Mobile Composite Layup Robot with Vacuum Pickup
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Solution Overview
Problem
Current methods for laying up and compacting composite prepreg plies are either labor-intensive and inaccurate, or require expensive and complex automated systems that need intricate programming and supervision, and are not suitable for complex or elongate structures with contoured surfaces.
Innovation Solution
A mobile system with a robot-manipulated vehicle that supplies and compact composite plies on a tool, featuring a ply supply, transfer platen, compactor, and inspection device, capable of precise alignment and compaction along elongate tools with minimal human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hand layup method is used, then labor intensity is high and accuracy is poor, but equipment cost is low
Solution Approach 1:
The system uses self-contained robotic end effectors with integrated vacuum pickup systems that automatically pick up plies, transfer them to the tool, and compact them without human intervention. The mobile vehicle autonomously navigates to positioned drawers and executes the layup sequence programmatically.
Solution Approach 2:
Manual mechanical operations are replaced with automated robotic systems. The robotic end effectors use vacuum-based pickup instead of manual handling, and automated compaction mechanisms replace manual rolling or pressing operations.
2Extent of automation
If automated fiber placement machine is used, then automation level is high and placement accuracy is good, but equipment cost is high and complexity is high
Solution Approach 1:
The system is divided into modular components: a mobile vehicle platform, multiple positionable drawers containing individual plies, robotic end effectors for pickup and compaction, and a guidance system. Each component performs a specific function and can be independently controlled or replaced.
Solution Approach 2:
The mobile vehicle serves multiple functions: it transports plies from drawers to the tool, positions the robotic end effectors, provides compaction capability, and navigates autonomously. The end effectors perform both pickup and compaction operations.
3Ease of operation
If ply carrier/transfer medium is used, then transfer capability is improved, but foreign object debris risk increases and production cost increases
Solution Approach 1:
The patent eliminates the intermediate ply carrier or transfer membrane from the process. Instead, the robotic end effectors directly pick up plies from the drawers and place them onto the tool surface, removing the potential source of foreign object debris associated with carrier materials.
Solution Approach 2:
The vacuum pickup system acts as a clean intermediary mechanism, using suction to hold and transfer plies without physical contact with carrier materials. The vacuum field transfers the ply directly from the drawer to the tool surface.
4Extent of automation
If pick and place end effectors are used, then automation level is partially improved, but ability to compact over contoured surfaces is lost
Solution Approach 1:
The system employs compliant end effectors with flexible pickup surfaces that can adapt to contoured tool surfaces. The mobile vehicle can position and orient the end effectors dynamically to match the tool geometry, and the compaction mechanism applies force adaptively to ensure proper consolidation over complex shapes.
Solution Approach 2:
The end effectors can change their physical parameters such as contact pressure, pickup force, and positioning coordinates to accommodate different tool geometries. The system adjusts compaction force and platen position to match the local surface curvature.
5Reliability
If manual supervision is used, then process control is maintained, but production rate is reduced and labor cost increases
Solution Approach 1:
The system incorporates sensors and control systems that monitor the layup process in real-time, tracking ply placement accuracy, compaction force application, and vehicle positioning. This automated feedback control maintains process reliability without requiring human supervision.
Solution Approach 2:
The mobile vehicle and robotic systems perform all operations autonomously based on pre-programmed sequences and real-time sensor feedback, eliminating the need for human operators to monitor or intervene in the layup process.
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 solution increases production rate, improves placement accuracy, and ensures consistent compaction of laminates on complex surfaces, reducing production costs and minimizing foreign object debris.
Implementation Method 1
the vacuum pickup system includes a plurality of perforations in the ply engaging face through which air may be drawn forming a vacuum that draws a ply against the ply engaging face
Data Source
AI summary
A mobile vehicle is used to place, compact and inspect composite plies at selected locations on a tool. The vehicle includes an on-board supply of composite plies, a transfer platen for transferring plies to the tool, a compactor for compacting plies on the tool, and an inspection device for inspecting plies on the tool, each operated and manipulated by an on-board manipulator such as a robot.