International Conferences on Composite Materials

11th Edition of International Conferences on Composite Materials

composite.sciencefather.com

Award Nomination - https://x-i.me/compram1

Abstract Submission - https://x-i.me/compabst2


Modular, robotic cells enable high-rate RTM using any material format


The use of composite materials in vehicle and aircraft manufacturing is proliferating. This is due to their many benefits, such as light weight, strength, durability, corrosion resistance and design flexibility. As the demand for composite components in these industries continues to grow, so does the need for high-rate, high-accuracy, flexible, intelligent and modular manufacturing technologies to produce them. Composites manufacturing systems company Airborne (The Hague, Netherlands) set out to address this by creating a concept called automated ply placement (APP).

APP is a robotically operated, automated and modular preforming technology that maximizes composite component design and material freedom before resin transfer molding (RTM) processing. It represents the culmination of advancements in robotics, intelligent software and process optimization.

“APP allows engineers to design for optimal performance without the limitations of hand layup, thanks to the high accuracy of robotics and automation software,” explains Joe Summers, managing director of Airborne UK. “Automated ply placement was invented to improve accuracy, reduce waste and enable the use of composites in any format to be produced in automated manufacturing.”

“Many composite materials come in the format of a roll of material,” Summers continues. “Automated fiber placement [AFP] and automated tape laying [ATL], which convert composite materials into laminates based on tape, are limited to the small portion of composite materials available in slit tape form. Starting with a tape form, typically unidirectional [UD] material, limits the scope for optimizing the resulting part. Conversely, APP can operate with all material formats — not only dry fiber, prepreg or thermoplastic UD tapes, but also textiles like noncrimp fabrics, as well as films, metal-layered sheet material such as cores to make a sandwich panel, pre-consolidated sub-laminates or homogenous materials that come in patches.”

 

APP process breakdown

In the first stage of the process APP uses a traditional conveyor cutter to precisely cut plies into the required shape. The APP robot(s) then picks up the ply and assesses it for accuracy using a camera-based vision system. It checks that the ply geometry is correct, validates the quality of each cut ply for precision and measures how the ply is positioned on the robot end effector.

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