Fiber Placement Machine Platform System Having Interchangeable Head and Creel Assemblies

• US 20090095410A1
• Filed: 10/16/2008
• Published: 04/16/2009
• Est. Priority Date: 10/16/2007
• Status: Active Grant

• Current Assignee: Ingersoll Machine Tools Incorporated (Camozzi Industries SpA)
• Original Assignee: Ingersoll Machine Tools Incorporated (Camozzi Industries SpA)
• Inventors: Oldani, Tino
• Granted Patent: US 8,151,854 B2
• Time in Patent Office: Days
• US Class Current: 156/189
• CPC Class Codes: B29C 70/382 Automated fiber placement [AFP]
• CPC Class Codes: B29D 99/001 Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings articles with hollow walls B29D24/00
• CPC Class Codes: B29L 2031/3082 Fuselages
• CPC Class Codes: Y10T 156/1348 Work traversing type
• CPC Class Codes: Y10T 156/1785 Magazine stack directly contacting work

Abstract

A modular fiber placement machine head assembly and refrigerated creel assembly affixed to a cradle for an interchangeable platform system adapted for composite fiber manufacturing through an automated, computer controlled, fiber placement machine is described.

Claims

1. An automated fiber placement system, comprising:

a plurality of modular cradles adapted to be interchangeable within a host gantry or platform system; and

an automated fiber placement machine mounted on the each of the plurality of modular cradles, the automated fiber placement machine including a compact fiber placement head and roller apparatus, a multi-axial articulated wrist apparatus, an internal power source that maneuvers an internal fiber redirect mechanism, a plurality of spools for mounting of fiber tows contained in a refrigerated creel assembly; and

wherein each of the modular cradles is adapted to maintain a fixed distance between the fiber placement head and the creel assembly and incorporates at least one fiber redirect mechanism between the fiber placement head mechanism and the creel assembly.

2. The automated fiber placement system of claim 1, further comprising a gantry supporting one of the modular cradles, and wherein the automated fiber placement machine is mounted on each of the modular cradles along a vertical axis to allow vertical application of fiber tows to either a fixed tablet or rotating mandrel having an attendant reciprocal headstock and tailstock mechanisms.

3. The automated fiber placement system of claim 1, further comprising a gantry supporting one of the modular cradles, and wherein the automated fiber placement machine is mounted on each of the modular cradles along a horizontal axis to allow horizontal application of fiber tows to either a fixed tablet or rotating mandrel having an attendant reciprocal headstock and tailstock mechanisms.

4. The automated fiber placement system of claim 1, further comprising a plurality of platforms adapted to receive and host the plurality of modular cradles, and wherein each of the plurality of cradles includes an interchangeable creel assembly.

5. The automated fiber placement system of claim 1, further comprising a plurality of platforms adapted to receive and host the plurality of modular cradles, and wherein each of the plurality of cradles includes an interchangeable fiber placement head assembly.

6. The automated fiber placement system of claim 1, further comprising a plurality of platforms adapted to receive and host the plurality of modular cradles, and wherein each of the plurality of cradles includes an interchangeable creel assembly and an interchangeable fiber placement head.

7. The automated fiber placement system of claim 6, wherein the automated fiber placement machine further includes a computer aided design software program, and wherein the interchangeable creel assembly and the interchangeable fiber placement head are operable by commands from, and within parameters provided by, the computer aided design software program.

8. The automated fiber placement system of claim 1, wherein the at least one fiber redirect mechanism between the fiber placement head mechanism and the creel assembly is an internal motor mounted on the modular cradle for positioning the fiber placement head, the internal motor having a hollow core for passage therethrough of the fiber tows from the creel assembly to the fiber placement head.

9. An automated fiber placement system, comprising:

a plurality of modular cradles including a fiber placement machine having a fiber placement head and creel assembly mounted thereon;

a gantry system having a platform moveable thereon, the platform being adapted to interchangeably accept and host at least one of the modular cradles at a time; and

a support structure adapted to interchangeably accept and host at least one of the plurality of modular cradles not being hosted by the platform.

10. The automated fiber placement system of claim 9, further comprising:

a fixed tablet onto which fiber tows are to be laid; and

wherein the fiber placement machine is mounted on each of the modular cradles along a vertical axis to allow vertical application of the fiber tows to the fixed tablet.

11. The automated fiber placement system of claim 9, further comprising:

a rotating mandrel onto which fiber tows are to be laid having an attendant reciprocal headstock and tailstock mechanisms; and

wherein the fiber placement machine is mounted on each of the modular cradles along a vertical axis to allow vertical application of the fiber tows to the rotating mandrel.

12. The automated fiber placement system of claim 9, further comprising:

a fixed tablet onto which fiber tows are to be laid; and

wherein the fiber placement machine is mounted on each of the modular cradles along a horizontal axis to allow horizontal application of the fiber tows to the fixed tablet.

13. The automated fiber placement system of claim 9, further comprising:

a rotating mandrel onto which fiber tows are to be laid having an attendant reciprocal headstock and tailstock mechanisms; and

wherein the fiber placement machine is mounted on each of the modular cradles along a horizontal axis to allow horizontal application of the fiber tows to the rotating mandrel.

14. The automated fiber placement system of claim 9, further comprising:

a fixed tablet onto which fiber tows are to be laid; and

wherein one of the fiber placement machines is mounted on one of the modular cradles along a vertical axis to allow vertical application of the fiber tows to the fixed tablet; and

wherein another one of the fiber placement machines is mounted on another one of the modular cradles along a horizontal axis to allow horizontal application of the fiber tows to the fixed tablet.

15. The automated fiber placement system of claim 9, further comprising:

a rotating mandrel onto which fiber tows are to be laid having an attendant reciprocal headstock and tailstock mechanisms; and

wherein one of the fiber placement machines is mounted on one of the modular cradles along a vertical axis to allow vertical application of the fiber tows to the rotating mandrel; and

wherein another one of the fiber placement machines is mounted on another one of the modular cradles along a horizontal axis to allow horizontal application of the fiber tows to the rotating mandrel.

16. The automated fiber placement system of claim 9, wherein each of the modular cradles is adapted to maintain a fixed distance between the fiber placement head and the creel assembly and incorporates at least one fiber redirect mechanism between the fiber placement head mechanism and the creel assembly.

17. A method of reducing interruption of fiber placement by an automated fiber placement machine due to exhaustion of fiber tows supplied from a creel assembly during the fiber placement operation, comprising the steps of:

providing a plurality of modular cradles including a fiber placement machine having a fiber placement head and creel assembly mounted thereon;

mounting a first one of the modular cradles on a movable platform of a gantry system;

applying fiber tows to either a fixed tablet or rotating mandrel via the fiber placement head and creel assembly of the first one of the modular cradles mounted on the platform until at least one of the fiber tows is exhausted from the creel assembly;

removing the modular cradle from the platform;

mounting a second one of the plurality of modular cradles on the platform; and

resuming application of fiber tows to either the fixed tablet or rotating mandrel via the fiber placement head and creel assembly of the second one of the modular cradles mounted on the platform in place of the first one of the modular cradles.

18. The method of claim 17, further comprising the step of storing at least one of the modular cradles on a support structure positioned in proximity to the gantry system.

19. The method of claim 17, wherein the step of providing the plurality of modular cradles including a fiber placement machine having a fiber placement head and creel assembly mounted thereon comprises the step of providing at least one of the plurality of modular cradles having the fiber placement machine mounted thereon along a vertical axis to allow vertical application of the fiber tows in the step of applying.

20. The method of claim 17, wherein the step of providing the plurality of modular cradles including a fiber placement machine having a fiber placement head and creel assembly mounted thereon comprises the step of providing at least one of the plurality of modular cradles having the fiber placement machine mounted thereon along a horizontal axis to allow horizontal application of the fiber tows in the step of applying.