Reversible Blade Insert for Automated Fiber Placement Cutter
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Solution Overview
Problem
Automated fiber placement (AFP) systems face high costs and downtime due to cutter blade wear and breakage, as existing designs have single cutting edges that require frequent replacement.
Innovation Solution
The AFP cutter blade assembly features a reversible blade insert with two cutting edges that can be configured to alternate between active and inactive positions, extending the usable lifespan and allowing for quick reconfiguration without replacing the blade.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a single cutting edge is used on the cutter blade, then the blade structure is simple, but the blade lifespan is short and frequent replacement is required
Solution Approach 1:
The blade is segmented into a blade body and a separate insert with multiple cutting edges. The insert can be detached and repositioned to expose different cutting edges, allowing the blade to be used multiple times before replacement is needed.
Solution Approach 2:
The blade design allows dynamic reconfiguration by rotating the insert to different positions, enabling the system to adapt and continue operation with a different cutting edge when one becomes worn or damaged.
2Reliability
If cutter blades are frequently replaced due to wear and breakage, then the blade can maintain cutting performance, but system downtime increases and operational costs rise
Solution Approach 1:
Multiple cutting edges are prepared in advance on the same insert. When one cutting edge becomes worn or damaged, another ready-to-use cutting edge is already available on the insert, eliminating the need for immediate blade replacement and reducing system downtime.
Solution Approach 2:
Instead of discarding the entire blade when one cutting edge fails, the design allows recovery and reuse of the blade body by repositioning the insert to expose a different cutting edge, thereby extending the operational life of the blade.
3Productivity
If a reversible blade insert with multiple cutting edges is used, then blade lifespan is extended and downtime is reduced, but the blade assembly complexity increases
Solution Approach 1:
The blade assembly is designed to perform multiple functions by incorporating several cutting edges on a single insert. The same blade assembly can cut different materials or handle different cutting requirements by simply repositioning the insert, eliminating the need for multiple separate blades.
4Ease of operation
If the cutting edge is exposed and operable, then cutting function is active, but the other cutting edge becomes inactive and disabled
Solution Approach 1:
The blade assembly allows dynamic switching between different cutting edges by rotating the insert to different positions. This enables the system to transition from one active cutting edge to another, maintaining operational readiness while providing flexibility in cutting edge selection.
Data Source
AI summary
Automated fiber placement (AFP) cutter blade assemblies, AFP cutter systems including the same, and associated methods. An AFP cutter blade assembly includes a blade base and a reversible blade insert configured to be coupled to the blade base in either of a first cutter blade configuration, in which a first cutting edge is an active cutting edge, and a second cutter blade configuration, in which a second cutting edge is the active cutting edge. In examples, an AFP cutter system includes a plurality of AFP cutter blade assemblies in combination with an actuator assembly. In examples, a method of reconfiguring a reversible blade insert of an AFP cutter blade assembly includes uncoupling the reversible blade insert from a blade base, rotating the reversible blade insert relative to the blade base, and operatively coupling the reversible blade insert to the blade base in a different configuration.