Planar Maglev Pick-and-Place for Wrinkle-Free Composite Forming
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Solution Overview
Problem
Current methods for forming composite materials into complex shapes are inefficient, prone to wrinkles, and limited by shear strength, leading to suboptimal product quality and increased production time.
Innovation Solution
A manufacturing system featuring a stator base with electromagnetic coils and levitated movers, allowing for coordinated, precise movement of end effectors to engage and form composite materials into complex shapes without manual handling, thereby reducing wrinkles and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated lamination machines (ALMs) are used for automated application of composite material, then productivity is improved, but device complexity increases and material deposition rate decreases with increased complexity of tooling surface
Solution Approach 1:
The patent replaces traditional mechanical ALM systems with a magnetic field-based planar motor system. The planar motor uses electromagnetic forces to levitate and move movers across the tooling surface, eliminating complex mechanical transmission mechanisms while maintaining automated material deposition capability. This substitution resolves the contradiction by improving productivity through automated control without the complexity of mechanical linkages.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the actuator and the mover. The electromagnetic field generated by the stator coils interacts with permanent magnets in the movers to achieve contactless actuation. This intermediary enables precise control of material deposition rate while avoiding the mechanical complexity of direct-drive systems.
2Device complexity
If manual handling of plies is used for forming composite material, then device complexity is reduced, but manufacturing precision deteriorates due to wrinkles from manual handling
Solution Approach 1:
The patent replaces manual mechanical handling with an automated planar motor system that uses electromagnetic forces to position and form composite plies. The system maintains simplicity by using a flat stator surface with coil arrays rather than complex mechanical forming apparatus, while achieving high manufacturing precision through automated control of mover positions and forces applied to the material.
Solution Approach 2:
The planar motor system enables self-service automation where the system automatically positions, transports, and forms composite plies without human intervention. The electromagnetic field automatically controls the movers to follow programmed paths and apply precise forces, eliminating wrinkles and surface defects that occur with manual handling while keeping the device structure relatively simple.
3Device complexity
If stamp or diaphragm forming is used for forming composite materials, then device complexity is reduced, but manufacturing precision is limited by material shear strength
Solution Approach 1:
The patent replaces traditional mechanical stamp and diaphragm forming mechanisms with a planar motor system that uses electromagnetic forces to manipulate composite plies. This substitution maintains device simplicity by using a flat stator with coil arrays instead of complex mechanical linkages, while dramatically improving manufacturing precision by enabling the formation of complex three-dimensional shapes through controlled magnetic forces that do not rely on material shear strength.
Solution Approach 2:
The patent changes the fundamental parameter of force application from mechanical contact (stamp/diaphragm) to electromagnetic field interaction. The planar motor can apply distributed forces through the magnetic field to gradually form complex shapes without exceeding material shear strength limits, enabling high manufacturing precision for complex geometries while keeping the device structure simple.
4Productivity
If levitated movers are used in the planar motor system, then friction is minimized improving productivity, but use of energy increases due to electromagnetic field generation
Solution Approach 1:
The patent replaces mechanical friction-based actuation with electromagnetic levitation and propulsion. The planar motor uses electromagnetic fields to levitate movers above the stator surface and propel them along programmed paths, eliminating friction entirely. This substitution improves productivity through high-speed, high-precision movement while the energy consumption is managed through efficient coil control and regenerative braking during deceleration.
Solution Approach 2:
The planar motor system uses periodic activation of coil groups to propel movers along the stator surface. By sequentially energizing coils in a traveling wave pattern, the system achieves continuous motion with minimized energy consumption. The periodic action allows for efficient energy utilization through pulsed field generation rather than continuous energization.
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 time-efficient formation of composite materials into complex shapes, overcoming limitations of existing methods by minimizing friction and maximizing material utilization.
Implementation Method 1
a planar motor system including a stator base having a planar stator surface covering an array of electrical coils configured to generate an electromagnetic field
Implementation Method 2
a plurality of movers, each containing 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
AI summary
A manufacturing system includes a stator base, a plurality of movers, one or more end effectors, and a controller. The stator base has a planar stator surface covering an array of electrical coils configured to generate an electromagnetic field. The movers each contain multiple permanent magnets configured to cause the movers to levitate and move relative to the stator surface in response to the electromagnetic field. The end effectors are coupled to the movers, and each end effector perform one or more functions in relation to a material sheet. The controller activates the electrical coils in a manner causing independent, coordinated movement of the movers over the stator surface, and causing the end effectors to engage with and operate on the material sheet.