DESC:FIELD OF INVENTION
[0001] The present invention relates to equipment for the manufacturing of the blades of the wind turbines. The present invention more specifically relates an apparatus for laying fibre material on a mould adapted for the manufacture of a fibre-reinforced blade for a wind power plant.

BACKGROUND OF THE INVENTION

[0002] Most wind turbines have three blades which are made mostly of fibreglass composites. Typically, turbine blades are 50% glass or carbon fibre composite by weight. Turbine blades vary in size, but a typical modern land-based wind turbine has blades of over 170 feet (52 meters). The largest turbine is GE's Haliade-X offshore wind turbine, with blades 351 feet long (107 meters) – about the same length as a football field. When wind flows across the blade, the air pressure on one side of the blade decreases. The difference in air pressure across the two sides of the blade creates both lift and drag. The force of the lift is stronger than the drag and this causes the rotor to spin.
[0003] Wind turbine rotor blades are the most highly stressed and vital component of any wind turbine. They are designed to absorb the kinetic power of the wind and convert the said energy into a rotary motion around a central hub. While the central hub of the blades may be rotating at a gently speed relative to the wind, the tips of the blades are rotating at a much higher velocity and the longer the blade is, the faster the tip rotates especially for propeller type blade designs.
[0004] The spar constitutes the main structural element of the wind turbine blade which carries the said blade’s main loads and transforms them to its root which in turn connects between the blade and the hub. A spar is usually consisting of upper and lower flanges (caps) in addition to a shear web. The shear web provides high resistance to shear force in which the bending moment over the blade is converted into in-plane shear forces which are carried by the said shear web.
[0005] The most stressed part of a wind turbine blade includes primarily the root of a wind turbine blade to which the structural members, i.e., the spars are longitudinally attached to provide structural integrity along the length of the said wind turbine blade. The ribs provided structural integrity in the transverse direction of the said wind turbine blade. A typical wind turbine structure consists of the skins, ribs, spar, and root or hub that connects between the blade and the wind turbine tower. The ribs represent the aerodynamic profile shape for a blade. They distribute the aerodynamic loads and transform them to the main spar, in addition to maintaining the skin profile shape. The skins protect and cover the blade structure elements. Stringers stiffen the skins and connect between the structure of the skins and ribs. A spar represents the main structure element which carries the blade’s main loads and transforms them to its root which in turn connects between the blade and the hub. A spar is usually consisting of upper and lower flanges (caps) in addition to a shear web. The shear web performs high resistance to shear force in which the bending moment over the blade is transformed into in-plane shear forces that are carried by the shear web.
[0006] Wind turbines have been made from different materials such as wood, aluminium, and composites. Modern wind turbines are usually made from composites such as carbon fibres and fibre glass. The wide use of composite materials turns to its relative high stiffness to weight ratio in addition to its ability to form complex shapes. Composites are found to be efficient with the large increase in wind turbines’ size and capacities. They also can be tailored to satisfy different stiffness and weight requirements. Composite fibre can be used in different orientation to improve the blade directional stiffness in addition to bending and torsional rigidity. Glass fibres are a key part of the composite—a material made up of multiple constituents such as polymers and fibres—used to create wind turbine blades. Typically, turbine blades are 50% glass or carbon fibre composite by weight.
[0007] Typically, the spar of a wind turbine is manufactured by the process of layup. Usually, the said spar of a wind turbine blade is made from a material selected from fibreglass sheets, carbon fibre sheets etc. The spar of a wind turbine blade is typically a composite structure composed of a plurality of layers of the said fibre sheets or also henceforth referred to as fabric. In the said layup process relates to the combining of the plurality of the layers of the selected fibre sheets or fabric to create a rigid composite structure. There are multiple ways to make a composite part: hand lay-up, hand lay-up with vacuum bag, vacuum infusion and pre-impregnated with vacuum bagging.
[0008] A number of layers of fibre material, or mats, are subsequently arranged in the mould, typically by hand, following which resin is finally applied, typically by injection into the closed mould, to attach the individual layers of fibre material to each other. The resin can be applied to the layers manually by RTM (resin transfer moulding), VARTM (vacuum assisted resin transfer moulding) or other suitable methods. Alternatively, the resin can be applied to the laminate layers prior to laying the layers (Prepeg). In the context of this, gelcoat will harden and form the surface of the product.
[0009] Arranging the layers of fibre material, or mats, within the interior of a mould is today a time-consuming and labour-intensive process. Depending of the size of the part to be manufactured, and thereby the size of the mould, walkways may be arranged alongside and/or above the mould such that the workers are allowed to walk along the edge or periphery of the mould and/or above the mould in order to arrange the layers of fibre material as required. Multiple rolls of fibre material comprising different types of fibre material are arranged on the walkways, such that the workers may pick suitable rolls comprising the required materials and arrange the materials on the form.
[0010] During the layup of fibre material, combined efforts of several workers are required, as the fibre material is heavy and not easy manipulable. Some workers assist in the rollout of material, while other workers positioned along the edge of the mould make sure that the layers are laid up correctly.
[0011] In order to secure a desired strength and stability of the part to be manufactured, it is of utmost importance that the layers are arranged correctly and without dents or wrinkles and the like. Depending on the application and structure of the part to be manufactured, multiple layers of fibre material may be arranged within the mould and the layers are typically arranged on top of each other or next to each other possibly with overlapping edges.
[0012] The parts typically consist of as many as fifty or more layers of material, i.e. mats, and the parts are typically built up from a main laminate provided in the centre of the mould. Moulds for manufacturing such parts may be very large, and the moulds are as a consequence expensive. The time required for the arrangement of material on the mould should be kept at a minimum such that the form time (the time which a part occupies the mould) required by a part to be manufactured is kept at a minimum, thus increasing the overall productivity of the mould.
[0013] In the industry, the spar of a wind turbine blade is made by laying sheets of fibre on top of each other on to a bed where the subsequent layers of the sheets of fibre get bonded to each other to form a composite structure. The number of the sheets to be composited is chosen as per the parameters of the wind turbine relating to the required strength and dimensions. The length of a spar of a wind turbine can extend beyond the length of 100 metres. In the industry, the laying of the fibre sheets done in a manual manner. The said manual manner usually involves at least two human workers, one on each side of the spar bed, the said two workers carrying a spool of the fibre sheet, unroll the said spool over the spar bed this laying a layer of the fibre sheet over the spar bed. The said process is repeated as many times as there are to be layers of the fibre sheets in the spar’s composite structure. Therefore, the laying of fibre sheets can involve at least two workers walking back and forth the length of the spar while carrying the heavy spool of fibre and unrolling it by hand. If the length of a spar is 80m then for laying 15 layers of the fibre sheet, the two workers have to walk at least 1.2 kms. The said methods present significant risk to the health of the works as, in the process, there always remains a possibility of accident of the workers.
[0014] The said process of layup further comprises a step of compacting the laid fibre sheets. According to traditional fibre placement methods, multiple pieces of composite material are typically compacted simultaneously to the surface using one larger roller or segmented roller which rotates on a single shaft. However, since the roller or roller segments rotate around a single shaft, compacting material onto the surface over sharp angles or complex contours is challenging. For example, as a wide roller or a segmented roller rolls over certain complex contours, a portion of the roller makes no contact against the surface, and a portion of the tape is not compacted. The portion of the material that is not compacted can result in delamination or porosity of the cured part formed by the material.
[0015] In addition, the fibre material is preferably arranged substantially even and flush, which is why any developed dents, wrinkles or curls etc. should be smoothed out. Further, as one layer is typically applied on top of a preceding layer, the lower layer including possible additional layers arranged below the lower layer, tend to move or slide within the mould causing the entire layup of fibre material to move away from an intended position within the mould.

[0016] Thus, there has always been a need for an apparatus that enables automated laying of fibre sheets and overcome abovementioned limitations.

SUMMARY OF THE INVENTION

[0017] The following is a summary description of illustrative embodiments of the invention. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point out the invention.
[0018] Embodiments of the present invention may provide a number of advantages depending on its particular configuration. Embodiments of the present application provide an automated apparatus for lay-up of fabric composites.
[0019] The present disclosure solves all the major limitation of traditional systems.
[0020] An objective of the present disclosure is to enable automated lay-up of fabric composites.
[0021] Another objective of the present disclosure is to reduce reliance on manual labour in the composite fabrication process.
[0022] Another objective of the present disclosure is to reduce human error, fatigue, and potential health risks while ensuring greater process consistency and reliability.
[0023] Another objective of the present disclosure is to increase the speed and efficiency of the composite lay-up process.
[0024] Yet another objective of the present disclosure is to achieve more accurate and uniform placement of fabric layers.
[0025] Yet another objective of the present disclosure is to optimize the use of fabric materials and minimize waste during the lay-up process.
[0026] The present subject matter relates to aspects, an automated apparatus for lay-up of fabric composites is disclosed herein. The apparatus comprising a track assembly further comprising at least two track rails running parallel to each other. The track assembly further comprising a support structure supporting the track assembly. The track assembly further comprising a stopper mechanism located at both the ends of the track assembly. The apparatus also comprising a spool located at either end of the track assembly and the spool configured to bear rolling and unrolling of the fibre sheets. The apparatus also comprising a layup wagon optimized to move along the track assembly and the layup wagon further comprising a plurality of roller wheel mated with the track rails. The roller wheels allow movement of the layup wagon along the track assembly. The layup wagon further comprising a sheet holding hinge assembly griping an end of a fibre sheet in order to pull it and unroll it from the spool. The sheet holding hinge assembly grips and pulls an open end of the fibre sheet to unroll from the spool.
[0027] In an example implementation of the present subject matter, the apparatus also includes a composite bed positioned between the widths of the track rails and running along the length of the track assembly.
[0028] In an example implementation of the present subject matter, the stopper mechanism further includes at least one stopper rod.
[0029] In an example implementation of the present subject matter, the stopper mechanism further includes at least one stopper spring provided along the length of the stopper rod in a concentric manner.
[0030] In an example implementation of the present subject matter, the stopper spring only compresses of decompresses along the length of the stopper rod.
[0031] In an example implementation of the present subject matter, the sheet holding hinge assembly also lay the unrolled part of the fibre sheet on the composite bed.
[0032] In an example implementation of the present subject matter, the layup wagon also includes at least one gantry provided with at least one roller wheel.
[0033] In an example implementation of the present subject matter, the layup wagon also includes at least one drive motor actuating the roller wheels to move along the track rails.
[0034] In an example implementation of the present subject matter, the gantry is a box-type structure having horizontal and vertical structural members with the joints formed at 90° angles.
[0035] In an example implementation of the present subject matter, the track assembly is hoisted at varying heights from ground level, corresponding to the shape of the fabric composite to be formed.
[0036] In an example implementation of the present subject matter, a compacting roller is attached to the layup wagon to presses the fibre sheet being laid on the composite bed over a previously laid fibre sheet to ensure proper bonding between the said two layers of fibre sheets by ensuring appropriate contact between the surface and the spread of the resin.
[0037] In an example implementation of the present subject matter, the apparatus also comprise a hinge plate assembly operationally coupled to the sheet holding hinge assembly.
[0038] These and other advantages will be apparent from the present application of the embodiments and solves abovementioned limitations in the traditional system.
[0039] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
[0040] These elements, together with the other aspects of the present disclosure and various features are pointed out with particularity in the claims annexed hereto and form a part of the present disclosure. For a better understanding of the present disclosure, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.

BRIEF DESCRIPTION OF DRAWINGS

[0041] The detailed description is described with reference to the accompanying figures. The accompanying drawing illustrates the embodiment of the invention and together with the following detailed description serves to explain the principles of the invention.
[0042] Fig. 1 depicts a block diagram of an automated apparatus for lay-up of fabric composites, in accordance with an implementation of the present subject matter;
[0043] Fig. 2 depicts an isometric illustration of the layup wagon 116 placed on the track assembly, in accordance with an implementation of the present subject matter;
[0044] Fig. 3 depicts a plan illustration of the track assembly in accordance with an implementation of the present subject matter;
[0045] Fig. 4 depicts an elevation illustration of the track assembly, in accordance with an implementation of the present subject matter;
[0046] Fig. 5 depicts a cross-sectional view of the layup wagon, in accordance with an implementation of the present subject matter;
[0047] Fig. 6 depicts a front view of the layup wagon placed on the track assembly, in accordance with an implementation of the present subject matter;
[0048] Fig. 7 depicts an isometric illustration of the stopper rod 108 and the stopper screw, in accordance with an implementation of the present subject matter;
[0049] Fig. 8 depicts an isometric illustration of the stopper assembly, in accordance with an implementation of the present subject matter;
[0050] Fig. 9 depicts an elevation illustration of the stopper assembly, in accordance with an implementation of the present subject matter;
[0051] Fig. 10 depicts an isometric illustration of the sheet holding hinge assembly, in accordance with an implementation of the present subject matter;
[0052] Fig. 11 depicts an elevation illustration of the sheet holding hinge assembly, in accordance with an implementation of the present subject matter;
[0053] Fig. 12 depicts a specification sheet for the layup wagon 116 and on the track assembly, in accordance with an implementation of the present subject matter;
[0054] Fig. 13 depicts a specification sheet for the stopper assembly, in accordance with an implementation of the present subject matter;
[0055] Fig. 14 depicts a specification sheet for the hinge plate assembly, in accordance with an implementation of the present subject matter; and
[0056] Fig. 15 depicts a specification sheet for the sheet holding hinge assembly, in accordance with an implementation of the present subject matter.

DETAILED DESCRIPTION OF THE INVENTION

[0057] The above and other features, aspects, and advantages of the subject matter will be better explained with regard to the following description and accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter along with examples described herein and, should not be construed as a limitation to the present subject matter. It is thus understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and examples thereof, are intended to encompass equivalents thereof. Further, for the sake of simplicity, and without limitation, the same numbers are used throughout the drawings to reference like features and components.

[0058] Fig. 1 depicts a block diagram of an automated apparatus 100 for lay-up of fabric composites, in accordance with an implementation of the present subject matter.

[0059] The apparatus 100 may comprise a track assembly 102, a spool 114, and a layup wagon 116.

[0060] The track assembly 102 may be further comprising at least two track rails 104 running parallel to each other. The track assembly 102 may be further comprising a support structure 106 supporting the track assembly 102. The track assembly 102 may be further comprising a stopper mechanism 108 located at both the ends of the track assembly 102.

[0061] The spool 114 may be located at either end of the track assembly 102 or the spool 114 configured to bear rolling and unrolling of the fibre sheets.

[0062] The layup wagon 116 may be optimized to move along the trac6k assembly 102 and the layup wagon 116 further comprising a plurality of roller wheel 118 mated with the track rails 104. The roller wheels 118 may allow movement of the layup wagon 114 along the track assembly 102.

[0063] The layup wagon 116 may further comprise a sheet holding hinge assembly 120 griping an end of a fibre sheet in order to pull it and unroll it from the spool 114. The sheet holding hinge assembly 120 may grip and pull an open end of the fibre sheet to unroll from the spool 114.

[0064] The apparatus 100 may also include a composite bed 128 positioned between the widths of the track rails 104 and running along the length of the track assembly 102.

[0065] The stopper mechanism 108 may further includes at least one stopper rod 110, and at least one stopper spring 112 provided along the length of the stopper rod 110 in a concentric manner.

[0066] The stopper spring 112 may only compresses of decompresses along the length of the stopper rod 110.

[0067] The sheet holding hinge assembly 120 may also lay the unrolled part of the fibre sheet on the composite bed 128.

[0068] The layup wagon 114 may also include at least one gantry 122 provided with at least one roller wheel 118. The layup wagon 114 may also include at least one drive motor 124 actuating the roller wheels 118 to move along the track rails 104.

[0069] The gantry 122 may be a box-type structure having horizontal and vertical structural members with the joints formed at 90° angles.

[0070] The track assembly may be hoisted at varying heights from ground level, corresponding to the shape of the fabric composite to be formed.

[0071] A compacting roller 126 may be attached to the layup wagon 114 to presses the fibre sheet being laid on the composite bed 128 over a previously laid fibre sheet to ensure proper bonding between the said two layers of fibre sheets by ensuring appropriate contact between the surface and the spread of the resin.

[0072] The apparatus 100 may also comprise a hinge plate assembly 130 operationally coupled to the sheet holding hinge assembly 120.

[0073] In a preferred embodiment, the layup wagon 116 may have four roller wheels 118, with two roller wheels mated to each track rail 104 for enhanced stability and guided movement along the track assembly 102.

[0074] Fig. 2 depicts an isometric illustration of the layup wagon 116 placed on the track assembly 102, in accordance with an implementation of the present subject matter.

[0075] Fig. 3 depicts a plan illustration of the track assembly 102, in accordance with an implementation of the present subject matter.

[0076] In an embodiment of the present disclosure, the composite bed 128 may run parallelly along the track rails 104. The layup wagon 116 may be placed on the track assembly 102.

[0077] In an embodiment of the present disclosure, the layup wagon 116 may have means for holding and dispensing the fibre sheet or fabric. The layup wagon 116 may be capable of holding a spool of the fabric and unrolling or uncoiling it over the composite bed 128 or the spar bed on which the layers of the fabric are to be composited.

[0078] In an embodiment of the present disclosure, the composite bed 128 may be a longitudinal surface, over which the layers of fabric are placed on top of each other to form the composite of the said fabric layers. The composite bed 128 may be an elongated surface having a curvature along the longitudinal direction as per the required design of the composite to be manufactured.

[0079] Fig. 4 depicts an elevation illustration of the track assembly 102, in accordance with an implementation of the present subject matter.

[0080] In another embodiment of the present invention, the spool 114 may be provided in the layup wagon 116 itself allowing the open end of the rolled fibre sheet to be gripped by a sheet holding hinge assembly 120 located at an end of the track assembly 102.

[0081] In an embodiment of the present disclosure, the track rails 104 are elongated members and are capable of interacting with at least one of the roller wheels 118 of the layup wagon 116 to enable the movement of the said roller wheel 118 along the longitudinal direction of the said track rail 104 while preventing the dislocation of the said roller wheel 118 away from the said track rail.

[0082] Fig. 5 depicts a cross-sectional view of the layup wagon 116, in accordance with an implementation of the present subject matter.

[0083] Fig. 6 depicts a front view of the layup wagon 116 placed on the track assembly 102, in accordance with an implementation of the present subject matter.

[0084] In the preferred embodiment of the present invention, the layup wagon 116 which has been placed over the track assembly 102 in order to place the layers of fibre sheets over the composite bed 128. The layup wagon 116 is actuated by the drive motor 124.

[0085] In an embodiment of the present disclosure, the layup wagon 116 may include an assembly for the dispensing of the fabric over the surface of the composite bed 128. The plurality of the layers of the fabric sheets placed on the composite bonded by resin form the required composite structure having the shape defined by the composite bed 128. In an embodiment of the present invention, the said dispensing assembly comprises a means for the storing of the sheets of the fabric to be composited. In the said embodiment, the said fabric is sheet is stored in the form of a roll over a roller, i.e., the spool 114, the said roller being attached to the layup wagon 116. In another embodiment of the present invention, the dispensing assembly grips the open end of the fabric while the fabric is stored in a rolled form on the spool 114 in a stationary position away from the layup wagon 116.

[0086] In an embodiment of the present disclosure, a means for the guided locomotion of the said layup wagon 116 may be provided, so that the layup wagon 116 may be enabled to move along the length of the composite in order to place the layers of the fabric to be composited. The said means for the locomotion of the layup wagon ensures that the layup wagon moves along the length of the composite bed 128 while accurately adhering to the profile of the composite bed 128 when laying the length of fabric on the composite bed 128.

[0087] Fig. 7 depicts an isometric illustration of the stopper rod 108 and the stopper screw 112, in accordance with an implementation of the present subject matter.

[0088] Fig. 8 depicts an isometric illustration of the stopper assembly 108, in accordance with an implementation of the present subject matter.

[0089] Fig. 9 depicts an elevation illustration of the stopper assembly 108, in accordance with an implementation of the present subject matter.

[0090] In a preferred embodiment, the layup wagon 116 may stop at the other end and then travels in the reverse direction while laying another layer of fibre sheet onto the previous laid layer of fibre sheet. To ensure that the layup wagon 116 may stops at either end in a smooth manner without any shock to the layup wagon 116 which could cause damage to both the said layup wagon 116 and the entire apparatus 100 due to the pulse of force generated during the stoppage of the layup wagon 116, which is provided by the stopper assembly 108.

[0091] Fig. 10 depicts an isometric illustration of the sheet holding hinge assembly 120, in accordance with an implementation of the present subject matter.

[0092] Fig. 11 depicts an elevation illustration of the sheet holding hinge assembly 120, in accordance with an implementation of the present subject matter.

[0093] In an embodiment of the present disclosure, the sheet holding hinge assembly 120 may pull and unroll pull the spool 114 located at either end of the track assembly 102 to lay the unrolled part of the sheet on the composite bed 128. In some embodiments of the present invention, the spools 114 of fibre sheet may located at both the ends of the track assembly 102 and the sheet holding hinge assembly 120 grips and pulls an open end of the sheet to unroll the spool 114.

[0094] Fig. 12 depicts a specification sheet for the layup wagon 116 and on the track assembly 102, in accordance with an implementation of the present subject matter.

[0095] In some embodiments, the layup wagon 116 may be provided with at least one roller wheel 118, which operatively couples with the track assembly 102 to establish the position of the layup wagon 116 with respect to the said track assembly 102 and in consequence, with the composite bed 128. The roller wheels 118 bear the complete weight of the layup wagon 116 and stabilise the same upon the track assembly 102 against in a direction perpendicular to the length of the track assembly 102 and thus with respect to the composite bed 128.

[0096] In an embodiment of the present invention, at least one of the roller wheels 118 may be actuated by any electric motor including, but not limited to, the drive motor 124. The drive motor 124 may be integrated into the layup wagon 116. The layup wagon 116 may have a plurality of roller wheel with each of the roller wheels 118 provided with the drive motor 124. In other embodiment of the present invention, the actuation may be provided by an internal combustion engine integrated into the layup wagon 116.

[0097] Fig. 13 depicts a specification sheet for the stopper assembly 108, in accordance with an implementation of the present subject matter.

[0098] In an embodiment of the present disclosure, the stopper spring 112 may be provided in parallel to the length of the stopper rod 110 to enables the layup wagon 116 to stop at an end of the composite bed 128 in a gradual manner by having the stopper spring 112 absorb the inertia of the layup wagon 116. The stopper rod 110 may make sure that the stopper spring 112 doesn’t buckle and compresses and relaxes along the intended direction.

[0099] Fig. 14 depicts a specification sheet for the hinge plate assembly 130, in accordance with an implementation of the present subject matter.

[00100] Fig. 15 depicts a specification sheet for the sheet holding hinge assembly 120, in accordance with an implementation of the present subject matter.

[00101] In an embodiment of the present disclosure, the layup wagon 116 comprising the support structure 106 may be a frame capable of supporting the weight of the said layup wagon 116 over the track assembly 102. In an embodiment of the present invention, the gantry 122 may be substantially a C-shaped structure when considered in a cross-sectional view. In some embodiments of the present invention, the two open ends of the C-shaped gantry 112 are provided with roller wheel 118 for mechanical contact with the track rails 104 of the track assembly 102 to relay the entire weight of the layup wagon 116 onto the said track assembly 102.

[00102] In an embodiment of the present disclosure, the composite bed 128 and as well as the track assembly 102 are supported by the support structure 106. The support structure 106 supports the entire length of the composite bed 128 along with the entire lengths of the two track rails 104 of the track assembly 102. In the preferred embodiment of the present invention, the two track rails 104 may be located along the composite bed 128 with each of the track rails 104 on either side of the said composite bed 128.

[00103] In the preferred embodiment of the present invention, the drive motor 124 for the actuation of the roller wheel 118 is mounted on the gantry 122 and the drive motor 124 is in communication with the said roller wheel 118. The coupling between the roller wheel 118 and the respective drive motor 124 may or may not be provided with a gearbox for controlling the rotational speed received at the roller wheel 118 from the drive motor 124.

[00104] A preferred embodiment of the present invention is further provided with a safety mechanism for ensuring the safety of the workers working in the vicinity of the apparatus 100 against hazardous situation created due to the movement of the layup wagon 116. The front and the rear of the said layup wagon 116 may be provided with safety sensors which detect for the presence of the humans in front and the rear of the layup wagon 116. If a person is detected in front of the layup wagon 116, then the electrical power to the drive motor 124 is cut off to prevent any accident. The safety sensor may also be capable of other types of obstructions which include non-human obstructions such as other objects and machineries on the factory floor, to prevent the collision of the layup wagon 116 with the said obstructions. In an embodiment of the present disclosure, the apparatus 100 may include an automatic dispensing assembly dispensing fabric in a dispensing direction.

[00105] The disclosed invention offers several advantages. The apparatus 100 may minimize human intervention, reducing the physical effort required from workers for laying fibre composite manually. This not only eases the workload but also potentially reduces labour costs. The apparatus 100 may substantially reduce the time required for manufacturing, leading to faster production cycles. This increase in efficiency allows manufacturers to meet higher production demands with less downtime.

[00106] The apparatus 100 may often result in more consistent and precise placement of fibre sheets compared to manual methods. This ensures a higher-quality composite structure with fewer errors and defects. The apparatus 100 may reduce the need for workers to engage in repetitive or potentially hazardous manual operations, and improves safety conditions in the manufacturing environment.

[00107] The apparatus 100 may, in the long run, lead to savings by reducing labour costs, minimizing material waste, and lowering the number of rejected or defective parts due to errors in fibre placement. The apparatus 100 may allow easy scaling-up than manual production methods, allowing manufacturers to increase output without significantly increasing labour costs or time. The apparatus 100 may lead to better material usage, as the precise laying of fibre sheets ensures minimal waste and optimal use of the fibre material, leading to cost savings on raw materials.

[00108] Although the subject matter has been described in considerable detail with reference to certain examples and implementations thereof, other implementations are also possible. As such, the present disclosure should not be limited to the description of the preferred examples and implementations containedthereind. ,CLAIMS:I/WE CLAIM:
1. An automated apparatus (100) for lay-up of fabric composites, the apparatus (100) comprising:
a.) a track assembly (102) further comprising:
i.) at least two track rails (104) running parallel to each other;
ii.) a support structure (106) supporting the track assembly (102);
iii.) a stopper mechanism (108) located at both the ends of the track assembly (102); and
iv.) a spool (114) located at either end of the track assembly (102), the spool (114) configured to bear rolling and unrolling of the fibre sheets.
b.) a layup wagon (116) optimized to move along the track assembly (102), the layup wagon (116) further comprising:
i.) a plurality of roller wheel (118) mated with the track rails (104), wherein the roller wheels (118) allow movement of the layup wagon (114) along the track assembly (102); and
ii.) a sheet holding hinge assembly (120) griping an end of a fibre sheet in order to pull it and unroll it from the spool (114), wherein the sheet holding hinge assembly (120) grips and pulls an open end of the fibre sheet to unroll from the spool (114).
2. The apparatus (100) as claimed in claim 1, wherein the apparatus (100) also includes a composite bed (128) positioned between the width of the track rails (104) and running along the length of the track assembly (102).
3. The apparatus (100) as claimed in claim 1, wherein the stopper mechanism (108) further includes:
a.) at least one stopper rod (110); and
b.) at least one stopper spring (112) provided along the length of the stopper rod (110) in a concentric manner.
4. The apparatus (100) as claimed in claim 3, wherein the stopper spring (112) only compresses of decompresses along the length of the stopper rod (110).
5. The apparatus (100) as claimed in claim 2, wherein the sheet holding hinge assembly (120) also lay the unrolled part of the fibre sheet on the composite bed (128).
6. The apparatus (100) as claimed in claim 1, wherein the layup wagon (114) also includes:
a.) at least one gantry (122) provided with at least one roller wheel (118); and
b.) at least one drive motor (124) actuating the roller wheels (118) to move along the track rails (104).
7. The apparatus (100) as claimed in claim 6, wherein the gantry (122) is a box-type structure having horizontal and vertical structural members with the joints formed at 90° angles.
8. The apparatus (100) as claimed in claim 1, wherein the trac6k assembly (102) is hoisted at varying heights from ground level, corresponding to the shape of the fabric composite to be formed.
9. The apparatus (100) as claimed in claim 1, wherein a compacting roller (126) is attached to the layup wagon (114) to presses the fibre sheet being laid on the composite bed (128) over a previously laid fibre sheet to ensure proper bonding between the said two layers of fibre sheets by ensuring appropriate contact between the surface and the spread of the resin.
10. The apparatus (100) as claimed in claim 1, wherein the apparatus (100) also comprise a hinge plate assembly (130) operationally coupled to the sheet holding hinge assembly (120).

Dated this 1st Day of October 2024
Signature:
Name: Bhavik Patel
Applicant’s Agent: IN/PA-1379
INFINVENT IP