Segmented Compaction Roller for Composite Fiber Placement
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Solution Overview
Problem
Existing compaction roller designs for automated fiber placement machines lack sufficient compliance and uniformity in applying compaction force, especially for parts lacking radial symmetry, leading to inadequate pressure distribution and material consolidation.
Innovation Solution
A compaction tool with a series of thin cylindrical segments, each with a movable and rotatable outer periphery, driven by pressure bladders or pistons, allowing for independent movement to apply uniform pressure across complex shapes and varying dimensions, and connected via fluid pressure to ensure consistent force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-diameter outer surface compaction tool is used, then the structure is simple, but the compaction force cannot be evenly applied to parts lacking radial symmetry
Solution Approach 1:
The compaction tool is divided into multiple segments (first segment, second segment, third segment, fourth segment) that can move independently relative to each other. Each segment is actuated by its own bladder, allowing differential movement to accommodate parts without radial symmetry while maintaining overall structural simplicity through modular design.
2Adaptability or versatility
If segmented compaction tools with fixed central portions are used, then the structure allows some movement, but the central portion cannot move sufficiently to compact material in areas with significant diameter changes
Solution Approach 1:
All segments including the central segment are designed to be movable rather than fixed. The central segment can move in response to bladders expansion/contraction, enabling the entire compaction tool to dynamically adapt to significant diameter changes in the part being compacted, thereby providing adequate compaction pressure throughout.
3Ease of operation
If outer rollers with low friction surfaces are used, then the rollers can rotate easily, but the compliance and pressure distribution are insufficient for complex part geometries
Solution Approach 1:
Each segment incorporates a flexible outer covering that can deform to conform to the part surface geometry. This flexible covering works in conjunction with the movable segments and bladders to provide both easy rotation and uniform pressure distribution across complex part geometries, resolving the contradiction between rotational ease and pressure uniformity.
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 tool achieves enhanced material consolidation with improved pressure distribution and compliance, ensuring stronger and more uniform composite parts by adapting to the shape and contour of the part being fabricated, even in areas with significant dimension changes.
Implementation Method 1
a first and a second bladder extending through apertures in the plurality of segments on either side of the shaft, wherein each of the plurality of segments is separately movable perpendicularly with respect to the shaft in response to a shape of the article and a pressure in the first or second bladder
Data Source
AI summary
Tools for compacting composite parts are disclosed. These tools are used while layers of composite material, such as tows or laminae, are being deposited onto a fabricating surface, such as a mold or other forming tool. The compacting tool is typically divided into a series of narrow segments, each segment able to advance or retreat individually so as to conform to the surface of a composite part being formed. Pressurized fluid, such as air or hydraulic fluid, or non-pressurized internal bladders with incompressible fluid, are used to evenly apply pressure to the segments in order to compact the material with which the tool and the segments are in contact. The compacting tool thus helps eliminate voids and helps the material conform to the desired shape on the forming tool.