Preform Shaping Apparatus with Segmented End Effector
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Producing preforms with complex three-dimensional shapes or large curvature often results in fiber wrinkles, zigzagging, and cracking during the shaping of reinforcing fiber base materials like sheet-shaped prepregs.
Innovation Solution
A preform production apparatus and method that uses a stationary mold with a corresponding surface shape and an end effector with adjustable pressure-contact elements to press and shape the reinforcing fiber base material, applying tension and controlling the pressure-contact elements' projection length to prevent wrinkles and cracking, while a control unit moves the end effector to ensure even shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a reinforcing fiber base material is shaped into a complex three-dimensional shape with large curvature, then the preform can achieve the desired shape, but wrinkles and zigzagging of fibers occur during shaping
Solution Approach 1:
The pressing device is divided into multiple pressing members that can independently press different regions of the reinforcing fiber base material. Each pressing member can be adjusted to apply pressure at optimal locations, preventing fiber distortion while achieving complex shapes.
Solution Approach 2:
The pressing members are made movable and adjustable, allowing dynamic adaptation to the complex three-dimensional shape being formed. This enables real-time adjustment of pressing positions and forces to maintain fiber alignment during shaping of large curvature surfaces.
2Shape
If pressure is applied to shape the reinforcing fiber base material, then the preform takes the desired shape, but cracking occurs in the material
Solution Approach 1:
Different pressing members apply different pressing forces and durations to different regions of the reinforcing fiber base material based on local requirements. This localized control prevents excessive pressure that would cause cracking while ensuring adequate shaping pressure where needed.
Solution Approach 2:
The pressing operation is performed in a controlled sequence with preliminary pressing stages that gradually increase pressure. This progressive approach allows the material to adapt to shaping without sudden stress that would cause cracking.
3Manufacturing precision
If the reinforcing fiber base material is evenly pressed, then the preform quality is improved, but the shaping process becomes complex
Solution Approach 1:
The pressing device uses multiple pressing members that can perform multiple functions: pressing, heating, and monitoring. This multi-functionality allows even pressing and high preform quality without requiring separate dedicated devices for each function, thereby managing overall system complexity.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Provided are a preform production apparatus and a preform production method which efficiently produce high quality preforms in which the occurrence of wrinkles, zigzagging of fibers and cracking are limited in production of a preform having a three-dimensional shape. The production apparatus is a preform production apparatus for shaping a reinforcing fiber base material into a specified shape prior to main molding thereof in order to obtain a fiber-reinforced resin molding of a desired shape, the apparatus comprising a stationary mold with a surface shape corresponding to the specified shape an end effector for pressing the reinforcing fiber base material on a surface of the stationary mold; and a control unit for moving the end effector.