Radius Filler Extrusion Controller for Composite Groove Deposition
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Solution Overview
Problem
Conventional radius-filler application techniques for composite structures are slow and inefficient, leading to excessive manufacturing lead time, high costs, complex fabrication, and large-footprint requirements.
Innovation Solution
An apparatus and method for in-situ radius-filler manufacturing and deposition, which includes a chassis with sensors and a controller to dynamically adjust the geometric characteristics of the radius filler to match the groove's shape, ensuring precise fitting and compacting, thereby reducing manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional radius-filler application techniques are used, then the filling process can be completed, but the manufacturing lead time becomes excessive and productivity is low
Solution Approach 1:
The patent replaces conventional mechanical application techniques with an automated extrusion system that uses a controller to regulate material flow and a sensor system to monitor groove geometry in real-time, enabling continuous automated operation that significantly improves productivity while reducing manufacturing lead time
Solution Approach 2:
The system performs self-adjustment through the controller that automatically regulates extrusion parameters based on sensor feedback about groove geometry, eliminating the need for manual intervention and enabling continuous operation that improves manufacturing efficiency and reduces lead time
2Ease of manufacture
If conventional radius-filler application techniques are used, then the filling process can be completed, but the cost becomes high
Solution Approach 1:
The apparatus integrates multiple functions into a single system: the extrusion means deposits filler material, the sensor means measures groove geometry, and the controller coordinates all operations automatically. This multi-functional integration simplifies the manufacturing process while reducing overall costs by eliminating the need for separate operations and manual labor
Solution Approach 2:
The sensor means provides real-time feedback about groove geometry to the controller, which automatically adjusts extrusion parameters to optimize material usage and ensure proper filling. This closed-loop control prevents material waste and rework, reducing manufacturing costs while maintaining process simplicity
3Device complexity
If conventional radius-filler application techniques are used, then the filling process can be completed, but the fabrication becomes complex
Solution Approach 1:
The sensor means continuously measures groove geometry and provides feedback to the controller, which automatically adjusts extrusion parameters to ensure precise filler deposition that matches the actual groove dimensions. This real-time feedback control achieves high manufacturing precision while keeping the fabrication process manageable through automated control
Solution Approach 2:
The controller dynamically changes extrusion parameters such as material flow rate, extrusion speed, and nozzle positioning based on sensor feedback about groove geometry. This automatic parameter adjustment ensures precise filler deposition that conforms to varying groove dimensions without requiring complex manual fabrication procedures
4Area of stationary object
If conventional radius-filler application techniques are used, then the filling process can be completed, but the footprint requirement becomes large
Solution Approach 1:
The patent combines the extrusion means, sensor means, and controller into an integrated apparatus that performs multiple operations simultaneously. This merging of functions into a single compact system reduces the equipment footprint while maintaining high productivity through coordinated automated operation of all components
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
The solution enables efficient, cost-effective, and precise deposition of radius fillers with desired lengths and cross-sectional shapes, addressing the inefficiencies of conventional methods by allowing real-time adjustment and quality assurance during the deposition process.
Implementation Method 1
first means for extruding the radius filler along an extrusion axis
Implementation Method 2
third means for compacting the radius filler in the groove
Data Source
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AI summary
An apparatus (100) for depositing a radius filler (102), made of a homogeneous material, into a groove (104), formed in a workpiece (106) comprises a chassis (110), first means (120) for extruding the radius filler (102) along an extrusion axis, second means (130) for providing the homogeneous material to the first means (120), and third means (140) for compacting the radius filler (102) in the groove (104). The apparatus (100) also comprises a first sensor configured to provide first-sensor output. The apparatus (100) further comprises a controller, operatively coupled to the first means (120), the second means (130), and the first sensor. Based on the first-sensor output, the controller is configured to determine the first geometric characteristics of the groove (104). In addition, based on the first geometric characteristics, the controller is configured to control second geometric characteristics of the radius filler (102), extruded by the first means (120), as the tool center point is moved relative to the groove (104).