Laser-Guided Fiber Bundle Width and Thickness Adjustment
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Solution Overview
Problem
Uneven spreading and thickening of fiber bundles during composite material molding leads to excessive voids, reducing the performance and efficiency of fiber products.
Innovation Solution
A filar guide with adjustable width and thickness adjustment mechanisms, combined with a width measuring laser mechanism, allows for real-time online control of fiber bundles, ensuring uniformity and adaptability for various composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If fiber bundles are spread and thickened during composite material molding, then the volume and coverage area increase, but uneven spreading causes excessive voids and reduces manufacturing precision
Solution Approach 1:
The patent employs dynamically adjustable rollers with variable pressure and spacing that can be modified in real-time during the molding process. This allows the system to adapt to different fiber bundle sizes and desired thicknesses, ensuring uniform spreading without excessive voids while maintaining the ability to increase volume when needed.
Solution Approach 2:
The system changes physical parameters such as roller pressure, roller spacing, and heating temperature to control the spreading and thickening of fiber bundles. By adjusting these parameters, the system achieves uniform fiber distribution while controlling the volume expansion, thereby resolving the contradiction between increasing volume and maintaining manufacturing precision.
2Area of stationary object
If fiber bundles are spread and thickened to increase coverage, then the area covered increases, but uneven spreading leads to excessive voids and reduces productivity
Solution Approach 1:
The dynamically adjustable roller system enables real-time optimization of fiber bundle spreading to achieve maximum coverage area while maintaining uniformity. This prevents rework and ensures consistent quality, thereby improving productivity despite the increased complexity of the spreading mechanism.
Solution Approach 2:
The system maintains continuous operation with consistent fiber bundle processing through automated control of roller pressure and spacing. This continuous uniform spreading eliminates voids and ensures consistent coverage area, improving overall production efficiency by preventing defects that would require stopping and reworking.
3Manufacturing precision
If real-time adjustment mechanisms are added to control fiber width and thickness, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The roller system performs multiple functions simultaneously: spreading, thickening, heating, and pressing fiber bundles. This multi-functionality reduces the need for separate adjustment mechanisms, thereby maintaining manufacturing precision while limiting the increase in device complexity.
Solution Approach 2:
The patent combines several adjustment functions into a single integrated roller system that can simultaneously control width, thickness, and uniformity of fiber bundles. By merging these functions, the system achieves high manufacturing precision without proportionally increasing device complexity.
4Productivity
If adjustment mechanisms are implemented to control fiber bundle dimensions, then production efficiency improves, but ease of operation decreases
Solution Approach 1:
The system incorporates automated control mechanisms that self-adjust roller pressure and spacing based on pre-set parameters, reducing the manual operation complexity while maintaining high production efficiency. The device performs adjustments automatically, improving productivity without significantly increasing operational difficulty.
Solution Approach 2:
The system uses feedback mechanisms to monitor fiber bundle dimensions in real-time and automatically adjusts roller settings to maintain optimal parameters. This automated feedback control improves production efficiency while minimizing the need for complex manual adjustments, thereby preserving ease of operation.
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 precise adjustment of fiber width and thickness, enhancing the production efficiency and performance of composite materials by minimizing voids and improving mechanical properties.
Implementation Method 1
a width measuring laser mechanism, which monitors the width of the expanded fiber in real time and feeds back to the above-mentioned executive mechanism
Data Source
AI summary
A real-time adjustment device for width and thickness of impregnated fiber bundles includes a width and thickness adjustment mechanism and a width measuring laser mechanism. The width and thickness adjustment mechanism is arranged under a filar guide, and is moved vertically by a cylinder. The width and thickness adjustment mechanism has a hollow concave roller and a hollow convex roller arranged vertically. A position of the hollow convex roller is fixed. Vertical positions of the hollow concave roller are controllable. Fibers pass between the hollow concave roller and the hollow convex roller. The width measuring laser mechanism is arranged between the filar guide and a processing workpiece to measure the fiber width in real-time and send the measurement results back to the control system. The position of the hollow convex roller can be adjusted based on the error between the width and the preset value.