Layup Headpath Compensation for Composite Compaction and Collision Checks
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Solution Overview
Problem
Existing layup procedures for composite components face challenges in accurately checking headpath data, leading to potential non-compaction of fibre reinforcement material and collisions between the applicator head and obstacles, due to discrepancies between defined headpath points and the actual substrate surface.
Innovation Solution
A computer-implemented method that receives baseline headpath data, determines head displacement along the compaction axis to achieve equilibrium between compaction and reaction forces, and checks for non-compacted portions and intersections with obstacles, allowing for the definition of offset headpath positions to avoid these issues, thereby ensuring proper compaction and collision avoidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If baseline headpath data is used without considering applicator roller deformation, then the headpath definition is simple, but non-compaction of fibre reinforcement material occurs
Solution Approach 1:
The method performs preliminary calculation of applicator roller deformation and head displacement before executing the layup operation. By pre-determining the deformation profile and adjusting headpath data accordingly, the system prevents non-compaction issues before they occur, rather than detecting them during actual manufacturing
Solution Approach 2:
The invention changes the parameters of headpath data by incorporating deformation-induced head displacement. Instead of using baseline headpath coordinates directly, the system adjusts them by the calculated displacement distance to compensate for roller deformation, transforming the headpath parameters to account for elastic deformation effects
2Device complexity
If baseline headpath position is used without head displacement compensation, then the control system is simple, but collisions between applicator head and obstacles occur
Solution Approach 1:
The system performs preliminary collision detection by calculating the displaced head position based on roller deformation before the actual layup operation. This advance calculation allows the control system to adjust headpath data to avoid obstacles, preventing collisions before they happen during manufacturing
Solution Approach 2:
The method implements a feedback mechanism where the calculated head displacement due to roller deformation is fed back into the headpath data. This closed-loop approach uses the deformation information to automatically adjust the headpath, creating a self-correcting control system that accounts for elastic deformation effects
3Productivity
If applicator roller deformation is not considered, then the calculation process is simple, but non-compacted portions of fibre reinforcement material are produced
Solution Approach 1:
The system performs preliminary calculation of deformation profile and head displacement before the layup operation. By pre-determining how the roller will deform under compaction force and calculating the resulting head displacement, the system adjusts headpath data in advance to ensure uniform compaction across all fibre reinforcement material
Solution Approach 2:
The invention changes the headpath parameters by incorporating the calculated head displacement caused by roller deformation. This parameter adjustment ensures that the applicator head compensates for the elastic deformation of the roller, maintaining consistent contact pressure and achieving uniform compaction of the fibre reinforcement material
4Device complexity
If headpath data does not account for head displacement, then data processing is simple, but the applicator head intersects with obstacles
Solution Approach 1:
The method performs preliminary detection of potential collisions by calculating the displaced head position based on roller deformation before actual manufacturing. This advance detection allows the system to modify headpath data to avoid obstacles, preventing intersections between the applicator head and tooling or previously laid plies
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 method enables accurate prediction and prevention of non-compaction and collisions, ensuring reliable application of fibre reinforcement material by adjusting headpath data to match the substrate surface profile, thereby improving the quality of composite components.
Implementation Method 1
determining a head displacement relative to the respective headpath positions along the compaction axis corresponding to an equilibrium condition between the compaction force and a reaction force through the fibre reinforcement material applied by the applicator roller
Data Source
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AI summary
There is disclosed a method of checking headpath data for a layup operation in which fibre reinforcement material is applied over a tool by an applicator roller of an applicator head biased against the tool along a compaction axis by a compaction force. The method comprises receiving baseline headpath data defining a baseline headpath position of the applicator head relative the tool; and determining a head displacement along the compaction axis corresponding to an equilibrium condition between the compaction force and a reaction force through the fibre reinforcement material. The method further comprises checking for at least one of a non-compacted portion of fibre reinforcement material and an intersection of the applicator head and an obstacle.