Vacuum Preform Placement and Compaction on Curved Rigid Tools
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Solution Overview
Problem
Large preforms struggle to remain secured on complex curved rigid tooling surfaces without peeling or shifting during placement and compaction, necessitating rework, and traditional methods like tacky tape are not suitable for composite material layup.
Innovation Solution
A two-phase vacuum system is employed to generate suction holds for picking and placing preforms onto rigid tools, ensuring secure compaction through a first phase for transport and a second phase for final placement, utilizing impermeable and permeable membranes to maintain vacuum without sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preforms are placed onto complex curved rigid tools without immediate compaction, then the layup process can be completed, but peeling or shifting occurs during or after placement
Solution Approach 1:
The vacuum system is activated during the layup process itself, creating a preliminary suction hold that secures preforms to the rigid tool immediately as they are placed. This preliminary action prevents peeling and shifting before compaction is complete, eliminating the need to wait until layup is finished to begin securing the preforms.
Solution Approach 2:
The vacuum suction hold operates continuously throughout the entire process from placement through compaction, maintaining constant securing force on the preforms. This continuous action ensures preforms remain firmly attached to the rigid tool at all times, preventing any peeling or shifting during the transition from placement to compaction.
2Reliability
If traditional vacuum bagging methods are used with contact-approved materials, then the process is safe for uncured composite material, but the entire layup must be completed prior to compaction
Solution Approach 1:
An impermeable membrane serves as an intermediary between the vacuum system and the uncured composite preforms. This membrane allows vacuum suction to be applied safely during the layup process without direct contact between the vacuum bagging materials and the uncured composite, enabling early compaction while maintaining process safety.
Solution Approach 2:
The impermeable membrane is installed and the vacuum system is activated during the layup process itself, performing the compaction function preliminarily rather than waiting until layup completion. This preliminary compaction action improves productivity by overlapping the compaction preparation with the layup execution.
3Adaptability or versatility
If large preforms are placed on sloped surfaces, then coverage of complex surfaces is achieved, but the preforms cannot support themselves and are prone to peeling
Solution Approach 1:
A vacuum suction system uses pneumatic pressure differential to secure large preforms to sloped and complex curved surfaces. The suction force counteracts gravity and prevents peeling on inclined surfaces, providing stable attachment regardless of the rigid tool's orientation or surface geometry.
Solution Approach 2:
The vacuum suction hold is established immediately during placement as a preliminary securing action, preventing preforms from peeling or shifting on sloped surfaces before they can be compacted. This preliminary stabilization ensures positional stability throughout the compaction process.
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 system effectively secures preforms to rigid tools quickly and efficiently, reducing peeling and rework by allowing immediate compaction during placement, eliminating the need for time-consuming tape application and reducing labor delays.
Implementation Method 1
applying a negative pressure via an end effector that is sufficient to offset any air leaks between a first portion of the impermeable membrane and the object, thereby forming a suction hold that secures the object to the impermeable membrane
Data Source
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AI summary
Systems and methods are provided for vacuum handling of composite parts. One embodiment is a method for picking up, placing, and compacting an object. The method includes covering a part of an object with an impermeable membrane, applying a negative pressure via an end effector that is sufficient to offset any air leaks between a first portion of the impermeable membrane and the object, thereby forming a suction hold that secures the object to the impermeable membrane, and transporting the object to a rigid tool while the suction hold is retained. The method further comprises applying a negative pressure via the end effector that offsets air leaks between a second portion of the impermeable membrane and the rigid tool, thereby forming a suction hold that compacts the object to the rigid tool.