Vacuum Take-Up Drum for Composite Fabric Handling
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Solution Overview
Problem
The manual handling of reinforcement fabrics in composite aircraft manufacturing is labor-intensive, prone to variations, and poses risks to personnel and material damage, limiting efficiency and consistency in composite production.
Innovation Solution
A gantry-type frame assembly with a movable robotic arm and a vacuum take-up drum system that securely picks up, rolls, and positions reinforcement fabrics, allowing for precise orientation and handling of fabrics, reducing manual labor and minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling of reinforcement fabrics is used, then flexibility and adaptability are maintained, but labor intensity increases and manufacturing precision decreases
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic system featuring a programmable arm that can pick, transport, and place fabric plies. The robotic system includes sensors and control mechanisms that eliminate manual labor while maintaining precise handling capabilities, directly resolving the contradiction between productivity improvement and reduction of manual labor intensity.
Solution Approach 2:
The system enables self-service through automated fabric handling where the robotic apparatus independently performs picking, transporting, and placing operations without continuous human intervention. The programmable control system allows the apparatus to autonomously manage the lay-up process, improving productivity while minimizing manual labor requirements.
2Manufacturing precision
If manual handling of reinforcement fabrics is used, then adaptability to different configurations is maintained, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The robotic system replaces manual positioning with automated control mechanisms that provide consistent, repeatable fabric placement. The programmable arm follows predetermined paths and uses sensors to ensure accurate orientation, eliminating the variability inherent in manual operations while maintaining high manufacturing precision across different fabric configurations.
Solution Approach 2:
The system incorporates feedback mechanisms through sensors that monitor fabric position and orientation during the lay-up process. This feedback allows the robotic control system to make real-time adjustments, ensuring consistent precision in fabric placement and orientation while eliminating the variability associated with manual operations.
3Reliability
If manual handling of large fabric plies is used, then flexibility in handling is maintained, but risk of injury and material damage increases
Solution Approach 1:
The robotic system replaces manual handling of large, heavy fabric plies with an automated apparatus designed to safely manage these materials. The robotic arm and associated mechanisms are specifically configured to handle large fabric sizes without posing injury risks to personnel, while the automated control reduces the likelihood of material damage through consistent, controlled movements.
Solution Approach 2:
The robotic system acts as an intermediary between the fabric material and the manufacturing process, eliminating direct human contact with large, potentially hazardous materials. This intermediary approach enhances safety by removing personnel from direct interaction with heavy fabrics while maintaining the necessary handling flexibility through programmable robotic movements.
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 method enables efficient, precise, and safe handling of reinforcement fabrics, ensuring proper orientation and sequencing, which enhances the structural integrity and consistency of composite materials, reducing labor costs and improving manufacturing efficiency.
Implementation Method 1
a vacuum take-up drum system that securely picks up, rolls, and positions reinforcement fabrics
Data Source
AI summary
An apparatus and accompanying method for handling fabrics used in the construction of composite components and in particular those used in aircraft includes a movable, gantry-type frame assembly having a movable robotic arm attached thereto. A drum assembly, attached to the robotic arm has one or more vacuum ports disposed along the surface of the drum. When vacuum from within the drum is applied to the ports and the drum is moved to contact flexible fabric material—such as the reinforcement fabric used for composite manufacture—an end of the fabric may be picked up through the effect of the applied vacuum and the fabric rolled-up around the drum. The movable gantry and/or the robotic arm may then move the drum to a desired location where the fabric is unrolled and prepared for composite manufacture. Variations to the vacuum ports permit the rolling and transport of a variety of materials and shapes.