Self-threading lamination head for composite layup
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Solution Overview
Problem
Conventional lamination heads for composite laminate manufacturing face inefficiencies due to excessive off-part movement and time-consuming tape threading processes, leading to increased production flow time and downtime.
Innovation Solution
A lamination head with self-threading capability and bi-directional layup capability, featuring a material supply drum, backing layer collection drum, and separation assembly that automatically threads and separates the backing layer from the layup material, reducing manual intervention and off-part movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the lamination head is configured to rotate 180 degrees at the end of a first course to lay up a second course, then the lamination head can apply layup material in opposite directions, but the complexity of the lamination system increases due to the need to rotate the entire weight of the lamination head, material supply, support cabling, and other associated components
Solution Approach 1:
The lamination head is divided into a stationary head portion and a movable carriage portion. The carriage can move independently along the tape path without requiring rotation of the entire lamination head assembly. This segmentation allows bi-directional layup while keeping the main system structure simple and stationary.
Solution Approach 2:
The lamination head is designed with universal support structures and cabling arrangements that can accommodate tape feeding in both forward and reverse directions without requiring physical reconfiguration or rotation of the head assembly. The support cabling is routed to provide flexibility for bidirectional operation.
2Productivity
If the lamination head lifts off of the layup surface and moves back over the layup surface in a second direction of travel to start applying another course, then the lamination head can apply layup material in side-by-side parallel relation, but the off-part movement adds to production flow time
Solution Approach 1:
The lamination head maintains continuous contact with the layup surface throughout the layup process. The carriage moves along the tape path in a continuous manner without lifting off the surface, eliminating idle movement time and maintaining productive action throughout the operation.
Solution Approach 2:
The system uses a dynamic carriage mechanism that can move forward and reverse along the tape path while maintaining contact with the layup surface. This dynamic positioning capability allows the head to efficiently traverse the work area without requiring lifting and repositioning operations.
3Ease of operation
If manual threading of the tape is performed after each material roll changeout, then the tape can be threaded through the lamination head components, but the threading process is time-consuming and results in significant lamination head downtime
Solution Approach 1:
The lamination head incorporates a self-threading mechanism with automatic tape guides and tensioning devices that automatically thread the tape through the head components when a new material roll is installed. This eliminates the need for manual threading operations and reduces downtime during roll changes.
Solution Approach 2:
Automatic tape guides and tensioning devices serve as intermediaries to facilitate the threading process. These components automatically direct the tape through the necessary paths and maintain proper tension, eliminating the need for manual intervention in the threading operation.
4Extent of automation
If the backing layer collection drum moves from a collection drum home position to a collection drum engagement position to engage the backing layer leading edge, then the backing layer can be automatically threaded, but additional movement mechanisms are required
Solution Approach 1:
The backing layer collection drum is designed with dynamic positioning capability, allowing it to move between a home position and an engagement position. This dynamic adjustment enables the drum to automatically engage the backing layer leading edge for threading while maintaining a compact overall structure.
Solution Approach 2:
The collection drum is positioned and prepared in advance to engage the backing layer leading edge automatically when needed. This preliminary positioning enables seamless automatic threading operations without requiring complex real-time adjustment mechanisms during the threading process.
Data Source
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AI summary
A lamination head has a material supply drum, a backing layer collection drum, and a backing layer separation assembly. The material supply drum supports a material roll of backed material comprising layup material backed by a backing layer. The backing layer collection drum moves from a collection drum home position to a collection drum engagement position proximate the material supply drum, engage a backing layer leading edge on the material roll, and moves back to the collection drum home position while dispensing a threadable portion of at least the backing layer. The backing layer separation assembly has a backing layer separation device and a backing layer separation mechanism. The backing layer separation device translates from a separation device home position to a separation device engagement position and pulls the threadable portion into proximity to the backing layer separation mechanism for separating the backing layer from the layup material.