Claims:WE CLAIM:
1. A system for automated layup making (ALM) for preparing carbon fiber uni-directional prepregs for hand layup, the system comprising:
a multi axis Computer Numeric Control (CNC) table (209) connectively coupled with a processor (210), the CNC table further comprising a bed (208) wherein, a thin plastic sheet (205) is laid on the bed (208);
at least one or more prepregs slit rolls (201) further comprising of carbon fiber prepreg slit tapes;
at least one or more ALM heads (202), fed via processor (210), wherein one or more prepreg slit rolls (201) are mounted on the ALM heads (202) enabled by a gantry support (206); and
at least one or more sheet cutter blades (207);
wherein, the processor (210) is fed with a plurality of executable instruction to generate a required geometric shape (204) on the thin plastic sheet (205);
wherein, at least one or more ALM head (202) comprising internal cutting mechanism which is further fed via processor (210) that enables the cutting of one or more carbon fiber prepreg tapes, in a predefined length to generate one or more carbon fiber prepreg slits (203) and lay the carbon fiber prepreg slits (203) as instructed via processor (210), on the thin plastic sheet (205) to generate the required geometric shape (204);
wherein, at least one or more sheet cutter blades (207) cuts the required geometric shape generated (306) on the thin plastic sheet (205), along with the thin plastic sheet (204) throughout the periphery of the required geometric shape (204).
2. The system of claim 1, wherein the bed (208) is either stationary or constantly in motion.
3. The system of claim 1, wherein at least one or more ALM heads (202) is either stationary or moving uni-directionally along a required fiber direction.
4. The system of claim 1, wherein at least one or more ALM heads lays a pre-defined fixed number of carbon fiber prepreg slits (203) uni-directionally and simultaneously over a thin plastic sheet (205) to generate the required geometric shape (204).
5. A method for automated layup making (ALM) for preparing carbon fiber uni-directional prepregs for hand layup, the method comprising:
laying, a thin plastic sheet (205) onto the bed (208) of the multi axis CNC table connectively coupled with a processor (209);
mounting, at least one or more prepreg slit rolls (201), onto at least one or more ALM heads (202) and guiding carbon fiber prepreg slit tapes around ALM head’s (202) rollers;
feeding, in the processor (209), with a plurality of executable instruction to generate the required geometric shape (204) by deposition of one or more carbon fiber prepregs slits (203) from at least one or more ALM head onto the thin plastic sheet (205) laid on the bed (208);
cutting; via a sheet cutter blade (207), the thin plastic sheet (205) comprising the required geometric shape (204), wherein the cutting is processed by a sheet cutter along the periphery of the required geometric shape (204); and
removing, the cut built layups (306) along with the thin plastic sheet (205) from the bed (208).
6. The method of claim 5, wherein one of the method of operating the ALM comprises:
the bed (208) being stationary at a predefined position when one or more carbon fiber prepreg slits (203) are laid on the thin plastic sheet (205) placed on the bed (208);
moving, at least one or more ALM heads (202) coupled with the sheet cutter blade (207) along the required direction, uni-directionally and laying, the carbon fiber prepreg slits (203) as per the required geometric shape (204) using a pre-defined fixed number of slit(s) simultaneously;
moving, at least one or more ALM heads (202) coupled with sheet cutter blade (207) to another adjacent position for laying up the carbon fiber prepreg slits (203) for same width on finishing the laying up with carbon fiber prepreg slits (203) along a line as required;
continuing, the process until the required geometric shape (204) is obtained; and
cutting, the thin plastic sheet (205) by the sheet cutter blade (207) along the periphery of the required geometric shape (204), on completion of generating the required geometric shape (204) by deposition of carbon fiber prepreg slits (203).
7. The method of claim 5, one of the method of operating the ALM comprises:
moving, the bed (208) along with thin plastic sheet (205) constantly and series of ALM heads (302) being stationary;
laying, the carbon fiber prepreg slits (203) of required lengths simultaneously, by the series of ALM heads (302), on continuously moving thin plastic sheet (205), throughout the width of the bed (208); and
cutting, the thin plastic sheet (205) along the periphery of the required geometric shapes (204) generated by the deposition of carbon fiber prepreg slits (203), on reaching the sheet cutter blade (207) mounted with the help of gantry support (206).
8. The method of claim 6 and 7, wherein the cut built layup (306) obtained as per the requirement are enabled to be placed over the molds, manually, for building the carbon fiber part. , Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
Title of invention:
AUTOMATED LAYUP MAKING SYSTEM AND METHOD FOR PREPARING CARBON FIBER UNI-DIRECTIONAL PREPREGS FOR HAND LAYUP
APPLICANT:
Fabheads Automation Pvt. Ltd.
An Indian entity having address at:
IITM Incubation Cell, Third Floor,
IIT Madras Research Park, Kanagam Road,
Taramani Chennai – 600113 (INDIA)
The following specification particularly describes the invention and the manner in which it is to be performed.
CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present application does not claim priority from any other patent application.
TECHNICAL FIELD
[002] The present subject matter described herein, in general, relates to an automated layup making (ALM) system and method. In particular, the present subject matter related to the automated layup making (ALM) system and method for preparing carbon fiber uni-directional prepregs for hand layup.
BACKGROUND
[003] Now-a-days, there is enormous growth in the techniques of carbon fiber part fabrication by layup process. These techniques are either completely automated or non-automated (manual layup). Non-automated carbon fiber part fabrication involves cutting of required layup shapes out of a roll of carbon fiber prepreg material as one of its steps. This cutting process is performed, at present, in industries either manually or by using automated cutting machines. Either way, this process generates a wastage of carbon fiber material of more than 30% on a global average.
[004] The automated systems and processes comprise of fully automatic computer-guided robotics to lay one or several carbon fiber tapes directly onto a mold one layer at a time one over other directly, to create a part or structure. Although the wastage is minimal here, these automated processes are only suitable for parts of certain simple geometries and are also extremely expensive.
[005] The state of the art systems and processes do not efficiently aid the technicians at present for manual layup process. These automated techniques are very rarely applicable for complex parts with high curvatures. Moreover, these techniques involve a lot of complexity and are expensive.
[006] Therefore, there is long standing need of an automated layup making (ALM) system and method for preparing carbon fiber uni-directional prepregs for hand layup which optimizes wastage of material upto 5-6%, is affordable, and less complex.
SUMMARY
[007] This summary is provided to introduce concepts related to. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[008] In one implementation, a system for automated layup making (ALM) for preparing carbon fiber uni-directional prepregs for hand layup is illustrated. The system may comprise a multi axis Computer Numeric Control (CNC) table connectively coupled with a processor, which further may comprise a bed wherein, a thin plastic sheet may be laid on the bed. Further the system may comprise, at least one or more prepregs slit rolls (201) which may comprise carbon fiber prepreg slit tapes. The system may comprise at least one or more ALM heads, fed via processor, wherein one or more prepreg slit rolls are mounted on the ALM heads enabled by a gantry support and at least one or more sheet cutter blades. In one aspect, the processor (210) is fed with a plurality of executable instruction to generate a required geometric shape on the thin plastic sheet. In another aspect, at least one or more ALM head may comprise internal cutting mechanism which may further be fed via processor that may enable the cutting of one or more carbon fiber prepreg tapes, in a predefined length to generate one or more carbon fiber prepreg slits and may lay the carbon fiber prepreg slits as instructed via processor, on the thin plastic sheet to generate the required geometric shape. In yet another aspect, at least one or more sheet cutter blades may cut the required geometric shape generated on the thin plastic sheet, along with the thin plastic sheet throughout the periphery of the required geometric shape.
[009] In another implementation, a method for automated layup making (ALM) for preparing carbon fiber uni-directional prepregs for hand layup is illustrated. The method may comprise laying, a thin plastic sheet (205) onto the bed of the multi axis CNC table connectively coupled with a processor. The method may further comprise mounting, at least one or more prepreg slit rolls, onto at least one or
more ALM heads and guiding carbon fiber prepreg slit tapes around ALM head’s rollers. The method may comprise feeding, in the processor, with a plurality of executable instruction to generate the required geometric shape by deposition of one or more carbon fiber prepregs slits from at least one or more ALM head onto the thin plastic sheet laid on the bed. The method may further comprise cutting, via a sheet cutter blade, the thin plastic sheet comprising the required geometric shape, wherein the cutting is processed by a sheet cutter along the periphery of the required geometric shape. The method may further comprise removing, the cut built layups along with the thin plastic sheet from the bed (208).
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.
[0011] Figure 1 illustrates, a system (100) using automated layup making process for preparing carbon fiber uni-directional prepregs for hand layup.
[0012] Figure 2 illustrates, a system (200) with a stationary bed (208) comprising of a thin plastic sheet (205) and a moving ALM head (202) in accordance with present subject matter.
[0013] Figure 3 illustrates, a system (300) with moving bed (208) comprising of the thin plastic sheet (205) and a stationary series of ALM head (302) in accordance with present subject matter.
[0014] Figure 4 illustrates, a method (400) for automated layup making process in accordance with present subject matter.
DETAILED DESCRIPTION
[0015] Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in
various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
[0016] Referring now to figure 1, an automated layup making system (ALM) (100), herein after referred as ALM, and method for preparing carbon fiber uni-directional prepregs for hand layup in accordance with an embodiment of the present subject matter is illustrated. In one embodiment, the system (100) may build layups (102) of required shapes over a plastic sheet (101) wherein the layups (102) may be laid in a pre-defined fixed number of slit(s) simultaneously. Further the layups (102), may be then handled for manual hand layup process.
[0017] Referring now to figure 2, a system (200) with a stationary bed comprising of a thin plastic sheet and a moving ALM head (202) in accordance with present subject matter is illustrated. In one embodiment, the system (200) may comprise of a multi axis Computer Numeric Control (CNC) table (209), hereon after referred as CNC table, connectively coupled with a processor (210) (not shown in figure) wherein, the processor (210) may be fed with a required data in accordance to the present subject matter. The system (200) may further comprise of a bed (208), stationary at a predefined position. A thin plastic sheet (205) may be laid manually, on the bed (208), wherein a layup of required geometric shape (204) may be built on the thin plastic sheet (205). In one embodiment, the system (200) may comprise at least one or more prepregs slit rolls (201) mounted on at least one or more ALM heads (202), wherein one or more carbon fiber prepreg slit tapes may be guided through a guiding mechanism around the ALM head’s (202) rollers for initial setup. Further the system (200) may comprise one or more relatively moving ALM heads (202) mounted with a help of gantry support (206) wherein, the ALM head (202) may be fed with internal cutting mechanism to cut the carbon fiber prepreg tape into at least one or more carbon fiber prepreg slits
(203) of required lengths. In one embodiment, the relatively moving ALM head (202) further, may lay the carbon fiber prepreg slits (203) in predefined number, simultaneously, to generate a geometric required shape (204) onto the thin plastic sheet (205). In one embodiment, the system (200) may comprise of at least one or more sheet cutter blade (207) coupled with the ALM head (202) wherein, the sheet cutter blade (207) may cut the thin plastic sheet (205) along the periphery of required geometric shape (204) generated by deposition of carbon fiber prepreg slits (203).
[0018] Referring now to figure 3, a system (300) with moving bed comprising of the thin plastic sheet (205) and a stationary series of ALM head (302) in accordance with present subject matter is illustrated. In one embodiment, the system (300) may comprise of the multi axis Computer Numeric Control (CNC) table (209) connectively coupled with the processor (210), wherein, the processor (210) may be fed with a required data in accordance to the present subject matter. The system (300) may further comprise of a bed (208), relatively moving. A thin plastic sheet (205) may be laid manually, on the bed (208), wherein a layup of required geometric shape (204) may be built on the thin plastic sheet (205). In one embodiment, the system (300) may comprise of a series of prepreg slit rolls (301) in plurality of (201), mounted onto a series of ALM head (302), wherein one or more carbon fiber prepreg slit tapes may be guided through a guiding mechanism around the series of ALM head’s (302) rollers for initial setup. Further, the system (300) may comprise of a stationary series of ALM head (302) in plurality of (202), placed across the whole width of the CNC table (209), wherein, the series of ALM head (302) may be fed via processor (210) with internal cutting mechanism to cut the carbon fiber prepreg tape into at least one or more carbon fiber prepreg slits (203) of required lengths. In one embodiment, the series of ALM head (302) further, may lay the carbon fiber prepreg slits (203) as instructed via processor (210) in predefined number, simultaneously, to generate a geometric required shape (204) onto the thin plastic sheet (205). In one embodiment, the system (300) may comprise of at least one or more sheet cutter blades (207)
mounted with the help of gantry support (206) wherein, the sheet cutter blade (207) may cut the thin plastic sheet (205) along the periphery of required geometric shape (204) generated by deposition of carbon fiber prepreg slits (203).
[0019] Referring now to figure 4, a method (400) for automated layup making process in accordance with present subject matter. At step (401), the thin plastic sheet (205) may be laid manually on the bed (208) of the CNC table (209). In one embodiment, the system (200) may have a stationary bed (208). In another embodiment, the system (300) may have relatively moving bed (208).
[0020] At step (402), the prepreg slit rolls (201) may be mounted onto the ALM head (202), and one or more carbon fiber prepreg slit tapes may be guided through a guiding mechanism around the ALM head’s (202) rollers for initial setup. In one embodiment, the system (200), comprises of at least one or more prepreg slit rolls (201) mounted onto at least one or more ALM head (202), wherein one or more carbon fiber prepreg slit tapes may be manually guided through a guiding mechanism around the ALM head’s (202) rollers for initial setup. In another embodiment, the system (300), may comprise of the series of prepreg slit roll (301), mounted onto the series of ALM head (302), wherein one or more carbon fiber prepreg slit tapes may be manually guided through a guiding mechanism around the series of ALM head’s (302) rollers for initial setup.
[0021] At step (403), the processor (210) may be fed with the required data in accordance with the present subject matter. In one embodiment, the processor (210) is fed with a plurality of executable instruction either stored in an internal storage means or through an external storage device. The executable instructions may comprise the required data for producing the required geometric shape (204) further comprising length of each prepreg slit, cutting time, cutting angle and the like. Furthermore, the internal storage and the external storage may be either of the primary storage medium or a secondary storage medium comprising a hard disk, SD card, a USB drive and the like.
[0022] In one embodiment, the method of generating the layups using ALM head (202) as described in block (403) in the system (200) may comprise of the moving ALM head (202) mounted with a help of gantry support (206). Further the ALM head (202) may be fed with internal cutting mechanism via the processor (210), to cut the carbon fiber prepreg tape into at least one or more carbon fiber prepreg slits (203) of required lengths wherein, the carbon fiber prepreg tape may be guided to the ALM head (202) via guiding mechanism. Furthermore, the relatively moving ALM head (202) may lay the carbon fiber slits (203) as instructed via processor (210), uni-directionally, in a predefined number, simultaneously, onto the thin plastic sheet (205) placed on the bed (208). Once the ALM head (202) may lay the carbon fiber prepreg slit (203), along a line as required, the ALM head (202) may move to another adjacent position with the help of gantry support (206) for laying the next carbon fiber prepreg slits (203) for same width. The process of generation of layups using the ALM head (202) as described in block (403) continues until the required geometric shape (204) is generated.
[0023] In another embodiment, the method of generating the layups using series of ALM head (302) as described in block (403) in the system (300) may comprise the stationary series of ALM head (302). Further the series of ALM head (302) may be fed with internal cutting mechanism via the processor (210), to cut the carbon fiber prepreg tape into at carbon fiber prepreg slits (203) of required lengths wherein, the carbon fiber prepreg slit tape may be guided to the series of ALM head (302) via guiding mechanism. Furthermore, the series of ALM head (302) may lay the carbon fiber prepreg slits (203) uni-directionally, in a predefined number, simultaneously onto the thin plastic sheet (205) placed on the relatively moving bed (208). Once the series of ALM head (302) may lay the carbon fiber slit (203) along the required lines, the thin plastic sheet (205) on the relatively moving bed (208) may move forward on completion of generation of required geometric shape (204). The process of generation of layups using series of ALM head (302) as described in block (403) keeps on repeating till a predefined number of time.
[0024] At step 404, the built layups (306), along with the thin plastic sheet (205) may be cut with a sheet cutter blade (207). In one embodiment, the system (200) comprises of the ALM head (202) coupled with a sheet cutter blade (207) wherein, the sheet cutter blade (207) may be pushed through the required geometric shape (204) on the thin plastic sheet (205) placed on the bed (208) and guided along the periphery of the required geometric shape (204) generated by deposition of carbon fiber prepreg slits (203) to cut the required geometric shape (204) along with the thin plastic sheet (205). In another embodiment, the system (300), may comprise the sheet cutter blade (207) mounted with the help of the gantry support (206), wherein the sheet cutter blade (207) may be pushed through the required geometric shape (204) on the thin plastic sheet (205) placed on the bed (208) and guided along the periphery of the required geometric shape (204) generated by deposition of carbon fiber prepreg slits (203) to cut the built layup (306) of required geometric shape (204) along with the thin plastic sheet (205).
[0025] At step 405, removing the cut built layups (306) from the bed (208) along with the thin plastic sheet (205) wherein, the thin plastic sheet (205) may provide the necessary back support for the required geometric shape (204).
[0026] Further these cut built layups (306) of required geometric shapes (204), produced from either of the systems (200, 300) may be placed over the molds manually for building the carbon fiber part.
[0027] Although implementations of an automated layup making (ALM) process for preparing carbon fiber uni-directional prepregs for hand layup have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features are disclosed as examples of an automated layup making (ALM) process for preparing carbon fiber uni-directional prepregs for hand layup.