WO2016018194A1

WO2016018194A1 - Fiber placement head having double roller system and a fiber placement head application method

Info

Publication number: WO2016018194A1
Application number: PCT/TR2014/000312
Authority: WO
Inventors: Gökhan Vargın GÖK; Halil İbrahim KURT; Metin USAN
Original assignee: Gök Gökhan Vargin
Priority date: 2014-08-01
Filing date: 2014-08-01
Publication date: 2016-02-04

Abstract

Fiber placement head (12) providing strip (8) fiber, fiber-reinforced, plastic-based or different composite materials used for coating of the surfaces (11) to be applied on the surface, characterized in comprising an upper roller (1) where the strip (8) advanced by strip advancing means (27) is directed, which is embedded in the x1 axis and contains a plurality of strip channels (18) thereon and double roller structure (28) having a lower roller (2) embedded in the x2 axis under said upper roller (1) and positioned in such a way that the strip channels (18) will correspond to strip tabs (19) of the upper roller (1).

Description

FIBER PLACEMENT HEAD HAVING DOUBLE ROLLER SYSTEM AND A

FIBER PLACEMENT HEAD APPLICATION METHOD

Technical Field

The invention is related to the fiber placement head enabling it for carbon fiber strip, glass fiber, aramid fiber-reinforced composite materials to be coated on the surface.

Said invention is related to the double roller fiber placement head eliminating the technical problems such as overlapping of the strips or spreading apart in uncontrolled area by guiding the strips to the application surface.

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Prior Art

The exterior body surfaces of the vehicles, especially airplanes, used in aviation, aerospace, automotive and wind turbine technology are coated with strip materials made of fiber-based materials. The strip materials are also known as tow. Carbon fiber, glass fiber or aramid fiber-reinforced composite materials expressed as strip or tow are formed into strips. After being formed into strip, the work is being done on surface through fiber placement head containing guiding pulleys and the pressure roller as strips in row. After fiber placement head is preferably adapted to a robot arm, the surface can be coated by means of the robot arm.

In figure-15 the two-dimensional side and front views of the strip fiber placement head of the prior art are illustrated. Tows i.e. the fiber materials cut into strips are led to the pressure roller by means of guiding strips and rollers. The strips transmitted to the pressure roller are applied via pressing on surface at this stage.

In current production technology the pressure is made on the surface where the strips will be applied by means of fiber placement head with a single roller. During the application the guiding and aligning operations of the strips can not be fully controlled. Because all stripes are in juxtaposition and there is no distance therebetween for

l guiding on a single roller at the exit of fiber placement head, no guiding operation can be performed after the strips get out from fiber placement head. The strips are guided in an uncontrolled manner from fiber placement head to the roller and therefrom to the application surface. This causes the fiber strips to be applied to the surface to overlap or spread apart. Thus the manufactured product decreases in quality. The other parts out of the desired tolerances are to be scrap and cause waste.

This production technique used in present art can not provide exactly the production speed, resistance of the finished product and production under the conditions required in design. Furthermore, at least half of the strips to be placed to body surface (plane, car, turbine and so on) are required be arranged in an angled way to the pressure roller and this leads strips to be exposed to problems like adhesion, writhing in the hand and causes the process to stop frequently and to lose productivity. Similar fiber placement rollers have a single type of placement surface diameter due to their nature. This diameter can not be changed.

In patent research done in relation to prior art, the U.S. patent numbered US6968883 has been encountered. In this application, the fiber coating on cylindrical and radius surfaces is mentioned. The fiber placement head used in this system discloses spools and pressure rollers propelling a great number of strips. A single pressure roller is used in this system.

In other U.S. patent numbered US6390169 a fiber placement head apparatus applying fiber coating on convex and concave surfaces is mentioned. An embodiment in eccentric form taking shape with respect to the concave structure on the surface where fiber coating will be applied is mentioned.

In other patent numbered US6096164 a fiber placement head having a single pressure roller movable in multi axis is mentioned.

Description of the Invention

The object of the invention is to introduce a different application technique bringing a new insight in this art, which is different from fiber strip methods applied on the surface in present technique. The object of the invention is that fiber-based strips are guided by a double roller system instead of a single roller to the surface (airframe, carbody, turbine, etc.) to be coated with fiber material. An object of the invention is that the strips are applied to the surface quickly and precisely with double roller system.

Another object of the invention is to continue the guiding process on the roller with double roller system. So the strips are made possible to be guided to the surface i.e. to last point where they will be applied.

Another object of the invention is that thanks to the double roller system the tolerance of the distance therebetween is accurately controlled. Another object of the invention is that because the strips are not exposed to any break or an angled guidance in fiber placement head with double-roller system, they can be fed properly and quickly. Thus the fiber placement head of strips are fed smoothly and evenly and also the strips can be guided to the last point where they will be applied. This increases the production quality and productivity.

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Another object of the invention is that it can be made demountable quickly as it is modular compared to similar systems. In this way, the maintenance and installation time is reduced. A different object of the invention is that it provides the use possibility with 1/8, 1/4, 1/2 fibers instead of uniform fibers, with double roller system as the modules thereon can be changed.

The object of the invention is that the weight and the size have been reduced thanks to design structure of the new embodiment. This has increased the ease of use in comparison with similar pleacement systems.

The object of the invention is that controlled pressure and rolling feature are provided thanks to double roller system and the material used. The placement diameter provides controlling in a manner to be increased or decreased.

In order to fulfill the objects described above; -an upper roller where the strip advanced by strip advancing means is directed, which is embedded in the x1 axis and contains a plurality of strip channels thereon,

- the double roller structure which has a lower roller embedded under said upper roller in the x2 axis and^' positioned such that the strip channels will correspond to the strip tabs of upper roller,

- an auxiliary additional pressure roller configured under the upper and lower roller simultaneously applying pressure to the application surface, are involved.

Figures Assisting the Understanding of the Invention

Figure-1 ; The upper perspective view of the fiber placement head of the invention providing fiber strips to be placed to the surface and to be applied thereto.

Figure-2; The lower perspective view of the fiber placement head of the invention.

Figure-3; Two-dimensional views of the fiber placement head of the invention from different angles.

Figure-4; Two-dimensional cross-section and close-up views of the fiber placement head of the invention.

Figure-5; The section C-C close-up view showing the application of strips to the surface representatively.

Figure-6; The individual, close-up perspective view of the double roller structure of the invention.

Figure-7; The individual, close-up two-dimensional views of double roller structure of the invention from different angles.

Fi ure-8; State change view of the pressure rollers when applying pressure to the application surface.

Figure-9; The individual views of pressure rollers on which channels have been formed for strips to be guided.

Figure-10; The views of the pressure rollers along with strips positioned in guide channels.

Figure-11 ; The perspective views of pressure rollers with a channel structure.

Figure-12; The two-dimensional front and side views with guide elements configured on the pressure roller bearing the channel structure.

Figure-13; The two-dimensional front and side views of strips with guide elements while they are on the pressure roller. Figure-14; The perspective views of strips with guide elements while they are on the pressure roller.

Figure-15; The two-dimensional front and side views of the fiber placement head with a single pressure roller of the prior art.

Number of the Parts

1. Upper Roller 18. Strip channels

2. Lower Roller 19. Strip tabs

3. Additional Pressure Roller 20 Bearing protrusions

21 Transition duct

4. Upper Back Guide

22 Bearing bore

5. Upper Front Guide

23 Robot mounting area

6. Lower Back Guide

24 Strip pulleys

7. Lower Front Guide

25 Guiding pulleys

8. Strip

26 Roller module

9. Upper Set strips

26.1 Module housing

10. Lower Set strips

26.2 Mounting openings

11. Application Surface

26.3 Holding elements

12. Fiber placement Head

26.4 Bearing axis

13. Flexible Roller Layer

26.5 Side edges

14. Roller Pressure Layer

27 Strip advancing means

15. Upper Router

28 Double roller structure

16. Lower Router

17. Feeding Engine

Detailed Description of the Invention

In Figure 1 and 2 the view of the fiber placement head (12) providing strip (8) fiber, fiber-reinforced, plastic-based or different composite materials used for coating of the surfaces (11) to be applied onto the surface is illustrated from different angles. As its general structure, the fiber placement head (12) has an upper roll (1) where the strip (8) advanced by the strip advancing means (27) is guided, which is embedded in the x1 axis and contains a plural number of strip channels (18) thereon. Similarly, it contains a double roller structure (28) which has another lower roller (2) embedded under the upper roller (1) in the x2 axis and positioned in such a way that the strip channels (18) will correspond to strip tabs (19) of the upper roller. (1) (See fig. 9 and 10)

In Figure-5, an auxiliary additional pressure roller (3) configured under the lower roller (2) and the upper roller (1), applying pressure simultaneously to the application surface (11)is provided. The additional pressure roller (3) has already been configured in order to ensure that strip (8) will not move from the application surface (11) and will be stuck thereto. An additional pressure is applied toward the application surface (11) also subsequent to placing of strip (8) already placed with this additional pressure roller (3) and stuck to the surface during placing.

In Figure 12, 13 and 14, the upper router (15) and lower router (16) configured between said upper roller (1) and lower roller (2) and on the upper roller (1), guiding said strips (8) have been detected. Likewise, a plurality of transition ducts (21) on upper router (15) and lower router (16) allowing the strips (8) to pass and formed in such a way that they will correspond to lower and upper roller (1 ,2) strip channels (18) are provided.

The strips (8) from feeding system and with their numbers varying depending on process are possible to be formed to have preferably 1 , 12, 60 or more numbers. After entering from upper part of the fiber placement head (12), for upper set strips (9), the strips (8) pass through upper back guide (4) and upper front guide (5), respectively which will move straight until the application surface (11). The guiding is provided in the fiber placement head (12) by means of lower back guide (6) and lower front guide (7), respectively, for lower set strips (10). After leaving from the upper front guide (5) being the last guiding in the fiber placement head (12), the upper set strips (9) enter the upper roller (1) enabling it for both pressure and guiding processes to be able to continue up to the application surface (11) thanks to the flexible structure thereof with channels. Lower set strips (10) exit from lower front guide (7) which is the last guiding in the fiber placement head (12). Then they enter the lower roller (2) enabling it for both pressure and guiding processes to be able to continue up to the application surface (1 1) thanks to the flexible structure thereof with channels. After upper set strips (9) arrive the upper roller (1) and lower set strips (10) arrive lower roller (2), the strips (8) are placed on the strip channels (18) of the related rollers by closing upper router (15) and lower router (16) over the lower and upper rollers (1 ,2) with the help of a propulsion before starting the placement. Both upper and lower rollers (1 , 2), thanks to the flexible roller layer (13) comprised therein, allow the strips (8) to be guided up to the application surface (11). Roller pressure layer (14), however, provides strips (8) to be pressed to the surface (1 1) in desired force. The fiber placement head (12) is continuously pressed to the application surface ( 1) by robot for the strips (8) to be applied on the surface. In the meantime, the flexible roller layers (13) enabling the guiding in upper roller (1) and lower roller (2) are stretched, thereby providing the strips (8) to be pinched between application surface (1 1) and roller pressure layers (14). Thus they allow the exposure to the desired pressure. In Figure-6 and 7, the module housing (26.1), on side edges (26.5) of which mounting openings (26.2) have been formed to stabilize upper roller (1) and lower roller (2) is illustrated. The holding elements (26.3) providing the upper router (15) and lower router (16) to be connected to the module housing (26.1) by means of bearing bore (22) and bearing axis (26.4) are stabilized. Roller pressure layer (14) and flexible roller layer (13) of said upper roller (1) and lower roller (2) are included. (See figure-8). It has an upper back guide (4) sent to said double roller structure (28) in a single axis at the same feeder. (See figure-2)

On the other hand, while the roller pressure layer (14) of upper roller (1) and lower roller (2) is made of the hard material, flexible roller layer (13) thereof is made of elastic material. Actually the strip channels (18) are formed on flexible roller layer (13) of the upper roller (1) and lower roller (2).

Upper back guide (4), upper front guide (5), lower back guide (6) and lower front guide (7) provide the strips (8) to be fed to the rollers evenly without any angle changes in the fiber placement head (12). This can be made possible only with a double roller structure (28) as an upper roller (1) and lower roller (2). In present systems, some technical problems like entrapping of the strips (8) in the fiber placement head (12) are eliminated. Also, the uncontrolled area where the strips (8) available in present systems are not guided is eliminated and the strips (8) are guided up to the desired last point, i.e. application surface (11). As upper front guide (5) and lower back guide (6) are coated with teflon material, adhesion of the strips (8) to the surface is prevented. On the other hand, because the system is cooled, an appropriate environment is provided for the flow of strips (8). A feeding engine (17) connected to the fiber placement head (12) provides movement for feeding system.

In Figure-15, the two-dimensional front and side views of the fiber placement head (12) with a single pressure roller of the prior art are illustrated. In this system, the strip (8) is based on the surface where the fiber coating will be applied from a single point i.e. through a single pressure cylinder. This system and similar systems used in present technique contain mostly single cylinder. And strip (8) guiding channels are not provided on the cylinder. That the guiding channels are not provided on the roller constitutes :the area described as uncontrolled area after strips (8) exit from the guides in the fiber placement head (12) and where the strips (8) are not guided up to the single pressure roller and from this roller to the application surface (11). On the other hand, the double roller system also eliminates the quality problems such as overlapping and spreading apart of the strips which will occur in the uncontrolled area by guiding the strips (8) up to the desired last point, i.e. application surface (11).

Claims

A fiber placement head (12) providing strip (8) fiber, fiber-reinforced, plastic- based or different composite materials used for coating of the surfaces (11) to be applied on application surface (11), characterized in comprising; an upper roller (1) where the strip (8) advanced by strip advancing means (27) is directed, which is embedded in the x1 axis and contains a plurality of strip channels (18) thereon

double roller structure (28) having a lower roller (2) embedded in the x2 axis under said upper roller (1) and positioned in such a way that the strip channels (18) will correspond to strip tabs (19) of the upper roller (1).

The fiber placement head (12) according to Claim 1 , characterized in comprising an auxiliary additional pressure roller (3) configured under the upper roller (1) and the lower roller (2) which simultaneously apply pressure on the application surface (11).

The fiber placement head (12) according to Claim 1 , characterized in comprising upper router (15) and lower router (16), guiding said strips (8), which is structured between said upper roller (1) and lower roller (2) and which is on the upper roller (1).

The fiber placement head (12) according to Claim 3, characterized in comprising a plurality of transition ducts (21) allowing the strips (8) to pass on said upper router (15) and lower router (16) and formed in such a way that they will correspond to lower and upper roller (1 , 2) strip channels (18).

The fiber placement head (12) according to Claim 1 , characterized in comprising a module housing (26.1), on side edges (26.5) of which said upper roller (1) and lower roller are (2) stabilized and mounting openings (26.2) are formed.

The fiber placement head (12) according to Claim 1 , characterized in comprising holding elements (26.3) providing the connection of said upper router (15) and lower router (16) with module housing (26.1) by means of bearing bore (22) and bearing axis (26.4).

7- The fiber placement head (12) according to Claim 1 , characterized in that said upper roller (1) and lower roller (2) comprise roller pressure layer (14) and flexible roller layer (13).

8- The fiber placement head (12) according to Claim 7, characterized in comprising upper roller (1) and lower roller (2) whose said roller pressure layer (14) is made of hard material and whose flexible roller layer (13) is made of elastic material.

9- The fiber placement head (12) according to Claim 7, characterized in comprising strip channels (18) formed on flexible roller layer (13) of said upper roller (1) and lower roller (2).

10- The fiber placement head (12) according to Claim 1, characterized in comprising an upper back guide (4) sent to said double roller structure (28) in a single axis at the same feeder.

11- A fiber placement head (12) application method providing strip (8) fiber, fiber- reinforced, plastic-based or different composite materials used for coating of the surfaces (11) to be applied on application surface (11), characterized in comprising the process steps of

- bedding of an upper roller (1) containing a plurality of strip channels (18) thereon in the x1 axis,

- bedding of the lower roller (2) in such a way that it will correspond to the strip tabs (19) of said upper roller (1),

- applying the double roller structure (28) containing upper roller (1) and lower roller (2) to the application surface (11) with upper set strips (9) and lower set strips (10) in a double-acting manner..

12- The fiber placement head (12) application method according to Claim 11 , characterized in comprising the process steps of positioning the lower roller (2) strip channels (18) in such a manner to correspond to said upper roller (1) strip channels (18). 13- The fiber placement head (12) application method according to Claim 11 , characterized in comprising the process steps of positioning the upper strips (9) in the strip channels (18) of said upper roller (1) and positioning the lower set strips (10) in the strip channels (18) of the lower roller (2).

14- The fiber placement head (12) application method according to Claim 11 , characterized in comprising the process steps of advancing upper strips (9) in strip channels (18) of said upper roller (1) and at the same time advancing lower set strips (10) in strip channels (18) of the lower roller (2).

15- The fiber placement head (12) application method according to Claim 1 1 , characterized in comprising the process steps of guiding the strips (8) continuously in strip channels (18) of said upper roller (1) and lower roller (2) in a double-acting manner during coating.