Robotic End Effector for Ceramic Composite Ply Placement
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Solution Overview
Problem
The placement of ceramic matrix composite plies on layup tools, especially over curved surfaces, results in variable quality and inconsistencies due to manual or partially automated methods, leading to increased life cycle time and rework.
Innovation Solution
A system and method utilizing a robotic manipulator with an end effector that includes a base, an arm, a base-gripper, and an arm-gripper to pick up and place ceramic matrix composite plies on a forming-surface, allowing for controlled draping over non-planar surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual or partially automated Pick-and-Place tools are used for placing ceramic matrix composite plies, then the placement operation can be performed, but the quality becomes variable and inconsistent especially over curved surfaces
Solution Approach 1:
The patent replaces manual mechanical Pick-and-Place tools with a robotic system that uses vacuum-based end effectors. The robotic manipulator provides automated, consistent placement while the vacuum gripping surfaces ensure uniform compression and contact with the forming surface, eliminating the variability associated with manual operations.
Solution Approach 2:
The end effector incorporates vacuum zones and gripping surfaces that use vacuum pressure to hold and compress the ceramic matrix composite ply during placement. This pneumatic mechanism ensures consistent contact and compression force distribution, particularly effective on curved and non-planar forming surfaces.
2Productivity
If manual or partially automated methods are used for ply placement, then the process can be completed, but the life cycle time increases due to inspection and rework requirements
Solution Approach 1:
The robotic Pick-and-Place system automates the entire placement process, eliminating manual operations and their associated time losses. The system performs placement with high precision and consistency, reducing or eliminating the need for inspection and rework, thereby shortening the overall life cycle time.
Solution Approach 2:
The robotic system enables continuous automated placement operations without the interruptions inherent in manual processes. The vacuum-based end effector maintains continuous contact and compression during placement, ensuring quality from the first ply to the last without requiring stopping for inspection or correction.
3Area of stationary object
If ceramic matrix composite plies are placed over curved surfaces using traditional methods, then coverage is achieved, but compaction becomes inconsistent
Solution Approach 1:
The end effector uses vacuum pressure distributed across multiple gripping zones to compress the ceramic matrix composite ply against curved forming surfaces. The vacuum mechanism adapts to the surface geometry, ensuring uniform contact and consistent compaction force distribution across the entire ply area, regardless of surface curvature.
Solution Approach 2:
The end effector is divided into multiple vacuum zones or gripping surfaces that can independently adapt to different portions of the curved forming surface. This segmentation allows each zone to maintain optimal contact and compression force, ensuring uniform compaction across complex geometries.
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 approach enables precise placement and draping of ceramic matrix composite plies on complex surfaces, reducing defects and increasing efficiency, thereby shortening the life cycle time for placement and compaction.
Implementation Method 1
an end effector that includes a vacuum source and a plurality of gripping surfaces with each gripping surface including a plurality of vacuum zones
Data Source
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AI summary
A method includes steps of: (1) positioning an end effector relative to a ply of the ceramic composite material, wherein the end effector includes: a base; an arm that is coupled to and movable relative to the base; a base-gripper that is coupled to the base; and an arm-gripper that is coupled to the arm; (2) adhering the base-gripper to a first ply-portion of the ply; (3) adhering the arm-gripper to a second ply-portion of the ply; (4) moving the end effector relative to a forming-surface such that the first ply-portion of the ply is placed on a first surface-portion of the forming-surface; and (5) moving the arm relative to the base and to the forming-surface such that the second ply-portion is placed on a second surface-portion of the forming-surface, wherein the first surface-portion and the second surface-portion are non-coplanar.