Prepreg Lay-up Position Correction for Composite Laminates
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Solution Overview
Problem
Automatic lay-up machines face quality degradation of prepreg laminates due to displacement of prepreg sheets caused by internal stress, leading to inconsistent gaps and reduced strength in the final laminate.
Innovation Solution
A lay-up-position correcting method that adjusts the position of the prepreg sheet with respect to the lay-up head in the width direction by determining deviations and moving the head device to cancel displacement, applying tension, and repositioning the raw-cloth roller, ensuring accurate alignment and tension management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the raw-cloth roller is positioned to coincide with the receiving surface in the width direction at the start of lay-up, then the initial alignment is accurate, but the prepreg sheet becomes displaced during the lay-up process due to internal stress
Solution Approach 1:
The invention applies preliminary action by detecting the edge position of the prepreg sheet before the lay-up operation begins and calculating the deviation from the target position. This allows the system to pre-correct the position of the raw-cloth roller and lay-up head, compensating for internal stress effects before they cause displacement during the actual lay-up process.
Solution Approach 2:
The invention implements feedback by using an edge detector to continuously monitor the position of the prepreg sheet edge relative to the target position. The system calculates the deviation and automatically adjusts the position of the raw-cloth roller and lay-up head to cancel the displacement, creating a closed-loop control system that maintains accurate alignment throughout the lay-up process.
2Productivity
If the prepreg sheet is wound around the raw-cloth roller with tension applied, then the sheet can be supplied continuously, but non-uniform tension distribution causes internal stress and displacement in the width direction
Solution Approach 1:
The system uses feedback control to detect the actual position of the prepreg sheet edge and calculate the deviation from the target position. Based on this feedback, the system automatically adjusts the position of the raw-cloth roller and lay-up head to compensate for displacement caused by non-uniform tension distribution during continuous winding and supply operations.
Solution Approach 2:
The invention changes the position parameters of the raw-cloth roller and lay-up head dynamically during the lay-up process. By adjusting these parameters based on detected edge position deviations, the system compensates for internal stress effects while maintaining continuous supply operations.
3Productivity
If the lay-up head presses the prepreg sheet against the receiving surface, then the prepreg is laid up effectively, but the displacement accumulates and exceeds allowable values
Solution Approach 1:
The invention performs preliminary position correction by detecting the edge position of the prepreg sheet and calculating the deviation before the lay-up operation begins. The system pre-adjusts the position of the raw-cloth roller and lay-up head to cancel the expected displacement, preventing gap inconsistency before it occurs during the lay-up process.
Solution Approach 2:
The system implements feedback control to continuously monitor the position of the prepreg sheet edge and automatically adjust the position of the lay-up head and raw-cloth roller. This feedback mechanism prevents displacement accumulation and maintains consistent gaps between adjacent prepreg sheets during efficient lay-up operations.
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
Prevents quality degradation by maintaining accurate alignment of prepreg sheets during the lay-up process, ensuring consistent gaps and improved strength of the prepreg laminate.
Implementation Method 1
determining a deviation between a position of an edge of the prepreg sheet and a lay-up position in the width direction
Implementation Method 2
a state in which a predetermined tension is applied to the prepreg sheet
Data Source
AI summary
An automatic lay-up machine includes a head device and a support mechanism. The head device includes a sheet supplying unit that supplies a prepreg sheet including sheet-shaped prepreg and release paper bonded to a surface of the prepreg, a lay-up unit that lays up the prepreg on a receiving surface by pressing the prepreg sheet against the receiving surface, and a sheet take-up unit that takes up the release paper separated from the prepreg. The support mechanism supports the head device and includes a mechanism for moving the head device in a lay-up direction of the prepreg and a width direction of the prepreg sheet. The head device is moved in the width direction while a position of an edge of the prepreg sheet coincides with a lay-up position and an end portion of the prepreg sheet is pressed against the receiving surface.