Robot End Effector for Carbon Fiber Ply Handling
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Solution Overview
Problem
Robots used in manufacturing environments face challenges in handling limp plies of carbon fiber, as existing end effectors can cause wrinkles and alter the shape of the material during transport and placement, leading to undesirable overlaps and warps in the final composite pre-form.
Innovation Solution
The implementation of enhanced robot end effectors featuring multiple floating cup assemblies with vacuum grippers and Bernoulli cups, which utilize suction to prevent drooping during transport and the Bernoulli principle to allow the ply to float and conform to the mandrel's surface without generating wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional end effectors apply force to hold the ply during transport, then the ply can be held in position, but the force applied may alter the shape of the ply and generate wrinkles
Solution Approach 1:
The patent employs vacuum grippers that utilize vacuum pressure to hold the ply during transport without applying mechanical force that could deform the material. The suction cups create a vacuum field that securely holds the ply in position while allowing it to maintain its natural shape, thus resolving the contradiction between stability and shape accuracy.
Solution Approach 2:
The system dynamically adjusts the vacuum pressure parameters during different phases of operation. During transport, vacuum pressure is applied to maintain position stability. During the shaping phase, the vacuum pressure is reduced or released to allow the ply to conform to the mandrel without restriction, thereby maintaining shape accuracy throughout the process.
2Shape
If the end effector applies force to conform the ply to the mandrel, then the ply can be shaped properly, but wrinkles and overlaps may be generated
Solution Approach 1:
During the shaping phase, vacuum pressure is applied through the suction cups to hold the ply in place while it conforms to the mandrel. This pneumatic holding mechanism allows the ply to naturally drape and conform to the curved surface without the need for mechanical force that could create wrinkles or overlaps.
Solution Approach 2:
The end effector system is designed to be dynamic, transitioning between different vacuum pressure states. The system allows the ply to move and conform during the shaping process while maintaining positional control through regulated vacuum pressure, enabling proper conformance without generating harmful deformations.
3Ease of operation
If the robot transports the limp ply without support, then the transport process is simple, but the ply will hang limp and fold underneath itself
Solution Approach 1:
The vacuum grippers provide distributed support across the ply surface during transport, preventing it from hanging limp or folding. The suction cups create multiple support points that maintain the ply in a flat, stable position throughout the transport process, while the overall operation remains automated and efficient.
4Quantity of substance
If multiple plies are placed on the mandrel to build up composite pre-form, then the desired thickness and structure are achieved, but wrinkles accumulate and compromise the final product
Solution Approach 1:
The vacuum grippers provide consistent, wrinkle-free placement for each ply in the stack. By using vacuum pressure to hold and position each ply uniformly during placement, the system ensures that multiple plies can be accumulated to achieve the desired thickness while maintaining high surface quality and preventing wrinkle accumulation throughout the building process.
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
This solution ensures that the end effector holds the ply in position during shaping without damaging it or creating wrinkles, maintaining the desired shape and preventing the formation of undesirable overlaps, thus improving the quality of the CFRP fabrication process.
Implementation Method 1
The grippers use suction to ensure that the ply does not droop or otherwise hang limp during transport
Implementation Method 2
The Bernoulli cups utilize the Bernoulli principle to enable portions of the ply to float horizontally while held to the end effector
Implementation Method 3
capable of pivoting and deflecting in order to conform the face of the ply to a surface of a mandrel upon which the ply is laid
Data Source
AI summary
Systems and methods are provided for enhancing picking and placement of plies of material. One embodiment is an apparatus that includes an end effector of a robot. The end effector includes a frame, and cup assemblies that are attached to the frame. The cup assemblies each include a shaft and a head. The end effector also includes Bernoulli cups attached to the heads of the cup assemblies, and grippers attached to heads of the cup assemblies.