL grade tape and fiber towpreg.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single application head is used for both tape laying and fiber placement, then device complexity is reduced, but manufacturing precision and adaptability are compromised because the same head cannot perform both functions
Solution Approach 1:
The system employs multiple application heads that can be quickly interchanged on the same gantry system. Each head is specialized for a specific function (tape laying or fiber placement), but the universal mounting interface and control system allow the system to adapt to different material types and processing requirements without redesigning the entire machine
Solution Approach 2:
The application head is divided into separable, interchangeable modules. Instead of one monolithic head attempting to do everything, the system uses distinct heads for tape and fiber that can be swapped independently, allowing each module to be optimized for its specific function while maintaining overall system versatility
2Adaptability or versatility
If duplicate axis hardware is built into each head to allow independent operation, then adaptability improves, but device complexity and cost increase significantly
Solution Approach 1:
The six motion axes are merged into a single gantry system that controls the position and orientation of the entire head assembly. By combining the axis hardware at the system level rather than duplicating it in each head, the patent achieves coordinated multi-head operation while eliminating redundant mechanisms and reducing overall complexity
Solution Approach 2:
The gantry system acts as an intermediary between the control system and the application heads. It provides the motion control and positioning functions that would otherwise need to be built into each head, allowing heads to be simplified while maintaining full operational capability through the intermediary gantry mechanism
3Adaptability or versatility
If the article is relocated between machines to switch material types, then adaptability is achieved, but productivity and manufacturing precision deteriorate due to the cumbersome and time-consuming process
Solution Approach 1:
Both tape laying and fiber placement capabilities are merged into a single integrated system. The article remains stationary on the same worktable while different application heads are brought to it, eliminating the need to move the article between separate machines and dramatically improving productivity
Solution Approach 2:
Multiple application heads are pre-positioned on the gantry system in ready positions. When a material type change is needed, the appropriate head is already in place or can be quickly swapped from a prepared position, eliminating setup time and allowing immediate continuation of the manufacturing process
4Adaptability or versatility
If the article is relocated between machines, then material type adaptability is achieved, but manufacturing precision is reduced due to loss of position reference
Solution Approach 1:
A single coordinate system and positioning reference system is maintained across all application heads on the gantry. Since all heads operate within the same reference frame and the article never moves between machines, ply-to-ply placement precision is preserved while still enabling switching between different material types through head interchange
Data Source
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AI summary
A composites lamination system (10) uses a six-axis positioner (11) and multiple removable heads (14, 51-54) for applying composite material to a tool (16). The six-axis positioner (11) has a gantry (12) and a wrist (30). The gantry (12) has two spaced uprights (21) that support a crossbeam (18) that is movable in the X-axis. A workzone (15) containing a tool (16) is positioned between the two spaced uprights (21). A movable column (23) is supported on the crossbeam (18), and is movable relative to the crossbeam (18) in the Y-axis and the Z-axis. A wrist (30) mounted on the column (23) rotates around an I-axis parallel to the X-axis, around a J-axis parallel to the Y-axis, and around a K-axis parallel to the Z-axis. A replaceable head (14, 51-54) is mounted on the wrist (30) so that the gantry (12) and the wrist (30) provide six axis of motion for the replaceable head (14, 51-54), and removal of the head (14, 51-54) from the wrist (30) allows the six axis of motion to remain with the positioner (11).