Multi-Faced Vacuum End Effector for Composite Ply Handling
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Solution Overview
Problem
The manual handling and processing of composite material plies in manufacturing are labor-intensive and time-consuming, leading to increased costs and potential material waste, as existing automated solutions struggle to adapt to various ply shapes and sizes without damaging the material.
Innovation Solution
An end effector system with a vacuum source and polygonally arranged gripping surfaces featuring non-smooth portions and multiple vacuum zones, allowing for the secure removal and handling of cut-outs or plies of diverse shapes and sizes, integrated with a robotic arm for automated processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual handling methods are used for ply removal and stacking, then adaptability to various ply shapes is maintained, but labor intensity and processing time increase significantly
Solution Approach 1:
The end effector is designed with multiple gripping surfaces arranged in different orientations, allowing a single tool to handle plies of various shapes and sizes. The polygonal arrangement of gripping surfaces enables the end effector to adapt to different ply geometries without requiring multiple specialized tools, thus resolving the contradiction between versatility and productivity.
2Extent of automation
If automated apparatus is used for ply removal, then labor intensity decreases, but difficulty in gripping various ply shapes without distortion increases
Solution Approach 1:
The end effector is divided into multiple independent gripping surfaces, each capable of independently contacting and supporting different portions of a ply. This segmentation allows the automated system to handle diverse ply shapes by engaging specific gripping surfaces appropriate to each ply geometry, reducing the complexity of the overall gripping mechanism while maintaining high automation.
3Object-affected harmful factors
If vacuum gripping is applied to remove plies, then material damage is minimized, but gripping effectiveness varies with ply shape and size
Solution Approach 1:
Different gripping surfaces of the end effector are optimized for different ply characteristics, with each surface providing locally appropriate vacuum gripping conditions. This allows the system to maintain effective and damage-free gripping across various ply shapes and sizes by selecting the appropriate gripping surface for each specific ply geometry.
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 enables efficient, automated removal and handling of composite material plies, reducing labor costs, minimizing material waste, and preventing distortion, while allowing for precise orientation and stacking of cut-outs, thereby improving manufacturing efficiency and accuracy.
Implementation Method 1
an end effector having a plurality of gripping surfaces with each gripping surface including a plurality of vacuum zones
Data Source
AI summary
An end effector is provided that includes a vacuum source and a plurality of gripping surfaces with each gripping surface including a plurality of vacuum zones having a non-smooth portion for distributing a vacuum, and a plurality of openings defined over the non-smooth portion for distributing the vacuum on the gripping surface using the vacuum source. The plurality of gripping surfaces is generally arranged in a polygonal shape. The plurality of vacuum zones are generally configured to grip cut-outs having a plurality of shapes. Methods are also provided for removing a cut-out from a sheet of material using an end effector having a plurality of gripping surfaces