Automated Fiber Placement Tape Control Module Lateral Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current automated fiber placement (AFP) machines have limitations in productivity, requiring additional tape supplies to increase laydown rate, which complicates the head and reduces flexibility due to difficulties in steering a larger head.
Innovation Solution
The method involves adjusting the lateral position of tape control modules automatically according to preprogrammed instructions, allowing for staggered tape courses and dynamic adjustment of tape positions to increase laydown efficiency and adapt to complex contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additional tape supplies are added to increase laydown rate, then productivity is improved, but device complexity increases and flexibility is reduced
Solution Approach 1:
The patent implements dynamically adjustable tape control modules that can laterally shift their positions during operation. This dynamic capability allows a fixed number of modules to achieve variable bandwidth output, eliminating the need for additional fixed tape supplies while maintaining high laydown rates. The modules can adapt their configuration in real-time to match part geometry requirements.
Solution Approach 2:
The tape application head is divided into multiple independently controllable tape control modules, each capable of lateral adjustment. This segmentation allows flexible reconfiguration of the bandwidth without adding overall head complexity, as each module operates semi-independently and can be positioned optimally for different part geometries.
2Productivity
If additional tape supplies are added to increase laydown rate, then productivity is improved, but ease of operation is reduced due to steering difficulties
Solution Approach 1:
Each tape control module is equipped with lateral adjustment mechanisms that enable dynamic repositioning during the laydown process. This dynamic capability allows the head to be steered more easily by adjusting individual module positions rather than moving the entire large head assembly, significantly improving ease of operation while maintaining high productivity.
Solution Approach 2:
By segmenting the head into independently adjustable modules, the steering operation is simplified from moving a single large mass to adjusting smaller, lighter modules individually or in groups, reducing the mechanical burden and improving operational ease.
3Productivity
If head size is increased to accommodate more tape supplies, then productivity is improved, but adaptability is reduced
Solution Approach 1:
The patent employs dynamically reconfigurable tape control modules that can change their lateral positions during operation. This dynamic adaptability allows a compact head design to achieve variable bandwidth output, maintaining productivity while improving adaptability to different part geometries and contours.
Solution Approach 2:
The system changes the operational parameters of the tape control modules, specifically their lateral positions, to adapt to different part requirements. This parameter adjustment capability allows a single head configuration to perform multiple functions across different applications, enhancing versatility without increasing head size.
4Productivity
If head size is increased to accommodate more tape supplies, then productivity is improved, but device complexity is reduced
Solution Approach 1:
The head is segmented into modular tape control units that can be independently controlled and adjusted. This modular segmentation allows the system to achieve high productivity through coordinated operation of multiple simple units rather than through a single complex large-scale mechanism, effectively reducing overall device complexity while maintaining high laydown rates.
Data Source
AI summary
A composite part is formed by a composite tape application machine that lays up a plurality of tapes on a substrate. The lateral position of the tapes may be adjusted as the tapes are being laid up.