Multi-Robot Prepreg Layup for Collision-Free 3D Mold Draping
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Solution Overview
Problem
The current manual process of laying down prepreg sheets on complex-shaped molds is time-intensive, labor-intensive, and prone to variability and defects due to human factors, resulting in low throughput and high labor costs.
Innovation Solution
A robotic system that automates the prepreg sheet layup process by generating collision-free trajectories and coordinating movements between multiple robots to conform and place prepreg layers on complex molds, minimizing human intervention and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual hand layup is used to drape prepreg sheets on complex molds, then fiber alignment and material placement can be achieved, but the process is time-intensive and has low throughput
Solution Approach 1:
The patent replaces manual mechanical hand layup operations with an automated robotic system that uses computer-controlled mechanisms to drape and conform prepreg sheets. The robotic system employs automated shear and compression loads applied by robotic arms, eliminating manual labor while maintaining precise fiber alignment through programmable motion control and real-time monitoring.
2Ease of manufacture
If manual hand layup is used by human operators, then prepreg sheets can be draped on complex molds, but labor costs are high and there is part-to-part variability
Solution Approach 1:
The robotic system performs self-service by automatically monitoring and adjusting its own operations through integrated sensors and control systems. The system uses real-time feedback from sensors to maintain consistent draping quality across multiple parts, eliminating human variability and ensuring repeatable results without continuous human intervention.
3Productivity
If automated robotic systems are used for prepreg layup, then throughput increases, but coordinating multiple robots without collisions becomes complex
Solution Approach 1:
The patent implements a centralized control system that uses real-time feedback from sensors monitoring the positions and movements of multiple robotic arms. This feedback mechanism enables the control system to dynamically adjust robot trajectories and speeds, coordinating their movements to prevent collisions while maintaining high throughput. The system continuously monitors and responds to the state of each robot and the prepreg sheet being manipulated.
Data Source
AI summary
Methods, systems, and robots for multi-layer prepreg composite sheet layup. The robotic system may include a memory for storing a dataset including start and end point pairs of a mold of a 3D part that defines a layup sequence, a first robot or a first robot arm that is configured to conform a prepreg layer or sheet onto the mold of the 3D part, and a second robot or a second robot arm that is configured to hold or grasp the prepreg layer or sheet above the mold of the 3D part and stretch or relax the prepreg layer or sheet when the first robot or the first robot arm conforms the prepreg layer or sheet onto the mold. The robotic system may also include one or more processors connected to the first robot or the first robot arm and the second robot or the second robot arm.