Weaving Assembly for Complex Contour Engine Components
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Solution Overview
Problem
Traditional methods for manipulating woven structures into molds with varying contours often weaken the structures and are inefficient in producing complex shapes, particularly for components like ceramic matrix composites used in jet engines.
Innovation Solution
A weaving method utilizing a wand, base, and warp fiber arms with positional controllers to move and position warp fibers relative to each other and a fill fiber, allowing for the formation of picks and the creation of complex contours by crossing and securing warp fibers over the fill fiber, while enabling the base to move in three dimensions and rotate around axes to match the mold shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional manipulation techniques are used to shape woven structures for molds with varying contours, then the structures can be formed into complex shapes, but the woven structures are weakened
Solution Approach 1:
The patent changes the fundamental parameters of the weaving process by enabling continuous fiber reinforcement with variable orientation and density. The fiber placement can be adjusted in real-time to match complex mold contours while maintaining structural integrity through controlled fiber routing and tension management during the weaving process.
2Ease of manufacture
If existing weaving methods are used for planar woven assemblies, then the structures are simple to manufacture, but they are difficult to manipulate into molds with varying contours
Solution Approach 1:
The invention introduces dynamic capabilities to the weaving system through computer-controlled fiber placement mechanisms that can continuously adjust fiber orientation, density, and routing. This allows the woven structure to adapt to complex three-dimensional mold contours while maintaining manufacturing efficiency through automated control systems.
Solution Approach 2:
The patent transitions from two-dimensional planar weaving to three-dimensional contour-following weaving by enabling fiber placement in multiple spatial dimensions. The system can route fibers along complex spatial paths and create varying fiber angles and densities to match the geometry of molds with varying contours.
3Device complexity
If traditional pick-by-pick weaving is used, then the process is simple to control, but the productivity is low for high-volume production
Solution Approach 1:
The invention implements continuous fiber reinforcement processes where fibers are laid down without interruption in a continuous motion sequence. This eliminates the stop-and-start nature of traditional pick-by-pick weaving, enabling high-speed automated production while maintaining precise control through computerized scheduling and coordination of multiple weaving operations.
Data Source
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AI summary
An exemplary weaving method includes placing a first section of a fill fiber between warp fibers, forming a pick, moving a base to reposition the warp fibers, and placing a second section of the fill fiber between the warp fibers.