Composite Preform Placement on Mandrels Using Coordinated PNP Machines
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Solution Overview
Problem
The placement of multi-layer preforms for composite parts is a time-consuming process, whether manual or automated, which hampers the speed of composite part manufacturing.
Innovation Solution
A system and method utilizing coordinated control of pick-and-place (PNP) machines to place preforms onto a mandrel, where PNP machines operate in tandem for large objects and independently for smaller objects, enhancing the speed of layup and fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple preforms are placed together onto a mandrel for curing, then complex composite parts can be manufactured, but the placement process becomes substantially time-consuming
Solution Approach 1:
The mandrel is divided into multiple stations, each responsible for placing specific preforms. This segmentation allows parallel processing where multiple preforms are placed simultaneously at different stations rather than sequentially at a single location, thereby reducing total placement time while maintaining the capability to manufacture complex multi-layer composite parts
Solution Approach 2:
The system transitions from a single-location sequential placement approach to a multi-station parallel placement approach, effectively adding the dimension of spatial distribution along the mandrel. This allows multiple PNP machines to operate simultaneously at different stations, increasing throughput without sacrificing the ability to create complex composite structures
2Speed
If PNP machines operate in tandem for large objects, then placement speed increases, but system complexity increases
Solution Approach 1:
A controller serves as an intermediary that coordinates the operation of multiple PNP machines. The controller manages the complex interactions between tandem-operating machines by providing centralized control logic, allowing the system to achieve high placement speeds through coordinated operation while the controller absorbs the complexity of managing multiple machines working together
3Adaptability or versatility
If PNP machines operate independently for smaller objects, then system flexibility increases, but placement efficiency decreases
Solution Approach 1:
The system is designed to be dynamic, allowing PNP machines to switch between independent and coordinated operation modes based on the size and type of objects being placed. This dynamic adaptability enables the system to optimize for flexibility when handling smaller objects or for efficiency when handling larger objects, with the controller managing the transition between operational modes
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 approach significantly increases the speed of preform placement and composite part fabrication by optimizing the use of PNP machines, allowing for increased work density and parallel processing operations.
Implementation Method 1
applying a vacuum that holds the preform in contact with the strong back
Data Source
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AI summary
Systems and methods are provided for placing preforms onto a mandrel. One illustrative method includes moving a mandrel in a process direction relative to a station that comprises multiple pick-and-place (PNP) machines, identifying a tray that stores a preform comprising an unhardened fiber-reinforced material, placing the strong back at the preform via at least one of the PNP machines, applying a vacuum to hold the preform in contact with the strong back, transporting the preform to a mandrel via the PNP machines, and placing the preform onto the mandrel.