Plasma Surface Preparation End Effector for Composite Bonding
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Solution Overview
Problem
Current repair systems for composite parts are largely non-automated, making it inefficient to inspect and repair composite parts, particularly in industrial settings where automation is crucial for efficiency and consistency.
Innovation Solution
A robot end effector system for surface preparation in an automated inspection and repair system, which includes a plasma control unit, a plasma jet nozzle, and a slave tool changer, allowing an industrial robot to move the end effector along a composite part to clean and increase the surface free energy of the composite part using atmospheric plasma.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If non-automated tools are used for inspection and repair of composite parts, then operational flexibility is maintained, but productivity and consistency are reduced
Solution Approach 1:
The end effector is designed with a slave tool changer that enables a single robotic system to perform multiple functions including inspection, surface preparation via plasma treatment, and repair operations. This multi-functional design resolves the contradiction by enabling automation across all repair stages while maintaining the flexibility to switch between different operational modes through tool changes.
Solution Approach 2:
The slave tool changer acts as an intermediary mechanism between the industrial robot and various end effectors. It enables automated tool replacement during repair processes, allowing the system to transition between different automated operations (inspection, plasma treatment, repair) without manual intervention, thereby resolving the contradiction between automation extent and operational flexibility.
2Manufacturing precision
If manual surface preparation is used, then equipment complexity is minimized, but manufacturing precision and surface quality are reduced
Solution Approach 1:
The system replaces manual mechanical surface preparation with automated plasma treatment. The plasma control unit generates atmospheric plasma that chemically treats the composite part surface, providing consistent and precise surface preparation quality. This substitution resolves the contradiction by achieving high manufacturing precision through automated plasma processes while managing device complexity through integrated control systems.
Solution Approach 2:
The plasma control unit enables precise control of plasma treatment parameters (power, gas flow, treatment duration) to optimize surface preparation quality. By adjusting these parameters, the system achieves consistent high-quality surface treatment for bonding preparation, resolving the contradiction between manufacturing precision and device complexity through controllable physical parameter changes.
3Reliability
If automated plasma treatment is implemented, then surface free energy and bonding quality are improved, but energy consumption increases
Solution Approach 1:
The plasma control unit optimizes plasma treatment by adjusting parameters such as power level, gas flow rate, and treatment duration to achieve the minimum effective energy input required for adequate surface preparation. This parameter optimization resolves the contradiction by ensuring reliable bonding quality while minimizing energy consumption through efficient plasma process control.
Solution Approach 2:
The system applies plasma treatment selectively only to the specific surface areas of composite parts that require bonding preparation, rather than treating entire parts or using excessive treatment duration. This partial action approach resolves the contradiction by achieving sufficient surface free energy increase for reliable bonding while reducing overall energy consumption through targeted treatment.
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 efficient and automated inspection and repair of composite parts by effectively cleaning and preparing the surface for bonding, thereby improving the repair process's efficiency and consistency.
Implementation Method 1
The plasma control unit is configured for directing a jet of atmospheric plasma through the plasma jet nozzle
Implementation Method 2
the atmospheric plasma surface preparation end effector is used to treat a surface the composite part... to increase a surface free energy of the composite part
Data Source
AI summary
A robot end effector for surface preparation in an automated inspection and repair system for composite parts has an end effector body and a plasma control unit and a plasma jet nozzle supported on the end effector body. The plasma control unit directs a jet of atmospheric plasma through the plasma jet nozzle. A slave tool changer is secured to the end effector body. The slave tool changer releasably and operatively connects the robot end effector to an industrial robot such that the industrial robot can move the robot end effector along a composite part as the plasma control unit directs a jet of atmospheric plasma through the plasma jet nozzle toward the composite part to clean the composite part and increase a surface free energy of the composite part.