Levitated Pick-and-Place Movers for Wrinkle-Free Composite Forming
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Solution Overview
Problem
There is a need for an automated system that can efficiently form composite materials into complex shapes without wrinkles, in a time-efficient manner.
Innovation Solution
A pick-and-place manufacturing system utilizing levitated movers with permanent magnets and a stator base with electrical coils to generate an electromagnetic field, allowing for coordinated movement and precise operation of end effectors on a material sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated lamination machines are used to automate composite material application, then productivity is improved, but device complexity increases and material deposition rate decreases with increased tooling surface complexity
Solution Approach 1:
The patent replaces traditional mechanical lamination machines with a magnetic field-based system. Electromagnets arranged in the die generate magnetic fields that interact with ferromagnetic or paramagnetic fibers in the preform, enabling automated material placement without complex mechanical deposition mechanisms. This substitution maintains high productivity while reducing mechanical complexity.
Solution Approach 2:
The system changes the physical state and properties of the preform by incorporating ferromagnetic or paramagnetic fibers. This parameter change enables the material to respond to magnetic fields, allowing for simplified control and actuation compared to traditional mechanical systems while maintaining high deposition rates even on complex tooling surfaces.
2Manufacturing precision
If electromagnets are arranged in the die to control preform forming, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by arranging electromagnets at specific locations within the die corresponding to the positions of ferromagnetic or paramagnetic fibers in the preform. Each electromagnet can be independently controlled to apply localized magnetic forces, enabling precise forming at specific areas without requiring complex overall die structure. The control device activates electromagnets based on the specific arrangement of magnetic fibers needed for the desired forming contour.
3Ease of operation
If stamp or diaphragm forming is used for composite material forming, then ease of operation is improved, but manufacturing precision deteriorates due to material shear strength limitations
Solution Approach 1:
The patent replaces traditional stamp or diaphragm forming mechanisms with a magnetic field-based system. Instead of applying mechanical force through stamps or diaphragms that are limited by material shear strength, the system uses electromagnets to generate magnetic fields that interact with ferromagnetic or paramagnetic fibers. This allows for precise control of material deformation without exceeding shear strength limits, improving forming accuracy while maintaining operational simplicity through automated control.
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
The system enables accurate, wrinkle-free, and efficient forming of composite materials into complex shapes by minimizing friction and allowing for precise control over the movement and operation of end effectors.
Implementation Method 1
A stator base has a planar stator surface covering an array of electrical coils configured to generate an electromagnetic field. A plurality of movers are associated with the stator base. Each mover has multiple permanent magnets configured to cause the movers to levitate and move relative to the stator surface in response to the electromagnetic field.
Implementation Method 2
Each mover has multiple permanent magnets configured to cause the movers to levitate and move relative to the stator surface in response to the electromagnetic field
Data Source
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AI summary
A manufacturing system (100) includes a stator base (142), a plurality of movers (160), one or more end effectors (200), and a controller (240). The stator base (142) has a planar stator surface (146) covering an array of electrical coils (144) configured to generate an electromagnetic field. The movers (160) each contain multiple permanent magnets configured to cause the movers (160) to levitate and move relative to the stator surface (146) in response to the electromagnetic field. The end effectors (200) are coupled to the movers (160), and each end effector (200) performs one or more functions in relation to a material sheet (300). The controller (240) activates the electrical coils (144) in a manner causing independent, coordinated movement of the movers (160) over the stator surface (146), and causing the end effectors (200) to engage with and operate on the material sheet (300).