Layup Mandrel Dynamic Indexing for Moving Composite Fabrication
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Solution Overview
Problem
In composite part fabrication, the need to re-position and re-index a layup mandrel due to misalignment increases time and labor, as existing methods require a stationary mandrel for precise indexing, which is not feasible when the mandrel is moved during the process.
Innovation Solution
Dynamic indexing systems that allow for real-time adjustment of a lamination machine's NC program based on 3D coordinates acquired as the lamination head traverses the moving mandrel, enabling precise alignment without the need for re-orientation of the mandrel, using a lamination head with a roller, suspension, position sensor, and dispenser to adapt to deviations from a nominal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mandrel is held stationary for precise indexing, then the alignment precision is improved, but the productivity is reduced due to re-positioning and re-indexing operations
Solution Approach 1:
The patent transitions from static indexing (mandrel held stationary) to dynamic indexing (mandrel in motion). The dynamic indexing system captures 3D coordinates while the mandrel moves through the work cell, allowing indexing to occur during motion rather than requiring the mandrel to be stopped and re-positioned. This resolves the contradiction by enabling precise alignment measurement without sacrificing fabrication speed.
Solution Approach 2:
The patent replaces mechanical re-positioning operations with a sensor-based measurement system. Instead of physically moving and re-indexing the mandrel, the system uses a sensor to capture 3D coordinates of mandrel features during motion, then computationally determines alignment. This substitution eliminates the need for manual re-positioning while maintaining alignment precision.
2Manufacturing precision
If the mandrel is re-oriented and re-indexed to correct misalignment, then the alignment precision is improved, but the loss of time and labor increases
Solution Approach 1:
The patent performs alignment measurement in advance during the natural motion of the mandrel through the work cell. By capturing 3D coordinates of mandrel features as it passes by, the system determines alignment before the actual layup operation begins. This preliminary measurement eliminates the need for time-consuming re-orientation and re-indexing operations that would otherwise be required to correct misalignment.
Solution Approach 2:
The patent implements a feedback loop where 3D coordinates captured during mandrel motion are used to calculate actual alignment, which then feeds into NC program modifications. The system continuously monitors and adjusts for alignment deviations by modifying toolpath coordinates, eliminating the need for manual re-positioning and reducing setup time while maintaining precision.
3Productivity
If dynamic indexing is implemented for moving mandrels, then the productivity is improved by eliminating re-positioning, but the device complexity increases due to sensor systems and NC program modification
Solution Approach 1:
The patent introduces a sensor as an intermediary between the moving mandrel and the indexing system. Rather than requiring complex mechanical indexing mechanisms for moving mandrels, the sensor captures 3D coordinates of mandrel features during motion, and a controller processes this data to determine alignment. This intermediary approach simplifies the overall system by replacing complex mechanical dynamic indexing with a sensor-based measurement and computation system.
4Manufacturing precision
If the NC program is modified to account for alignment deviations, then the manufacturing precision is maintained without re-positioning, but the device complexity increases due to real-time program alteration
Solution Approach 1:
The patent modifies NC program parameters (toolpath coordinates) based on measured alignment deviations. By capturing 3D coordinates of the mandrel and calculating the transformation needed to compensate for misalignment, the system adjusts the layup coordinates in the NC program. This parameter transformation approach maintains placement accuracy without requiring complex mechanical adjustment mechanisms, as the correction is applied through software coordinate transformation.
Data Source
AI summary
Systems and methods are provided for indexing a layup mandrel. One embodiment is a method for indexing a layup mandrel for a composite part. The method includes identifying a surface of a layup mandrel that travels in a process direction during fabrication of a composite part, placing a lamination head in contact with the surface, traversing the surface of the layup mandrel with the lamination head, acquiring a stream of 3D coordinates of the lamination head as the lamination head traverses the surface, characterizing the layup mandrel based on the stream of 3D coordinates, altering a Numerical Control (NC) program that directs layup of fiber reinforced material at the layup mandrel, based on a difference between the alignment of the layup mandrel and a nominal alignment of the layup mandrel.