Multi-Robot Prepreg Layup for Complex 3D Mold Conforming
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Solution Overview
Problem
The manual layup of prepreg composite 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 layup process by generating collision-free trajectories and instructions for multiple robots to conform and place prepreg layers on complex molds, minimizing human intervention and reducing defects through coordinated movements and controlled grasping and releasing of the prepreg layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual hand layup is used to place prepreg sheets on complex molds, then human operators can manually apply shear and compression loads to conform the material, but the process becomes time-intensive with low throughput and high labor costs
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that uses controlled mechanical forces. The robotic arm applies shear and compression loads through automated tools to conform prepreg sheets to complex mold geometries, eliminating manual labor while maintaining the necessary mechanical actions for proper material placement and fiber alignment.
2Ease of operation
If manual hand layup is used to place prepreg sheets on complex molds, then human operators can adjust and conform the material, but the process results in part-to-part variability due to human factors
Solution Approach 1:
The automated robotic system incorporates feedback mechanisms through programmable control that precisely replicate the optimal manual conforming process for each part. The system uses pre-programmed trajectories, forces, and sequences based on engineering data to ensure consistent application of shear and compression loads, eliminating variability introduced by different human operators and achieving uniform part quality across production batches.
3Productivity
If automated robotic systems are used to place prepreg sheets, then labor costs decrease and throughput increases, but the system must generate collision-free trajectories for multiple robots
Solution Approach 1:
The patent divides the automated layup process into distinct operational phases and assigns different robotic systems to specific tasks. One robotic arm is dedicated to holding and positioning the prepreg sheet, while another robotic arm performs the conforming and placement operations. This segmentation allows each robot to operate independently with simplified control algorithms, avoiding the complexity of coordinating multiple robots performing all functions simultaneously.
4Manufacturing precision
If prepreg sheets are draped onto complex mold geometry, then the desired fiber orientations can be achieved, but the relatively inextensible material must be carefully manipulated to avoid damage
Solution Approach 1:
The robotic conforming system employs dynamic, adaptive motion control that adjusts the application of shear and compression loads in real-time based on the mold geometry and material response. The system uses controlled, progressive deformation through programmed trajectories that gradually drape the prepreg sheet over complex surfaces, maintaining fiber orientations within specified tolerances while preventing excessive stresses that could damage the material.
Data Source
AI summary
Methods, systems, and robots for multi-layer prepreg composite sheet layup. The method includes obtaining a dataset including start and end point pairs of a mold of the 3D part. The method includes generating a layup sequence based on the dataset and generating multiple trajectories for one or more movements of the first robot or the first robot arm based on the layup sequence. The method includes causing a second robot or a second robot art to hold or grasp the prepreg layer or sheet a threshold distance above the mold or the 3D part. The method includes causing the first robot or the first robot arm to place or conform the prepreg layer or sheet to the mold of the 3D part.