U.S. patent application number 15/632524 was filed with the patent office on 2018-12-27 for systems and methods of forming a composite layup structure.
The applicant listed for this patent is General Electric Company. Invention is credited to Thomas Kluge, Andreas Lutz, Sultan Shair.
Application Number | 20180370159 15/632524 |
Document ID | / |
Family ID | 62599529 |
Filed Date | 2018-12-27 |
United States Patent
Application |
20180370159 |
Kind Code |
A1 |
Lutz; Andreas ; et
al. |
December 27, 2018 |
SYSTEMS AND METHODS OF FORMING A COMPOSITE LAYUP STRUCTURE
Abstract
A layup system for use in forming a composite layup structure
from a plurality of plies of composite material, wherein an
outermost ply of composite material has a removable film adhered
thereto. The system includes a robotic device and an end effector
coupled to the robotic device. The end effector includes a layer of
compressible material configured to compress the plurality of plies
of composite material together when positioned over the composite
layup structure. The end effector further includes a first suction
device configured to grip the removable film adhered to the
outermost ply of composite material. The robotic device is
configured to translate the end effector relative to the composite
layup structure such that the removable film is peeled from the
outermost ply of composite material while the first suction device
grips the removable film.
Inventors: |
Lutz; Andreas; (Freising,
DE) ; Shair; Sultan; (Ismaning, DE) ; Kluge;
Thomas; (Lenggries, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Family ID: |
62599529 |
Appl. No.: |
15/632524 |
Filed: |
June 26, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 156/1989 20150115;
B29C 70/54 20130101; B29C 70/34 20130101; B29K 2105/256 20130101;
B32B 3/263 20130101; Y10T 156/1168 20150115; B25J 15/0616 20130101;
B32B 7/14 20130101; B29C 70/38 20130101; B32B 43/006 20130101; Y10T
156/1978 20150115 |
International
Class: |
B29C 70/34 20060101
B29C070/34; B29C 70/38 20060101 B29C070/38; B32B 7/14 20060101
B32B007/14; B32B 3/26 20060101 B32B003/26 |
Claims
1. A layup system for use in forming a composite layup structure
from a plurality of plies of composite material, wherein an
outermost ply of composite material has a removable film adhered
thereto, said system comprising: a robotic device; and an end
effector coupled to said robotic device, said end effector
comprising: a layer of compressible material configured to compress
the plurality of plies of composite material together when
positioned over the composite layup structure; and a first suction
device configured to grip the removable film adhered to the
outermost ply of composite material, wherein said robotic device is
configured to translate said end effector relative to the composite
layup structure such that the removable film is peeled from the
outermost ply of composite material while said first suction device
grips the removable film.
2. The system in accordance with claim 1, wherein said end effector
further comprises a rigid plate coupled to said layer of
compressible material.
3. The system in accordance with claim 1, wherein said layer of
compressible material has an opening defined therein, and wherein
said first suction device is sized for insertion within said
opening such that said first suction device is positioned for
gripping the removable film.
4. The system in accordance with claim 1, wherein said layer of
compressible material is defined by a central portion and an outer
edge portion, and wherein said first suction device is positioned
at said outer edge portion of said layer of compressible
material.
5. The system in accordance with claim 1 further comprising a
biasing mechanism coupled to said first suction device, wherein
said biasing mechanism is configured to translate said first
suction device relative to said end effector.
6. The system in accordance with claim 1, wherein the plurality of
plies of composite material are stacked unevenly such that the
composite layup structure has a non-uniform thickness, and wherein
said layer of compressible material is configured to conform to a
contour of the composite layup structure when positioned over the
composite layup structure.
7. The system in accordance with claim 1, wherein said robotic
device is configured to translate in a first direction to initiate
separation of the removable film from the outermost ply of
composite material, and wherein said robotic device is configured
to translate in a second direction, different from the first
direction, to peel the removable film from the outermost ply of
composite material.
8. The system in accordance with claim 1 further comprising a
heater thermally coupled to said layer of compressible material,
wherein said heater is configured to increase a temperature of said
layer of compressible material.
9. The system in accordance with claim 1 further comprising: a work
surface having at least one aperture defined therein, wherein the
composite layup structure is positionable over said at least one
aperture; and a second suction device in communication with said at
least one aperture, wherein said second suction device is
configured to hold the composite layup structure in position on
said work surface.
10. An end effector for use in forming a composite layup structure
from a plurality of plies of composite material, wherein an
outermost ply of composite material has a removable film adhered
thereto, said end effector comprising: a rigid plate; a layer of
compressible material coupled to said rigid plate, wherein said
layer of compressible material is configured to conform to a
contour of the composite layup structure, and is configured to
compress the plurality of plies of composite material together,
when positioned over the composite layup structure; and a first
suction device coupled to said rigid plate, wherein said first
suction device is configured to grip the removable film adhered to
the outermost ply of composite material such that the removable
film is peelable from the outermost ply of composite material when
the end effector translates relative to the composite layup
structure while said first suction device grips the removable film;
wherein said layer of compressible material has an opening defined
therein, and wherein said first suction device is sized for
insertion within said opening such that said first suction device
is positioned for gripping the removable film.
11. (canceled)
12. The end effector in accordance with claim 10, wherein said
layer of compressible material is defined by a central portion and
an outer edge portion, and wherein said first suction device is
positioned at said outer edge portion of said layer of compressible
material.
13. The end effector in accordance with claim 10 further comprising
a biasing mechanism coupled to said first suction device, wherein
said biasing mechanism is configured to bias said first suction
device against the removable film.
14. The end effector in accordance with claim 10 further comprising
a heater thermally coupled to said layer of compressible material,
wherein said heater is configured to increase a temperature of said
layer of compressible material.
15. A method of forming a composite layup structure from a
plurality of plies of composite material, wherein an outermost ply
of composite material has a removable film adhered thereto, said
method comprising: positioning an end effector over the composite
layup structure, wherein the end effector includes a layer of
compressible material and a first suction device; applying pressure
to the composite layup structure with the end effector such that
the layer of compressible material conforms to a contour of the
composite layup structure, and such that the layer of compressible
material compresses the plurality of plies of composite material
together; gripping the removable film with the first suction
device; and translating the end effector relative to the composite
layup structure such that the removable film is peeled from the
outermost ply of composite material while the first suction device
grips the removable film.
16. The method in accordance with claim 15 further comprising
orienting the end effector such that the first suction device grips
a peripheral edge of the removable film.
17. The method in accordance with claim 15 further comprising
heating the layer of compressible material to an increased
temperature.
18. The method in accordance with claim 15, wherein translating the
end effector comprises: translating the end effector in a first
direction to initiate separation of the removable film from the
outermost ply of composite material; and translating the end
effector in a second direction, different from the first direction,
to peel the removable film from the outermost ply of composite
material.
19. The method in accordance with claim 15 further comprising:
stacking a plurality of plies of composite material on a work
surface to form the composite layup structure, wherein the work
surface has at least one aperture defined therein, and wherein the
plurality of plies are stacked over the at least one aperture; and
drawing a vacuum through the at least one aperture such that the
composite layup structure is held on the work surface.
20. The method in accordance with claim 19, wherein stacking a
plurality of plies comprises stacking the plurality of plies
unevenly such that the composite layup structure has a non-uniform
thickness.
Description
BACKGROUND
[0001] The present disclosure relates generally to manufacturing
composite structures and, more specifically, to systems and methods
of forming a composite layup structure with an integral ply
compaction and film removal tool.
[0002] Composite laminate components generally include a plurality
of layers or plies of composite material assembled together to
provide the composite component with improved engineering
properties. Composite components are typically manufactured by
stacking a plurality of plies on top of each other until a desired
thickness and shape is achieved. For example, the manufacturing
process typically includes cutting plies of composite material to a
desired shape, stacking the plies layer by layer, and compacting
the plies after each additional ply is layered over the previously
stacked plies. The plies of composite material may be produced with
a removable polyfilm that extends over at least one side of the
plies, and that facilitates maintaining separation between stacked
plies in storage. During manufacture of composite components, the
polyfilm is removed from the plies of composite material before a
subsequent ply is stacked on top of the previously layered ply.
Removal of the polyfilm after each ply has been stacked can be a
time-consuming and laborious task.
BRIEF DESCRIPTION
[0003] In one aspect, a layup system for use in forming a composite
layup structure from a plurality of plies of composite material,
wherein an outermost ply of composite material has a removable film
adhered thereto, is provided. The system includes a robotic device
and an end effector coupled to the robotic device. The end effector
includes a layer of compressible material configured to compress
the plurality of plies of composite material together when
positioned over the composite layup structure. The end effector
further includes a first suction device configured to grip the
removable film adhered to the outermost ply of composite material.
The robotic device is configured to translate the end effector
relative to the composite layup structure such that the removable
film is peeled from the outermost ply of composite material while
the first suction device grips the removable film.
[0004] In another aspect, an end effector for use in forming a
composite layup structure from a plurality of plies of composite
material, wherein an outermost ply of composite material has a
removable film adhered thereto, is provided. The end effector
includes a rigid plate and a layer of compressible material coupled
to the rigid plate. The layer of compressible material is
configured to conform to a contour of the composite layup
structure, and is configured to compress the plurality of plies of
composite material together, when positioned over the composite
layup structure. A first suction device is coupled to the rigid
plate. The first suction device is configured to grip the removable
film adhered to the outermost ply of composite material such that
the removable film is peelable from the outermost ply of composite
material when the end effector translates relative to the composite
layup structure while the first suction device grips the removable
film.
[0005] In yet another aspect, a method of forming a composite layup
structure from a plurality of plies of composite material, wherein
an outermost ply of composite material has a removable film adhered
thereto, is provided. The method includes positioning an end
effector over the composite layup structure, wherein the end
effector includes a layer of compressible material and a first
suction device. The method also includes applying pressure to the
composite layup structure with the end effector such that the layer
of compressible material conforms to a contour of the composite
layup structure, and such that the layer of compressible material
compresses the plurality of plies of composite material together.
The method further includes gripping the removable film with the
first suction device, and translating the end effector relative to
the composite layup structure such that the removable film is
peeled from the outermost ply of composite material while the first
suction device grips the removable film.
DRAWINGS
[0006] These and other features, aspects, and advantages of the
present disclosure will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0007] FIG. 1 is a cross-sectional view of an exemplary layup
system that may be used to form a composite layup structure, the
layup system in a first operational position;
[0008] FIG. 2 is a cross-sectional view of the layup system shown
in FIG. 1 in a second operational position;
[0009] FIG. 3 is a cross-sectional view of the layup system shown
in FIG. 1 in a third operational position; and
[0010] FIG. 4 is a cross-sectional view of the layup system shown
in FIG. 1 in a fourth operational position.
[0011] Unless otherwise indicated, the drawings provided herein are
meant to illustrate features of embodiments of the disclosure.
These features are believed to be applicable in a wide variety of
systems comprising one or more embodiments of the disclosure. As
such, the drawings are not meant to include all conventional
features known by those of ordinary skill in the art to be required
for the practice of the embodiments disclosed herein.
DETAILED DESCRIPTION
[0012] In the following specification and the claims, reference
will be made to a number of terms, which shall be defined to have
the following meanings.
[0013] The singular forms "a", "an", and "the" include plural
references unless the context clearly dictates otherwise.
[0014] "Optional" or "optionally" means that the subsequently
described event or circumstance may or may not occur, and that the
description includes instances where the event occurs and instances
where it does not.
[0015] Approximating language, as used herein throughout the
specification and claims, may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change in the basic function to which it is related. Accordingly, a
value modified by a term or terms, such as "about",
"approximately", and "substantially", are not to be limited to the
precise value specified. In at least some instances, the
approximating language may correspond to the precision of an
instrument for measuring the value. Here and throughout the
specification and claims, range limitations may be combined and/or
interchanged. Such ranges are identified and include all the
sub-ranges contained therein unless context or language indicates
otherwise.
[0016] Embodiments of the present disclosure relate to systems and
methods of forming a composite layup structure with an integral ply
compaction and film removal tool. More specifically, the systems
described herein include an automated robotic device and an end
effector that includes the integral ply compaction and film removal
tool. The end effector may be affixed to a robotic arm or a gantry
system, for example. The end effector includes a layer of
compressible material that facilitates compressing plies of
composite material together when positioned over the composite
layup structure. The end effector further includes a suction device
that engages a removable film on an outermost ply of composite
material as the layer of compressible material compresses the plies
of composite material together. The suction device is then actuated
to grip the removable film, and the robotic device is operable to
translate the end effector relative to the composite layup
structure after compression of the plies has been achieved. More
specifically, the robotic device translates the end effector to
peel the removable film from the outermost ply of composite
material while the suction device continues to grip the removable
film. As such, ply compaction and film removal may be achieved in
the same robotic sequence, thereby reducing the manufacturing time
of the composite layup structure.
[0017] FIG. 1 is a cross-sectional view of an exemplary layup
system 100 that may be used to form a composite layup structure
102. In FIG. 1, layup system 100 is in a first operational position
104. In the exemplary embodiment, layup system 100 includes a
robotic device 106, including a robotic arm 108, and an end
effector 110 coupled to robotic arm 108 of robotic device 106. As
will be explained in more detail below, robotic device 106 is
programmed to enable end effector 110 to perform a ply compaction
and film removal operation on composite layup structure 102.
[0018] In the exemplary embodiment, composite layup structure 102
is formed from a plurality of plies 112 of composite material. The
plurality of plies 112 of composite material are stacked layer by
layer to facilitate forming composite layup structure 102. In
addition, each ply 112 of composite material has a removable film
114 adhered thereto that is removed prior to layering an additional
ply 112 on an outermost ply of composite material, as will be
explained in more detail below. In one embodiment, the plurality of
plies 112 of composite material are stacked unevenly such that
composite layup structure 102 has a non-uniform thickness. For
example, composite layup structure 102 includes a thick portion 116
and a thin portion 118, where thick portion 116 includes more plies
112 of composite material than thin portion 118. As such, composite
layup structure 102 has an uneven contour, and end effector 110 is
designed to compensate for contours in composite layup structure
102 when compressing plies 112 laid up therein, as will be
explained in more detail below.
[0019] In the exemplary embodiment, end effector 110 includes a
rigid plate 120, a layer 122 of compressible material coupled to
rigid plate 120, and a first suction device 124 coupled to rigid
plate 120. Rigid plate 120 provides support for layer 122 of
compressible material during operation of layup system 100. The
compressible material is any material that enables layup system 100
to function as described herein. In one embodiment, the
compressible material is configured to conform to a contour of
composite layup structure 102 when positioned over composite layup
structure 102 to compress plies 112. As such, layer 122 of
compressible material is capable of applying a compression force
across a whole area of composite layup structure 102 even when
plies 112 are stacked unevenly therein. In addition, in one
embodiment, the compressible material has a compressibility such
that a compression force applied to composite layup structure 102
by end effector 110 increases at a substantially linear rate as end
effector 110 is displaced towards and biased against composite
layup structure 102. An example compressible material includes, but
is not limited to, a foam material. In addition, the rate of
compression force versus displacement of the compressible material
varies based on the type of compressible material used by end
effector 110.
[0020] As noted above, end effector 110 includes first suction
device 124 coupled to rigid plate 120. First suction device 124 is
selectively operable, and positioned, to grip removable film 114
adhered to outermost ply 126 of composite material. For example, in
one embodiment, layer 122 of compressible material has an opening
128 defined therein. First suction device 124 is sized for
insertion within opening 128 such that first suction device 124 is
positioned for gripping removable film 114. Moreover, layer 122 of
compressible material is defined by a central portion 130 and an
outer edge portion 132. Opening 128 is defined in outer edge
portion 132 such that first suction device 124 is likewise
positioned at outer edge portion 132 of layer 122 of compressible
material. As such, as will be explained in more detail below, first
suction device 124 is positioned for gripping a peripheral edge 134
of outermost ply 126, which enables end effector 110 to initiate
separation of removable film 114 from outermost ply 126. In an
alternative embodiment, end effector 110 includes any device or
component capable of selectively gripping and releasing removable
film 114.
[0021] Layup system 100 further includes a biasing mechanism 136
coupled to first suction device 124. In operation, biasing
mechanism 136 facilitates translating first suction device 124
relative to end effector 110. For example, biasing mechanism 136
facilitates positioning first suction device 124 for engagement
with removable film 114, and also facilitates translation of first
suction device 124 in a direction away from removable film 114 as
end effector 110 is biased towards composite layup structure 102.
Example biasing mechanisms include, but are not limited to, a
spring actuation device and a pneumatic actuation device.
[0022] Layup system 100 further includes a heater 138 thermally
coupled to layer 122 of compressible material. Heater 138 increases
a temperature of layer 122 of compressible material such that an
adhesive in plies 112 of composite material is activated when
contacted by layer 122 of compressible material. As such, plies 112
of composite material at least partially adhere to each other.
Heater 138 is selectively actuated when an ambient temperature is
below a threshold for activating the adhesive.
[0023] In one embodiment, layup system 100 includes a work surface
140 having at least one aperture 142 defined therein. In the
exemplary embodiment, composite layup structure 102 is positioned
over the at least one aperture 142. A second suction device 144 is
in communication with the at least one aperture 142, and second
suction device 144 is operable to hold composite layup structure
102 in position on work surface 140. More specifically, in
operation, the suction force induced by second suction device 144
is greater than the suction force induced by first suction device
124. As such, second suction device 144 facilitates holding
composite layup structure 102 in position as removable film 114 is
separated and peeled from outermost ply 126.
[0024] In operation, the plurality of plies 112 of composite
material are stacked on work surface 140 to facilitate forming
composite layup structure 102. Second suction device 144 draws a
vacuum through the at least one aperture 142 such that composite
layup structure 102 is held on work surface 140. In addition, in
first operational position 104, robotic device 106 positions end
effector 110 over composite layup structure 102.
[0025] FIG. 2 is a cross-sectional view of layup system 100 in a
second operational position 146. In operation, robotic device 106
translates end effector 110 in a first direction 148 towards work
surface 140 such that pressure is applied to composite layup
structure 102. When end effector 110 is positioned over composite
layup structure 102, layer 122 of compressible material conforms to
a contour of composite layup structure 102, and layer 122 of
compressible material compresses the plurality of plies 112 of
composite material together. First suction device 124 is then
activated to grip removable film 114 adhered to outermost ply 126.
Moreover, in some embodiments, heater 138 is activated to
facilitate activating the adhesive in plies 112 when an ambient
temperature is less than a predetermined threshold.
[0026] FIGS. 3 and 4 are cross-sectional views of layup system 100
in a third operational position 150 and a fourth operational
position 152. In operation, robotic device 106 translates end
effector 110 relative to composite layup structure 102 such that
removable film 114 is peeled from outermost ply 126 of composite
material while first suction device 124 continues to grip removable
film 114. More specifically, referring to FIG. 3, robotic device
106 translates end effector 110 in a second direction 154, away
from work surface 140, to initiate separation of removable film 114
from outermost ply 126 at peripheral edge 134 thereof. In one
embodiment, robotic device 106 translates end effector 110 away
from work surface 140, towards work surface 140, and away from work
surface 140 a second time to facilitate ensuring removable film 114
has been effectively separated from outermost ply 126. Referring to
FIG. 4, robotic device 106 then translates end effector 110 in a
third direction 156, different from second direction 154 (e.g.,
substantially perpendicular to second direction 154), to peel
removable film 114 from outermost ply 126 of composite material.
Once removed, additional plies 112 of composite material are
layered until composite layup structure 102 is formed from a
predetermined number of plies 112.
[0027] An exemplary technical effect of the systems and methods
described herein includes at least one of: (a) removing a polyfilm
from a composite ply in a quick and efficient manner; (b) reducing
the manufacturing time of a composite layup structure; and (c)
providing a tool that enables ply compaction and polyfilm removal
in the same robotic sequence.
[0028] Exemplary embodiments of a layup system are provided herein.
The systems and methods are not limited to the specific embodiments
described herein, but rather, components of systems and/or steps of
the methods may be utilized independently and separately from other
components and/or steps described herein. For example, the
configuration of components described herein may also be used in
combination with other processes, and is not limited to practice
with only removing a polyfilm from composite plies, as described
herein. Rather, the exemplary embodiment can be implemented and
utilized in connection with many applications where removing a film
from a sheet of material is desired.
[0029] Although specific features of various embodiments of the
present disclosure may be shown in some drawings and not in others,
this is for convenience only. In accordance with the principles of
embodiments of the present disclosure, any feature of a drawing may
be referenced and/or claimed in combination with any feature of any
other drawing.
[0030] This written description uses examples to disclose the
embodiments of the present disclosure, including the best mode, and
also to enable any person skilled in the art to practice
embodiments of the present disclosure, including making and using
any devices or systems and performing any incorporated methods. The
patentable scope of the embodiments described herein is defined by
the claims, and may include other examples that occur to those
skilled in the art. Such other examples are intended to be within
the scope of the claims if they have structural elements that do
not differ from the literal language of the claims, or if they
include equivalent structural elements with insubstantial
differences from the literal languages of the claims.
* * * * *