Composite Preform Placement on Mandrels Using Coordinated PNP Machines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The placement of preforms for composite parts, such as Carbon Fiber Reinforced Polymer (CFRP), is a time-consuming process, especially when fabricating complex parts, as it requires manual or automated alignment and curing of multiple layers, which slows down the manufacturing speed.
Innovation Solution
A system and method utilizing coordinated control of pick-and-place (PNP) machines to efficiently place preforms onto a mandrel, where PNP machines operate in tandem for larger objects and independently for smaller ones, enhancing the speed of layup and fabrication by synchronizing automated and manual operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple preforms are placed manually or with single PNP machines, then placement precision can be maintained, but manufacturing speed decreases
Solution Approach 1:
The system divides the placement task into segments handled by multiple PNP machines working in parallel. Each PNP machine handles specific preforms or regions, allowing simultaneous placement operations across different locations on the mandrel, thereby increasing overall manufacturing speed while maintaining precision through coordinated control.
Solution Approach 2:
Multiple PNP machines are merged into a coordinated system under unified control. The system integrates the operations of multiple machines to work together on the same mandrel, combining their capabilities to achieve high-speed placement while maintaining the precision of individual machines through synchronized coordination.
2Device complexity
If PNP machines operate independently, then system complexity is reduced, but placement coordination for large objects deteriorates
Solution Approach 1:
The control system dynamically adapts its coordination mode based on object size and placement requirements. For large objects requiring high precision, the system activates coordinated control mode where multiple PNP machines work synchronously with integrated positioning. For smaller objects, the system transitions to independent operation mode, reducing control complexity while maintaining sufficient placement accuracy.
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 reduces the time required for placing preforms, thereby increasing the manufacturing speed and efficiency of composite part fabrication by optimizing the use of PNP machines in both synchronous and asynchronous modes.
Implementation Method 1
applying a vacuum that holds the preform in contact with the strong back
Data Source
Figure 1
Figure 2
Figure 3
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.