Parallel Lamination Units for High-Speed Composite Layup

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Solution Overview

Problem

Current Flat Tape Laying Machine (FTLM) techniques are time-consuming and incapable of high throughput for laying up flat laminates, requiring repositioning and reorientation for each layer, leading to inefficiencies and increased costs due to the need for batch production and storage of composite parts.

Innovation Solution

A system with sequential lamination units that cut and place pieces of fiber-reinforced material onto a surface, allowing multiple layers to be laid up simultaneously, eliminating the need for repositioning and reorientation, and utilizing pick-and-place devices controlled by sensors and a controller for precise placement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a single FTLM head is used to lay up layers sequentially, then the equipment complexity is reduced, but the productivity and fabrication speed decrease significantly

Engineering Contradiction:

Improvelayup speedVSAvoidnumber of lamination units

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides the layup process into multiple parallel lamination units (first, second, third lamination units), each capable of independently laying up layers. This segmentation allows simultaneous operation of multiple units, dramatically increasing productivity while maintaining manageable complexity through modular architecture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple lamination units are combined to operate in parallel on the same laminate, with each unit contributing to different layers. This merging of parallel operations achieves high throughput by laying up multiple layers simultaneously, resolving the contradiction between productivity and device complexity

Inventive Principle:

Principle #5Merging (Combining)

2Loss of time

If the FTLM head repositions itself for each new course of material, then the equipment remains simple and flexible, but the layup time increases substantially

Engineering Contradiction:

Improverepositioning timeVSAvoidcoordination system

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

Multiple lamination units are pre-positioned at different locations along the laminate before the layup process begins. Each unit is prepared with its material supply and cutting mechanism ready, eliminating the need for repositioning during operation. This preliminary positioning resolves the time loss from repositioning while maintaining system flexibility

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical repositioning system is replaced with a coordinated multi-unit system where each unit remains stationary. The controller synchronizes the operation of multiple fixed units, substituting mechanical movement with coordinated stationary operation, thereby eliminating repositioning time

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of time

If the FTLM head is reoriented after each layer, then the equipment maintains versatility for different fiber orientations, but the layup process becomes time-consuming

Engineering Contradiction:

Improvereorientation timeVSAvoidmulti-unit coordination

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The system segments the layup task across multiple lamination units, with each unit specialized for specific fiber orientations. This allows different units to handle different orientations simultaneously without requiring any single unit to reorient, eliminating reorientation time while maintaining versatility through distributed specialization

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each lamination unit is designed with universal capability to lay up material at various angles, and the controller coordinates them to handle different fiber orientations. This multi-functionality at the unit level, combined with coordinated operation, eliminates the need for reorientation while preserving versatility for different laminate designs

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If batch production with storage and freezing machinery is used, then the layup speed can be maintained, but the associated costs and space requirements increase

Engineering Contradiction:

Improvelayup throughputVSAvoidstorage and freezing system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple lamination units operate continuously in parallel, laying up layers without interruption or batch processing. This continuous parallel operation achieves high throughput inherently, eliminating the need for batch production and associated storage/freezing infrastructure, thereby reducing device complexity and costs while maintaining productivity

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS10710318B2High speed composite layup via multiple machines

Publication Date: 2020.07.14 THE BOEING CO

AI summary

Systems and methods are provided for laying up laminates. One embodiment is a method that includes laying up a multi-layer laminate of fiber reinforced material onto a surface, by: feeding a tape of fiber reinforced material to tape cutters which cut the tape into pieces, picking up pieces of the fiber reinforced material via pick-and-place devices at each of multiple lamination units that are in sequence in a direction of travel, and placing the pieces of fiber reinforced material via the pick-and-place devices to form a laminate as the surface and the lamination units change position with respect to each other and multiple pieces are laid-up concurrently.