Resilient End Effector for Flexible Sheet Pre-shaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automated end effector solutions for handling flexible sheets, such as carbon fiber mats, face challenges with complexity, lack of dexterity, and increased risk of air pockets or bubbles when stacking on complex or curved surfaces, leading to reduced quality and higher scrap rates in composite component manufacturing.
Innovation Solution
An end effector system comprising a support frame with manipulator assemblies, linear actuators, multiaxial joints, and resilient members that allow for precise pre-shaping and orientation of sheets to fit complex layup surfaces, using linear actuators to apply pushing forces and resilient members to adjust the orientation of holding tools for improved fit and reduced air pocket formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional automated end effector solutions are used for handling flexible sheets, then automation is achieved, but the structure becomes complex and lacks dexterity for complex surfaces
Solution Approach 1:
The end effector is divided into multiple independent holding tools (first, second, third, fourth holding tools) that can be individually controlled by separate linear actuators. Each holding tool can be displaced independently along its displacement axis, allowing the system to achieve complex sheet manipulation through coordinated action of simpler, modular components rather than a single complex mechanism.
2Manufacturing precision
If holding tools are displaced relative to each other to pre-shape sheets, then sheet conformability to complex surfaces improves, but air pockets or bubbles may form between sheets
Solution Approach 1:
The system performs preliminary pre-shaping of the sheet by displacing holding tools to specific positions that conform the sheet to the target complex surface geometry before final placement. This preliminary action ensures the sheet is pre-formed to match the layup surface contours, reducing the risk of air pocket formation during subsequent bonding operations.
Solution Approach 2:
The resilient members provide continuous mechanical feedback between adjacent holding tools, allowing the system to sense and respond to sheet deformation and positioning requirements in real-time. This feedback mechanism enables automatic adjustment of holding tool positions to maintain optimal sheet contact and minimize air pocket formation during the pre-shaping process.
3Manufacturing precision
If resilient members are positioned between adjacent holding tools, then sheet pre-shaping capability improves, but device complexity increases
Solution Approach 1:
Resilient members are positioned between adjacent holding tools to act as mechanical intermediaries that transmit and balance forces during sheet pre-shaping operations. These resilient members enable coordinated displacement of multiple holding tools while automatically compensating for variations in sheet properties and tool positioning, reducing the need for complex active control systems.
4Measurement precision
If linear actuators are used to displace holding tools, then positioning precision improves, but device complexity and cost increase
Solution Approach 1:
Multiple linear actuators are designed with identical structures and control characteristics, allowing them to perform the same positioning function for different holding tools. This universal design simplifies the overall system architecture by using standardized components rather than custom-designed mechanisms for each actuator, reducing complexity while maintaining high positioning precision through coordinated control of multiple identical units.
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 precise pre-shaping and application of sheets on complex surfaces, reducing air bubbles and improving the quality and yield of composite components by providing a controlled and stiff structure that can handle curved surfaces with low radii of curvature, thus enhancing manufacturing efficiency and reducing scrap rates.
Implementation Method 1
the resilient members are configured to non-permanently deform in the space when adjacent holding tools are displaced relative to each other
Implementation Method 2
each linear actuator is configured to apply a pushing force at the distal coupling part
Data Source
AI summary
An end effector for handling a sheet of flexible material. The end effector includes a support frame and manipulator assemblies, each attached to the support frame by a support mount. The manipulator assemblies include a holding tool having a lifting surface. The manipulator assemblies include a linear actuator, and the holding tool is connected to the linear actuator by a multiaxial joint. A drive provides—the displacement of the holding tool by the linear actuator. The end effector includes resilient members each rigidly affixed to two adjacent holding tools and positioned in a space providing a mutual distance between opposing faces of the adjacent holding tools, where each holding tool is connected to—adjacent holding tools—by the resilient members. The resilient members are configured to non-permanently deform in the space when adjacent holding tools are displaced relative to each other along displacement axes.