Adaptive Ply Manipulation Tool Module for Composite Handling
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Solution Overview
Problem
The manual handling and stacking of composite plies in manufacturing processes are labor-intensive and time-consuming, leading to increased costs and potential health risks, and existing automated solutions struggle to adapt to various ply shapes and sizes without damaging the material.
Innovation Solution
A modular ply manipulation tool module with shuttles, grippers, and clamping elements that can adjust to different ply shapes and sizes, using lead screws and nut assemblies to position grippers accurately and maintain tension, allowing for automated removal and storage of composite plies without displacing the remaining material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated apparatus is used to remove and handle composite plies, then productivity and labor safety are improved, but the device complexity increases and adaptability to various ply shapes is reduced
Solution Approach 1:
The automated apparatus is divided into modular components including a robotic arm, end effector with grippers, and tensioning mechanisms. Each module performs a specific function (positioning, gripping, tensioning) allowing independent optimization and simplifying the overall system architecture while maintaining high productivity
Solution Approach 2:
The end effector is designed with adjustable grippers and universal mounting interfaces that can accommodate various ply shapes and sizes. The same apparatus can handle different composite material configurations through programmable robot control and adjustable mechanical components, reducing device complexity while improving adaptability
2Device complexity
If fixed-position grippers are used in the automated apparatus, then device complexity is reduced, but adaptability to various ply shapes and manufacturing precision are worsened
Solution Approach 1:
The gripper positions are made dynamically adjustable through the robotic arm's multi-axis movement capabilities. The end effector can be positioned at different locations and orientations according to the specific ply geometry being handled, allowing high adaptability without requiring complex fixed-position mechanisms for each possible configuration
3Loss of time
If automated ply removal is implemented, then labor costs and cycle time are reduced, but the risk of displacing skeleton or remaining composite sheet material increases
Solution Approach 1:
The apparatus performs preliminary positioning and gripping actions before ply removal. The robotic arm precisely positions the grippers on the ply edges, and tensioning mechanisms are pre-engaged to secure the ply before extraction, preventing displacement of the skeleton or remaining material during the removal process
Solution Approach 2:
Manual handling mechanics are replaced with controlled robotic mechanics that offer higher precision and consistency. The automated system uses programmed movement paths and controlled gripping forces to reliably remove plies without the variability and risk associated with manual handling, improving both speed and material integrity
4Device complexity
If tension is not maintained on large composite plies during removal, then device complexity is reduced, but manufacturing precision and material quality are worsened due to ply damage
Solution Approach 1:
Tensioning mechanisms serve as intermediary elements between the grippers and the ply material. These mechanisms maintain controlled tension on large plies during removal and transfer, preventing damage while the robotic arm handles the ply. The tensioning system adds minimal complexity but significantly improves ply integrity
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 solution enables efficient, automated handling of composite plies, reducing labor costs and health risks while maintaining material integrity by adapting to various shapes and sizes, thereby improving the efficiency and safety of the manufacturing process.
Implementation Method 1
The tool module includes a lead screw with a first lead screw portion and a second lead screw portion extending in opposite directions along the longitudinal axis
Implementation Method 2
a first nut assembly threaded on the first lead screw portion and a second nut assembly threaded on the second lead screw portion such that rotating the lead screw moves the nut assemblies toward and away from one another
Data Source
AI summary
Various adaptive apparatus and systems for automated handling of components such as composite plies are provided. In one embodiment, a ply manipulation tool module is provided that comprises a first shuttle including a first gripper and a first clamping element, and a second shuttle including a second gripper and a second clamping element. The first and second shuttles move with respect to one another along a path to position the first and second grippers to grip a ply and to position the first and second clamping elements outside the ply. In a particular embodiment, the ply manipulation tool module includes a lead screw and nut assemblies, the nut assemblies moving along the lead screw to position one or more grippers for gripping components. Ply manipulation tool assemblies comprising at least two modules also are provided.