Robotic Creel Loader Automates Spool Replenishment
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Solution Overview
Problem
The process of replacing empty spools with full spools in a creel of a fiber placement machine is time-consuming and inefficient, especially when dealing with multiple spools, as it requires manual intervention and takes significant time to complete.
Innovation Solution
A robotic system is implemented to load a spool magazine that automatically removes empty spool cores from the creel and replaces them with full spools, utilizing turret mechanisms and a robot to streamline the spool replenishment process, allowing for simultaneous transfer of multiple spools in a short time frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual spool replacement is used in the creel, then the machine can operate with simple equipment, but the productivity decreases due to time-consuming spool replacement
Solution Approach 1:
The creel loader is equipped with an automatic spool magazine that can self-load spools into the creel without manual intervention. The system uses automated mechanisms including spool pushers, core grippers, and turret rotations to automatically replace spools, transforming a manual operation into an autonomous self-service system that eliminates operator involvement in spool replacement
Solution Approach 2:
The spool magazine pre-stores multiple spools in readiness before they are needed. The system prepares spools in advance by loading them into the magazine during non-critical periods, and when replacement is needed, the pre-positioned spools can be quickly deployed to the creel without delay for manual handling or preparation
2Extent of automation
If a robot system with spool magazine is implemented, then the spool replacement automation increases, but the device complexity increases
Solution Approach 1:
The creel loader is designed as a multi-functional device that combines robot operations, spool magazine storage, automatic spool pushing, core gripping and removal, and turret rotation mechanisms into a single integrated system. This universal device performs multiple functions that would otherwise require separate equipment, managing complexity through functional integration rather than proliferation of separate systems
Solution Approach 2:
The system employs nested structures where the spool magazine is positioned within or adjacent to the creel loader, the turret mechanisms are integrated into the magazine structure, and the core grippers are nested within the spool handling path. This nesting approach consolidates multiple components into compact arrangements, reducing spatial complexity while maintaining automation functionality
Data Source
AI summary
An apparatus for loading spools into a creel of a fiber placement machine that is used to charge a mold includes a creel loader and a spool magazine carried by the creel loader. At least one loader mandrel in the spool magazine receives full spools and transfers the full spools to the creel of the fiber placement machine.