Modular Fibre Placement Tool Segments
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Solution Overview
Problem
Current metallic fibre placement tools are stiffness-limited, leading to difficulties in controlling and manufacturing long, thin composite fibre components, requiring frequent tool replacement due to damage or design changes, and resulting in restricted component length and increased mass.
Innovation Solution
A modular fibre placement tool composed of removably mounted tool segments on elongate shafts, with high-density foam and composite fibre reinforcement, allowing for adjustable geometry and increased stiffness without the mass constraints of traditional metallic tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic placement tools are used, then structural strength is maintained, but mass increases and stiffness is insufficient for long components
Solution Approach 1:
The placement tool uses composite construction with a metallic shaft and foam tool segments. The shaft provides structural strength and stiffness, while the foam segments provide the necessary geometry and reduce overall mass. This composite approach resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The tool is divided into modular segments that can be independently attached to the shaft. This segmentation allows the tool to achieve the required geometry for long components while using lightweight foam material instead of solid metallic construction, reducing mass while maintaining necessary strength.
2Reliability
If metallic placement tools are used, then durability is maintained, but flexibility for design changes is reduced
Solution Approach 1:
The tool segments are made as separate, removable components that can be easily replaced or reconfigured on the shaft. This modular design provides flexibility for design changes while maintaining the durability of the metallic shaft structure.
Solution Approach 2:
The tool transitions from a static, monolithic metallic structure to a dynamic, reconfigurable modular system. The segments can be added, removed, or repositioned along the shaft to adapt to different component designs, providing versatility while maintaining structural reliability.
3Strength
If metallic placement tools are used, then structural integrity is maintained, but manufacturing precision is compromised due to deflection
Solution Approach 1:
The metallic shaft provides the necessary structural integrity and stiffness to prevent deflection, while the foam segments provide the precise geometry required for manufacturing. This composite structure resolves the contradiction by separating the structural and geometric functions.
Solution Approach 2:
By segmenting the tool and using foam segments with precise geometry, the design achieves manufacturing precision without requiring the entire tool to be made of heavy metallic material, thereby maintaining structural integrity through the shaft while enabling precise component formation.
4Strength
If metallic placement tools are used, then strength is maintained, but device complexity increases due to monolithic construction
Solution Approach 1:
The tool is segmented into modular components that can be independently manufactured and assembled. This reduces construction complexity compared to monolithic metallic tools, as each segment can be optimized separately and the assembly process is simpler than machining a single large component.
Solution Approach 2:
The composite construction with distinct shaft and segment components simplifies the manufacturing process compared to producing a single monolithic metallic tool. Each component can be manufactured using appropriate processes for its material, and assembly is straightforward, reducing overall device complexity.
Data Source
AI summary
A fiber placement tool comprising a plurality of tool segments, each tool segment having an outer surface defining a predetermined profile, each tool segment being removably mounted on at least one elongate shaft.