Integrated Lay-Up Head Welding for Accurate Thermoplastic Prepreg Placement
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Solution Overview
Problem
Existing automatic laminating apparatuses for thermoplastic prepregs suffer from positional deviations during temporary welding, leading to poor quality in fiber-reinforced composite materials due to the separation of the lay-up head and welding device, which causes time delays and vibrations.
Innovation Solution
The apparatus integrates a welding device with a pressing mechanism that presses the thermoplastic prepreg on both sides of the welding head, allowing for simultaneous lamination and temporary welding without separation, using a common drive mechanism to control the lay-up head and welding head movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welding device is installed at a position different from the lay-up head, then the welding device can perform temporary welding after lamination operation is completed, but time is consumed and positional deviation occurs causing poor quality
Solution Approach 1:
The welding device is integrated into the lay-up head, merging two previously separate functions (laying and welding) into a single unified device. This allows the welding operation to occur simultaneously with the lamination operation, eliminating the time delay and preventing positional deviation that occurs when the lay-up head is retracted and the welding device moves separately.
2Reliability
If the lay-up head is retracted to separate from the laid thermoplastic prepreg, then the welding device can access the prepreg for welding, but positional deviation occurs due to vibration
Solution Approach 1:
By integrating the welding device into the lay-up head, the patent eliminates the need for coordinated retraction and movement operations. The welding head remains positioned with the lay-up head throughout the operation, ensuring the thermoplastic prepreg is welded at the correct position without deviation caused by retraction and subsequent movement.
3Manufacturing precision
If thermoplastic prepreg is laid without simultaneous welding, then the lamination operation can be completed, but the prepreg deviates from intended position due to low surface viscosity
Solution Approach 1:
The welding operation is performed during the lamination operation itself, applying the welding action preliminarily while the prepreg is still being laid. This ensures the prepreg is secured to the lamination surface at the correct position before any potential deviation can occur, while maintaining continuous production flow.
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
This integration prevents positional deviations and reduces the time required for each lamination operation, enhancing the quality and efficiency of fiber-reinforced composite material production by ensuring immediate and stable adhesion.
Implementation Method 1
an ultrasonic welding device, an infrared welding device and the like are known as the welding device
Implementation Method 2
an ultrasonic welding device, an infrared welding device and the like are known as the welding device
Data Source
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AI summary
An automatic laminating apparatus includes: a lay-up head (20) provided with a raw-cloth roller (21) on which a thermoplastic prepreg is wound and a pressing device for pressing the thermoplastic prepreg drawn from the raw-cloth roller (21) against a lamination surface; and a welding device (29) provided with a welding head (29a) pressed against the thermoplastic prepreg to temporarily weld the thermoplastic prepreg to the lamination surface, the automatic laminating apparatus laminating the thermoplastic prepreg by performing a lamination operation of moving the lay-up head (20) to lay the thermoplastic prepreg having a predetermined length on the lamination surface, in which the welding device (29) is provided in the lay-up head (20), and the automatic laminating apparatus further comprises a drive control device (32) that causes the welding device (29) to perform temporary welding of the thermoplastic prepreg laid in the lamination operation in a course of the lamination operation.