EP2928801B1 - Method and system for feeding material to a lay-up machine - Google Patents

Description

STATE OF THE ART Field of the invention

The present embodiments relate generally to advanced composites, and more particularly to systems and methods for continuous material feeding in an automated lay-up system. The embodiments relate to the equipment and systems used to make advanced composite components using the automated lay-up process using materials that are typically provided in the form of coiled tapes.

Background of the invention

The present invention relates to the equipment and systems for making advanced composite components using the automated lay-up process using materials typically provided in the form of a coiled-up belt. The material coils are of finite length and must be replaced after unwinding to hang up the next part. It is also advantageous in many cases, a multilayer composite part using a mixture of different Constructing composite materials and / or strip materials of different widths. The manufacturing process for such parts therefore involves a high degree of unproductive time for refilling spent spools of material and / or changing from one type of material to another. In addition, if a malfunction occurs in the tape feed system, production is often interrupted until the problem is solved.

Automated lay-up systems of the prior art typically use a motorized chuck to hold the material spool. A combination of the rotation of the jig and the movement of the traction drive by one or more motor-driven pinch roller devices serves to unwind the strip material from the spool and insert it into the lay-up machine. When a spool of material is consumed or the part requires a different material or width, production is halted and an operator must manually pull out residual tape from the pinch rollers and remove the empty core of material from the jig. Thereafter, a new material spool is mounted on the jig and aligned, whereupon the beginning of the new spool is inserted into the pressure rollers. Thereafter, production is resumed and continued until the material reel is consumed again, the part requires a material of different type or width, or a malfunction occurs.

Such a system is z. B. from the US 2011/0042012 A1 known.

It is therefore an object to provide a system and method for feeding material to a lay-up machine which overcomes the foregoing disadvantages.

It is a further object to provide a system and method for delivering material to a lay-up machine that will minimize any interruptions in production.

It is a still further object to provide a system and method for feeding material to a lay-up machine which enables a continuous supply of material, in particular recharging, maintenance and repair work being performed off-line .

SUMMARY

The above and other objects are achieved with a system and method for feeding material to a lay-up machine as defined in claims 1 and 5. Further preferred embodiments are set forth in the dependent claims.

As a solution, there is provided a system for feeding material to a lay-up machine, the system comprising first to fourth material drives, each of which can be loaded with a material spool, and each having a motor-driven jig, pulleys and a motor-driven pinch roller device; each of the first to fourth material drives can deliver material from the respective material spool via a respective tape path to a feeder of the laying machine; the first and second material drivers form a first pair of material drives mounted on a first common support driven by a first drive means, the first and second material drives being loadable with material spools of different material types and / or material widths; the third and fourth material drives form a second pair of material drives mounted on a second common support driven by a second drive means, the third and fourth material drives being loadable with material spools of different material types and / or widths; The material type of the third material spool corresponds to the material type of the first material spool and the material type of the fourth material spool corresponds to the material type of the second material spool, and if the first or the second pair of material drives is in an active zone in the active mode of supplying the lay-up machine, the other, second or first pair of material drives are positioned in a maintenance zone, in an inactive state to allow access for reload, maintenance or repair personnel, and wherein the system is arranged when a material spool is one of the material propulsion e of the pair of material drivers in the active zone is consumed to actuate the first and second drive means to swap the position of the first and second pairs of material drives to drive the pair of material drives in the To move the active zone into the maintenance zone and to place the inactive pair of material drives located in the maintenance zone in the active zone for supplying the laying machine.

Preferably, the system is arranged to actively supply material to the lay-up machine at any one time with one of the first to fourth material drivers of the first or second pair, while the other material drive of the pair in question remains at rest / standby until a parts lay-up program requires a change of material, and if the parts lay-up program requires a change of material, the other material drive of the respective first or second pair is positioned by operating the first drive means on the lay-up machine aligned with the feeder.

Preferably, it can be provided that the first and the second common support are formed by a first and a second support arm, and the first and second drive means are formed by a first and a second rotary drive, wherein the first and the second rotary drive mounted on a base support structure wherein the first and second rotary drives are coaxially positioned so that each pair of material drives can move independently of the other about the same pivot point, and wherein a rotation axis is arranged so that each of the material drives are positioned in alignment with the feeding machine can.

Alternatively it can be provided that the first and the second common support are formed by a first and a second carriage means, and the first and second drive means are formed by a first and a second linear drive, wherein the first and the second linear actuator are positioned offset parallel to each other such that each pair of material drives can move independently of the other along the same linear path, the first and second linear drives being supported by a series of base support structures, and wherein the linear drives are arranged so that each of the material drives are aligned for delivery Slip machine can be positioned.

As another solution, a system is provided for feeding material to a lay-up machine, the system comprising first to fourth material drives, each of which can be loaded with a material spool, and each having a motor-driven jig; the first and the second material drive form a first pair of material drives, wherein the first and the second material drive can be loaded with material spools of the same material types and material widths, the third and the fourth material drive are arranged at a distance from the first and the second material drive, and a second material drive Pair of material drives form, wherein the third and the fourth material drive can be loaded with material coils of the same material types and material widths, the first and the second material drive material over a first tape path in the laying machine (68), and the third and the fourth material drive material over a second belt path into the lay-up machine, the system being arranged such that for each pair of material drives one of the material drives of the pair can actively supply material while the other material drive of the pair can remain in a standby / standby state, wherein the belt paths of the material drives of a respective pair of material drivers unite at a splicing mechanism, the system being arranged to activate the splicing mechanism in the event of a spent material spool of one of the pair's material drives so that one end of the spent material spool is automatically at the beginning of a fresh one Material spool of the other material drive of the pair can be attached or spliced, and can resume production with the other material drive.

Preferably, it can be provided that the tape path of the first material drive and the second material drive are each determined by a plurality of pulleys, which are each mounted on a first carriage or a second carriage, wherein the first and the second carriage form the splicing mechanism, the first and the second carriage may each move linearly and independently via a driven sliding mechanism, the first and second carriages each comprise a cutter, an adjustable guide, a material clamp, and a movable belt deflector, the first carriage further comprises a movable welding stopper, and the second carriage further comprises a movable welding device, wherein the system is arranged to fix the end of a spent material spool of the first material drive automatically at the beginning of a fresh material spool of the second material drive of the pair to stop the supply of strip material from the first material drive, the second carriage by the sliding mechanism so that the material of the second material drive is aligned on the tape path to the lay-up machine to actuate the tape deflecting means of the first and second carriage and thus causing it to extend, so that the tape material comes from the first material drive in contact with the strip material from the second material drive, the movable welding stop means extend on the first carriage to contact the strip material from the first material drive, extend the welding device on the second carriage in contact with the strip material from the second material drive to the strip material from the second material Antri eb and pressing the strip material from the first material drive against the movable welding stop device of the first carriage, the welding device at the second carriage for activating for connecting the strip material from the first material drive with the strip material from the second material drive device to actuate the cutting device at the first carriage, to disconnect the belt from the first material drive, retract the material clamping device and the welder on the second carriage, retract the movable welding stopper on the first carriage, retract the movable belt deflectors on the first and second carriages, feed material, until the severed end of the Bandmaterial arrives from the first material drive in the position opposite to the movable welding device of the second carriage to re-actuate the belt deflection devices on the first and the second carriage and to cause the outward movement so that the severed end of the strip material from the first material drive comes into contact with the strip material from the second material drive to re-extend the movable weld stopper on the first carriage to contact the severed end of the strip material from the first material drive to extend the welder on the second carriage again in contact with the strip material from the second material drive to push the strip material from the second material drive and the cut end of the material from the first material drive against the movable welding stop means (65) of the first carriage the welding device on the second carriage again to retract the severed end of the strip material from the first material drive with the strip material from the second material drive, retract the material clamp and the welder on the second carriage, retract the movable weld stopper on the first carriage, retract the movable belt deflectors on the first and second belts withdraw the second slide again and resume production.

Preferably, sensors are further provided for detecting a spliced portion of the strip material entering the feeder of the lay-up machine, the sensors being arranged to trigger the cutting mechanism and separate the leading edge of the splice from the trailing edge of the preceding strip material from the first material drive. which has already been fed to the lay-up machine, and further comprising sensors for detecting the trailing edge of the spliced portion, the sensors being arranged to again trigger the cutting mechanism to separate the spliced portion from the new strip material from the second material drive.

As yet another solution, there is provided a method of feeding material to a lay-up machine, the method being more particularly performed with a system for feeding material to a lay-up machine, comprising: feeding material of a first type of material from the first material drive to the lay-up machine; if one of the material spools on the first material drive or the second material drive is consumed or a malfunction is detected: depending on which of the material drives actively supplies the lay-up machine with material, operating the pinch roller device and the motorized jig on the relevant material drive to engage with the feeder to rewind band material still connected on the laying machine; Actuating the first and second drive means so as to simultaneously displace the first and second material drives from the active zone to the maintenance zone and the third and fourth material drives from the maintenance zone to the active zone; Resumption of production by the third and fourth material drive themselves in the role of the supplier of the laying machine In accordance with the requirements of the parts laying program alternate; and recharging, cleaning and / or servicing the first and / or the second material drive.

Preferably, it may be provided that the method further comprises: continuing production until the parts lay-up program requests a change to a second type of material; Actuating the pinch roller means and the motorized jig on the first material drive to wind the first type of material strip still connected to the feeder on the lay-up machine along the first tape path; Actuating the first drive means to align the second material drive with the feeder on the lay-up machine; Actuating said pinch roller means and said motorized jig on said second material drive to further advance said second material type strip material along said tape path into said feed on said lay-up machine; and resuming production by supplying the lay-up machine with strip material through the second material drive.

As yet another solution, there is provided a method of feeding material to a lay-up machine, the method being more particularly performed with a system for feeding material to a lay-up machine, comprising: feeding tape material to the lay-up machine from the first material drive via the first tape path ; when the material spool is consumed at the first material drive: stop the strip material supply from the first material drive; Displacing the second carriage by the sliding mechanism so that the material from the material drive is now aligned with the tape path to the laying machine; Actuating the belt deflection means on the first and second carriages so that the belt material from the first material drive comes in contact with the belt material from the second material drive; Extending the movable welding stop means on the first carriage to contact the strip material from the first material drive; Extending the welding device on the second carriage into contact with the strip material from the second material drive, pressing the strip material from the second material drive and the strip material from the first material drive against the movable welding stop device on the first carriage; Activating the welding device on the second carriage and connecting the strip material from the first material drive to the strip material from the second material drive; Actuating the cutting device on the first carriage to separate the strip material from the first material drive; Retracting the material clamping device and the welding device on the second carriage; Retracting the movable welding stop device on the first carriage; Retracting both movable belt deflectors on the first and second carriages; Feeding material until the severed end of the strip material from the first material drive arrives at the position opposite the movable welding device; re-operating the tape deflectors on the first and second carriages so that the severed end of the tape material from the first material drive comes in contact with the tape material from the second material driver; rewinding the movable welding stop device on the first carriage to contact the severed end of the strip material from the first material drive; rewinding the welding device on the second carriage into contact with the strip material from the second material drive and pressing the strip material from the second material drive and the cut end of the material from the first material drive against the movable welding stop means; re-activating the welding device on the second carriage to connect the severed end of the strip material from the first material drive to the strip material from the second material drive; retracting the material clamping device and the welding device on the second carriage again; retracting the movable welding stop device on the first carriage again; retracting both movable belt deflectors on the first and second carriages again; Resuming production with the material supplied by the second material drive; Cleaning the tape path through the first carriage, reloading the first material drive with a fresh material spool and threading the leading edge of the tape through the cutter, the adjustable guide means, the material clamping means and the movable tape deflecting means on the first carriage; and extending the material clamp and the movable belt deflector on the first carriage to hold the fresh material fixed while the first material drive is awaiting the next material change and splicing operation.

Preferably, the method may further include: as the spliced portion of the tape penetrates the feeder of the lay-up machine, detecting the spliced portion by sensors that trigger the cutting mechanism and separate the leading edge of the splice from the trailing edge of the preceding tape material from the first material drive already has been fed into the laying machine; further forward feeding the leading edge of the spliced band section and deflecting from the lay-up machine into a waste container; Sensing the trailing edge of the spliced portion by sensors that again trigger the cutting mechanism to separate the spliced portion from the new ribbon material from the second material drive; Resuming production after the spliced section has been completely redirected to the waste container.

There is further provided an automated lay-up system comprising a lay-up machine and a system for feeding material to the lay-up machine.

The embodiments provide systems and methods for continuous material feeding in an automated lay-up system. The embodiments may be particularly applied to the methods and systems fully incorporated in this document U.S. Patent Application No. 13 / 557,621, filed July 25, 2012 , are disclosed.

Other systems, methods, features, and advantages of the embodiments will be readily apparent to those skilled in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included in this specification and summary, be within the scope of the embodiments, and be protected by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 bis 3

ein System zur kontinuierlichen Ladung von Spulenmaterialien gemäß einem ersten Ausführungsbeispiel;

Fig. 4 bis 6

ein System zur kontinuierlichen Ladung von Spulenmaterialien gemäß einem zweiten Ausführungsbeispiel; und

Fig. 7 bis 11

ein System zur kontinuierlichen Ladung von Spulenmaterialien gemäß einem dritten Ausführungsbeispiel;

The embodiments can be better understood with reference to the figures and descriptions presented below. The components in the figures are not necessarily to scale, it is primarily to the illustration of the principles of the embodiments. In addition, it should be noted that identical reference numerals denote identical parts throughout the different views of the figures. Show it:

Fig. 1 to 3

a system for continuously charging coil materials according to a first embodiment;

4 to 6

a system for continuously charging coil materials according to a second embodiment; and

Fig. 7 to 11

a system for continuously charging coil materials according to a third embodiment;

DETAILED DESCRIPTION

The present embodiments relate to the equipment and systems for making advanced composite components using the automated lay-up process using materials typically provided in the form of a coiled-up belt. The material coils are of finite length and must be replaced after unwinding to hang up the next part. It is also advantageous in many cases to construct a multilayer composite part using a mixture of different composite materials and / or band materials of different widths.

Double Feed Methods and Continuous Charge Media Systems - Rotary Configuration

In a first embodiment (cf. FIG. 1 ), four material drives (each material drive being composed of a motor-driven jig, a material reel, pulleys, and a motor-driven pinch roller device) are configured to rotate about a common axis. Two of the material drives are mounted on a common bracket, which in turn is driven by a rotary drive. The two other material drives are mounted on a second common bracket, which in turn is driven by a second rotary drive. The two rotary actuators are coaxially positioned so that each pair of material drives can move around the same pivot independently of the other. The rotation axis is arranged so that each of the material drives can be positioned in alignment with the material feed of the lay-up machine.

The two material drives in a particular pair are loaded with spools of different material types and / or widths so that each type of material can be fed to the lay-up machine while that particular pair of material drives is active. At any one time, one of the material drives of a particular pair actively feeds the lay-up machine with material while the other material drive remains in the idle / standby position until the parts lay-up program requires a change of material. If the parts lay-up program requires a change of material, the transition occurs with minimal production breaks (for repositioning the material drives and feeding material) and without personnel intervention. The two material drives alternate with each other in the role as a provider of the laying machine, depending on the requirements of the parts laying program.

The second pair of material drivers are configured, loaded and operated in an identical manner as the first pair. While the first pair of material drives are in the active mode of supplying the lay-up machine, the second pair of material drives is positioned in the maintenance zone where it waits in an inactive state upon completion of re-charge, maintenance or repair by an operator.

If a material spool is consumed or a malfunction is detected in the first pair of material drivers, production is interrupted while the first pair and the second pair of material drivers change positions, i. the second pair of material drives take over the tasks of supplying the lay-up machine while the first pair is placed in the maintenance zone. After the first pair of material drives have been reloaded and / or repaired by an employee, this goes to an inactive state in the waiting position.

This arrangement provides a pair of material drivers with the ability to be available to provide the lay-up machine with both types of material at minimum production stoppages while the other pair of material drives can be reloaded, cleaned or repaired. In this way, a more or less continuous supply of a laying machine is secured with tape material.

Referring to Figure 1 to 3 follows a detailed description of the system:

The rotatable automated loading system 15 is composed of two pairs of material drives together with their support arms, two rotary drives and a base support structure. The material drives 1 and 2 comprise one of the two pairs and are loaded with coils of different material types and / or widths. The material drive 1 supplies material from the material spool 5 (material type "A") via the tape path 9 to the feed 49 of the laying machine 16. The material drive 2 delivers material from the material spool 6 (material type "B") via the tape path 10 to the feeder 49 of the laying machine 16. The material drives 1 and 2 are mounted on the support arm 7, which in turn is mounted on the rotary drive 13.

The material drives 3 and 4 comprise the second pair described above and are also loaded with coils of different material types and / or widths. The material drive 3 supplies material from the material spool 5 (material type "A") via the tape path 11 to the feed 49 of the laying machine 16. The material drive 4 supplies material from the material spool 6 (material type "B") via the tape path 12 to the feeder 49 of the laying machine 16. The material drives 3 and 4 are mounted on the support arm 8, which in turn is mounted on the rotary drive 14. Both rotary actuators are mounted on the base support structure 17.

In the initial operating configuration, the material type "A" of the lay-up machine 16 is supplied continuously from the material drive 1 via the tape path 9. Production continues until the Part Loader requests a change to Material Type "B" at which point the following event sequence occurs:

The pinch roller device 18 and the motor-driven jig 22 on the material drive 1 are operated to wind the strip material (type "A") still connected to the feeder 49 on the lay-up machine 16 along the tape path 9.

The rotary drive 13 is actuated, and the support arm 7 is rotated to align the material drive 2 on the feeder 49 on the laying machine 16.

The pinch roller device 19 and the motor-driven jig 23 on the material drive 2 are actuated to further move the strip material (material type "B") along the tape path 10 into the feeder 49 on the lay-up machine 16.

The production is resumed by the material drive 2 supplies the laying machine 16 with strip type "B".

If one of the material spools on the material drive 1 or the material drive 2 is consumed or a malfunction is detected, the following event sequence takes place:

Depending on which material drive the lay-up machine 16 actively supplies material, the pinch roller means 18 and the motorized chuck 22 on the material drive 1 or the pinch roller means 19 and the motorized jig 23 on the material drive 2 are actuated to engage with the feeder 49 on the lay-up machine To rewind 16 remaining band material.

The rotary actuators 13 and 14 are both actuated, and the support arms 7 and 8 are rotated in a coordinated manner, so that simultaneously the material drives 1 and 2 are offset from the active zone to the maintenance zone and the material drives 3 and 4 from the maintenance zone to the active zone.

The rotary drive 13 is set in the inactive state.

Depending on which type of material is currently required by the lay-on program, the rotary drive 14 positions either the material drive 3 or the material drive 4 on the laying machine 16 aligned with the feed 49.

Depending on what type of material is currently required by the lay-on program, the Andruckrolleneinrichtung 20 and the motor-driven jig 24 on the material drive 3 or the Andruckrolleneinrichtung 21 and the motor-driven jig 25 on the material drive 4 are operated to the tape along the tape path 11 or the tape path 12 in to move the feeder 49 on the laying machine 16 on.

The production is resumed by the material drives 3 and 4 alternating in the role of the supplier of the laying machine 16 in accordance with the requirements of the parts laying program.

At the same time, the material drives 1 and 2 are reloaded, cleaned and / or repaired by an operator and wait in an inactive state in the maintenance zone until the next transition event.

If one of the material spools on the material drive 3 or the material drive 4 is consumed or a malfunction is detected, the following event sequence takes place:

Depending on which material drive the lay-up machine 16 actively supplies material, the pinch roller device 20 and the motor-driven jig 24 on the material drive 3 or the pinch roller device 21 and the motor-driven jig 25 on the material drive 4 are actuated, to rewind the strip material still connected to the feeder 49 on the laying machine 16.

The rotary actuators 13 and 14 are both actuated, and the support arms 7 and 8 are rotated in a coordinated manner, so that simultaneously the material drives 3 and 4 are offset from the active zone to the maintenance zone and the material drives 1 and 2 from the maintenance zone to the active zone.

The rotary actuator 14 is set in the inactive state.

Depending on which type of material is currently required by the laying-on program, the rotary drive 13 positions either the material drive 1 or the material drive 2 on the laying machine 16 aligned with the feed 49.

Depending on what type of material is currently required by the lay-on program, the Andruckrolleneinrichtung 18 and the motor-driven jig 22 on the material drive 1 or the Andruckrolleneinrichtung 19 and the motor-driven jig 23 on the material drive 2 are operated to the tape along the tape path 11 or the tape path 12 in to move the feeder 49 on the laying machine 16 on.

The production is resumed by the material drives 1 and 2 again in the role of the suppliers of the laying machine 16 in accordance with the requirements of the parts-laying program alternate.

At the same time, the material drives 3 and 4 are reloaded, cleaned and / or repaired by an operator and wait in an inactive state in the maintenance zone until the next transition event.

The above described mode of operation may be continued indefinitely, with the two pairs of material drivers alternating between an active supply of strip material to the lay-up machine in the active zone and the readiness for recharge or repair in the maintenance zone. Due to the more or less continuous feeding of two different material types to one Laying machine and the provision of a means for an employee to safely reload the material reels or to perform maintenance and / or repair tasks during production, the above-described embodiments bring a significant reduction of unproductive times in connection with the lay-up method for producing multilayer composite parts.

Double Feed Methods and Continuous Charge Systems of Rolled Materials - Linear Configuration

In an alternative embodiment (cf. FIG. 4 ) are four material drives (each material drive composed of a motorized jig, a material reel, pulleys, and a motorized pinch roller device) configured to travel along a common axis. Two of the material drives are mounted on a common carriage, which in turn is driven by a linear drive. The two other material drives are mounted on a second common carriage, which in turn is driven by a second linear drive. The two linear drives are offset parallel to each other so that each pair of material drives can move independently of the other along the same linear path. The linear drives are arranged so that each of the material drives can be positioned in alignment with the material feed of the lay-up machine.

The two material drives in a particular pair are loaded with spools of different material types and / or widths so that each type of material can be fed to the lay-up machine while that particular pair of material drives is active. At any one time, one of the material drives of a particular pair actively feeds the lay-up machine with material while the other material drive remains in the idle / standby position until the parts lay-up program requires a change of material. If the parts lay-up program requires a change of material, the transition occurs with minimal production breaks (for repositioning the material drives and feeding material) and without personnel intervention. The two material drives change into each other depending on the requirements of the parts lay-up program.

The second pair of material drivers are configured, loaded and operated in an identical manner as the first pair. While the first pair of material drives are in the active mode of supplying the lay-up machine, the second pair of material drives is positioned in the maintenance zone where it waits in an inactive state upon completion of reloading, maintenance, or repair by an operator.

If a material spool is consumed or a malfunction is detected in the first pair of material drivers, production is interrupted while the first pair and the second pair of material drivers change positions, i. the second pair of material drives take over the tasks of supplying the lay-up machine while the first pair is placed in the maintenance zone. After the first pair of material drives have been reloaded and / or repaired by an employee, this goes to an inactive state in the waiting position.

This arrangement provides a pair of material drivers with the ability to be available to provide the lay-up machine with both types of material at minimum production stoppages while the other pair of material drives can be reloaded, cleaned or repaired. In this way, a more or less continuous supply of a laying machine is secured with tape material.

Referring to FIGS. 4 to 6 follows a detailed description of the system:

The automated loading linear system 26 is composed of two pairs of material drives together with their carriages, two linear drives, and a fabric of base support structures. The material drives 1 and 2 comprise one of the two pairs and are loaded with coils of different material types and / or widths. The material drive 1 supplies material from the material reel 31 (material type "A") via the belt path 29 to the feed 49 of the laying machine 16. The material drive 2 delivers material from the material reel 35 (material type "B") the belt path 33 for feeding 49 of the laying machine 16. The material drives 1 and 2 are mounted on the carriage means 27, which in turn is mounted on the linear drive 45.

The material drives 3 and 4 comprise the second pair described above and are also loaded with coils of different material types and / or widths. The material drive 3 supplies material from the material spool 39 (material type "A") via the belt path 37 to the feed 49 of the laying machine 16. The material drive 4 delivers material from the material spool 43 (material type "B") via the belt path 41 to the feeder 49 of the laying machine 16. The material drives 3 and 4 are mounted on the carriage device 28, which in turn is mounted on the linear drive 46. Both linear drives 45 and 46 are supported by a series of base support structures 47.

In the initial operating configuration, the material type "A" of the lay-up machine 16 is fed continuously from the material drive 1 via the belt path 29. Production continues until the Part Loader requests a change to Material Type "B" at which point the following event sequence occurs:

The pinch roller assembly 30 and the motorized jig 32 on the material drive 1 are actuated to rewind the tape material (type "A") still connected to the feeder 49 on the lay-up machine 16 along the tape path 29.

The linear drive 45 is actuated, and the carriage means 27 moves laterally to align the material drive 2 on the feeder 49 on the laying machine 16.

The pinch roller device 34 and the motor-driven chuck 36 on the material drive 2 are actuated to further move the strip material (material type "B") along the belt path 33 into the feed 49 on the lay-up machine 16.

The production is resumed by the material drive 2 supplies the laying machine 16 with strip type "B".

If one of the material spools on the material drive 1 or the material drive 2 is consumed or a malfunction is detected, the following event sequence takes place:

Depending on which material drive the lay-up machine 16 actively supplies material, the pinch roller means 30 and motorized chuck 32 on the material drive 1 or pinch roller means 34 and the motorized chuck 36 on the material drive 2 are actuated to engage with the feeder 49 on the lay-up machine To rewind 16 remaining band material.

The linear actuators 45 and 46 are both actuated, and the slide assemblies 27 and 28 are moved in a coordinated manner, simultaneously displacing the material drives 1 and 2 from the active zone to the maintenance zone 48 and the material drives 3 and 4 from the maintenance zone 50 to the active zone.

The linear drive 45 is set in the inactive state.

Depending on which type of material is currently required by the parts laying program, the linear drive 46 positions either the material drive 3 or the material drive 4 on the laying machine 16 aligned with the feed 49.

Depending on what type of material is currently required by the lay-on program, the Andruckrolleneinrichtung 38 and the motor-driven jig 40 on the material drive 3 or the Andruckrolleneinrichtung 42 and the clamping device 44 are actuated on the material drive 4 to the tape along the tape path 37 or the tape 41 in the Feeder 49 on the laying machine 16 continue to move.

The production is resumed by the material drives 3 and 4 alternating in the role of the supplier of the laying machine 16 in accordance with the requirements of the parts laying program.

At the same time, the material drives 1 and 2 are reloaded, cleaned and / or repaired by an operator and wait in an inactive state in the maintenance zone 48 until the next transient event.

If one of the material spools on the material drive 3 or the material drive 4 is consumed or a malfunction is detected, the following event sequence takes place:

Depending on which material drive the lay-up machine 16 actively supplies material, the pinch roller means 38 and the motorized jig 40 on the material drive 3 or pinch roller means 42 and the jig 44 on the material drive 4 are actuated to engage with the feeder 49 on the laying machine 16 to rewind connected tape material.

The linear drives 45 and 46 are both actuated, and the slide assemblies 27 and 28 are moved in coordination so that the material drives 3 and 4 are simultaneously displaced from the active zone to the maintenance zone 50 and the material drives 1 and 2 are moved from the maintenance zone 48 to the active zone.

The linear drive 46 is set in the inactive state.

Depending on which type of material is currently required by the parts laying program, the linear drive 45 positions either the material drive 1 or the material drive 2 on the laying machine 16 aligned with the feed 49.

Depending on what type of material is currently required by the lay-on program, the Andruckrolleneinrichtung 30 and the motor-driven jig 32 on the material drive 1 or the Andruckrolleneinrichtung 34 and the motor-driven jig 36 on the material drive 2 are actuated to the tape along the tape path 29 or the tape 33 in to move the feeder 49 on the laying machine 16 on.

The production is resumed by the material drives 1 and 2 again in the role of the suppliers of the laying machine 16 in accordance with the requirements of the parts-laying program alternate.

At the same time, the material drives 3 and 4 are reloaded, cleaned and / or repaired by an operator and wait in an inactive state in the maintenance zone 50 until the next transient event.

The above-described mode of operation may be continued indefinitely, with the two pairs of material drives alternating between an active supply of strip material to the lay-up machine in the active zone and the readiness for recharge or repair in the maintenance zone. Due to the more or less continuous feeding of two different types of material to a laying machine and the provision of a means for an employee to safely reload the material reels or perform maintenance and / or repair tasks during production, bring the above-described embodiments, a significant reduction of unproductive Times associated with the lay-up process for making multilayer composite parts.

Methods and systems for automatic splicing

In one embodiment (cf. FIG. 7 ) are four material drives (each material drive composed of a driven jig and a material coil) arranged as two pairs. Each pair of material drivers feed material to the lay-up machine along a fixed path of travel. At any given time, one of the material drives actively supplies material while the other material drive remains in a standby / standby state. Likewise, the other pair of material drivers deliver material to the lay-up machine along another separate belt path, with one of the material drives actively feeding material while the other remains in a rest / standby condition.

The tape paths of each material drive in a given pair unite at a splicing mechanism such that the end of a spent material spool automatically attached to the beginning of the fresh material spool. When a spool of material in a particular pair is consumed, the splicing mechanism is activated. When the spliced section finally penetrates into the feeder of the lay-up machine, it is located, cut out and removed. The production is then resumed with the previously dormant material drive, which now actively supplies the lay-up machine. The used material spool is refilled offline, whereupon this material drive is placed in the idle / standby state. The two material drives in a particular pair alternate with each other in the active and standby states, thus providing a means for more or less continuous supply of material to the lay-up machine via a single strap path for each type of material.

Adjacent to the material feed on the laying machine, a shuttle (also called an auto loader) is provided which is adapted to receive material from both belt paths. The shuttle includes separate, powered pinch rollers for each tape path and can move as needed to align both tape paths on the feeder on the feeder. If the lay-up program requires a different type of material or width of material for a particular part, a unit of the pinch rollers on the shuttle / car loader is activated to remove the material from the feeder of the lay-up machine. The shuttle / car loader then moves so that the tape path for the new material is aligned with the feeder on the lay-up machine. Subsequently, another unit of powered pinch rollers on the shuttle / car loader is activated to feed the new material to the lay-up machine, whereupon production resumes. This arrangement provides an effective means for automatically changing and feeding material into the lay-up machine from one tape path or the other.

Referring to FIGS. 7 to 11 follows a detailed description of the system:

The material drives 51 and 52 comprise one of the two pairs described above and are loaded with coils of the same material type and width. The material drives 51 and 52 provide material via the tape path 55 over the Car loader 67 in the lay-up machine 68. The material drives 53 and 54 are spaced from the material drives 51 and 52 and loaded with coils of the same material type and the same width, which may correspond to or differ from the material loaded on the material drives 51 and 52 , The material drives 53 and 54 deliver material to the lay-up machine 68 via the belt path 56 through the car loader 67.

The tape path from the material drive 51 is determined by a plurality of deflection rollers 59 which are mounted on a carriage 57. The carriage 57 can move linearly and independently via a driven slide mechanism 60. The carriage 57 comprises a cutting device 61, an adjustable guide device 62, a material clamping device 63, a movable belt deflection device 64 and a movable welding stop device 65.

The tape path from the material drive 52 is determined by a plurality of deflection rollers 59 which are mounted on a carriage 58. The carriage 58 can also move linearly and independently via a powered slide mechanism 60. The carriage 58 comprises a cutting device 61, an adjustable guide device 62, a material clamping device 63, a movable belt deflection device 64 and a movable welding device 66.

In FIG. 8 the initial operating configuration is shown, in which the laying machine 68 from the material drive 51 via the tape 55 continuously material is supplied. The carriage 57 has been positioned by the sliding mechanism 60 so that the material from the material drive 51 on the belt path 55 is aligned with the laying machine 68. The cutter 61, the material clamping device 63, the movable belt deflector 64 and the movable welding stopper 65 on the carriage 57 are all in the retracted position without contact with the moving belt material.

In contrast, the carriage 58 is positioned away from the belt path 55 to provide a safety area in which an employee can replace used spools and perform maintenance and / or repair work. The The material clamp 63 and the movable belt deflector 64 on the carriage 58 are in the extended position to hold the belt material fixed while the cutter 61 and the movable welder 66 remain retracted.

When the spool at material drive 51 is consumed, the following event sequence occurs:

The strip material feed from the material drive 51 is stopped.

The carriage 58 is offset by the sliding mechanism 60 so that the material from the material drive 52 is now aligned on the belt path 55 to the laying machine 68.

The belt deflectors 64 on both carriages 57 and 58 are actuated, thereby causing them to extend, whereby the belt material from the material drive 51 comes into contact with the belt material from the material drive 52.
The movable welding stopper 65 on the carriage 57 extends to contact the strip material from the material drive 51.

The welder 66 on the carriage 58 moves out of contact with the strip material from the material drive 52 and pushes both this and the material from the material drive 51 up against the movable welding stopper 65.

The welding device 66 on the carriage 58 is then activated and connects the strip material from the material drive 51 with the strip material from the material drive 52.

The cutter 61 on the carriage 57 is operated to separate the tape from the material drive 51.

The material clamping device 63 and the welder 66 on the carriage 58 retract.

The movable welding stopper 65 on the carriage 57 retracts.

Both movable belt deflectors 64 on the carriages 57 and 58 retract.

The driven pinch rollers on the belt path 55 of the car loader 67 are activated to feed material until the severed end of the strip material from the material drive 51 arrives at the position opposite the movable welder 66.

The belt deflectors 64 on both carriages 57 and 58 are again actuated and caused to move outwardly, whereby the severed end of the belt material from the material drive 51 comes into contact with the belt material from the material drive 52.

The movable welding stopper 65 on the carriage 57 extends again to contact the severed end of the strip material from the material drive 51.

The welder 66 on the carriage 58 again travels in contact with the strip material from the material drive 52 and pushes it and the cut end of the material upwardly from the material drive 51 against the movable weld stopper 65.

The welder 66 on the carriage 58 is then reactivated and connects the severed end of the strip material from the material drive 51 with the strip material from the material drive 52.

The material clamping device 63 and the welder 66 on the carriage 58 retract again.

The movable welding stopper 65 on the carriage 57 retracts again.

Both movable belt deflectors 64 on the carriages 57 and 58 retract again.

Production is resumed, and with material spliced together from the material drivers 51 and 52, the remainder of the material from the material drive 51, which is still threaded down to the tray machine, serves to drive the strip material from the material drive 52 through the tape path 55 via the auto loader 67 and continue to pull into the lay-up machine 68.

As the spliced portion of the belt passes through the autoloader 67 and enters the feeder of the lay-up machine, it is detected by sensors which trigger the cutting mechanism 70 and separate the leading edge of the splice from the trailing edge of the preceding web material from the material drive 51 already in the Laying machine has been supplied.

The leading edge of the spliced tape portion is fed further forward and deflected by the lay-up machine 68 into a waste container.

The trailing edge of the spliced section is detected by sensors that again trigger the cutting mechanism 70 and separate it from the new strip material from the material drive 52 that is inserted from the car loader 67 into the feeder 49 of the lay-up machine 68.

When the spliced portion has been completely deflected into the waste container, production is resumed with the material supplied by the material driver 52.

The carriage 57 is displaced by the sliding mechanism 60 to a position away from the tape path 55.

An operator cleans the tape path through the carriage 57, loads the material drive 1 with a fresh tape reel and thread the leading edge of the tape through the cutter 61, the adjustable guide 62, the material clamp 63, the movable tape deflector 64 and the movable weld stopper 65 at Carriage 57.

The material clamp 63 and the movable belt deflector 64 on the carriage 57 are extended to hold the fresh material fixed while the material drive 51 waits for the next material change and splicing operation.

Production continues until the spool is consumed at material drive 52, then the next material change and splicing operation takes place:

The tape feed from the material drive 52 is stopped.

The carriage 57 is offset by the sliding mechanism 60 so that the material from the material drive 51 is now aligned with the tape path 55 to the laying machine.

The belt deflectors 64 on both carriages 57 and 58 are actuated, thereby causing them to extend, whereby the belt material from the material drive 51 comes into contact with the belt material from the material drive 52.

The movable welding stopper 65 on the carriage 57 extends to contact the strip material from the material drive 51.

The welder 66 on the carriage 58 moves out of contact with the strip material from the material drive 52 and pushes both this and the material from the material drive 51 up against the movable welding stopper 65.

The welding device 66 on the carriage 58 is then activated and connects the strip material from the material drive 51 with the strip material from the material drive 52.

The cutter 61 on the carriage 58 is actuated to separate the belt from the material drive 52.

The material clamping device 63 and the welder 66 on the carriage 58 retract.

The movable welding stopper 65 on the carriage 57 retracts.

Both movable belt deflectors 64 on the carriages 57 and 58 retract.

The driven pinch rollers on the belt path 55 of the car loader 67 are activated to supply material until the severed end of the strip material from the material drive 52 arrives at the position opposite the welder 66.

The belt deflectors 64 on both carriages 57 and 58 are again actuated and caused to move outwardly, whereby the severed end of the belt material from the material drive 52 comes into contact with the belt material from the material drive 51.

The movable welding stopper 65 on the carriage 57 extends again to contact the strip material from the material drive 51.

The welder 66 on the carriage 58 again moves out of contact with the severed end of the strip material from the material drive 52 and pushes it and the material from the material drive 51 up against the movable welding stopper 65.

The welder 66 on the carriage 58 is then reactivated and connects the severed end of the strip material from the material drive 52 with the strip material from the material drive 51.

The material clamping device 63 and the welder 66 on the carriage 58 retract again.

The movable welding stopper 65 on the carriage 57 retracts again.

Both movable belt deflectors 64 on the carriages 57 and 58 retract again.

Production is resumed, and with material spliced together from material drivers 51 and 52, the remainder of the material from material drive 52, which is still threaded down to lay-up machine 68, serves to convey the strip material from material drive 51 through belt path 55 via the auto loader 67 and continue to pull into the laying machine.

As the spliced portion of the belt passes through the autoloader 67 and enters the feeder 49 of the lay-up machine 68, it is detected by sensors which trigger the cutting mechanism 70 and separate the leading edge of the splice from the trailing edge of the preceding web material from the material drive 52 already has been fed into the laying machine.

The leading edge of the spliced tape portion is fed forward and deflected away from the lay-up machine 68 into a waste container.

The trailing edge of the spliced tape portion is detected by sensors which again trigger the cutting mechanism 70 and separate it from the new tape material from the material drive 51 which is fed from the auto loader 67 into the feeder 49 of the laying machine 68.

When the spliced portion has been completely deflected into the waste container, production is resumed with the material supplied from the material driver 51.

The carriage 58 is displaced by the sliding mechanism 60 to a position away from the tape path 55.

An operator cleans the tape path through the carriage 58, reloads the media drive 52 with a fresh ribbon spool, and thread the leading edge of the tape through the cutter 61, adjustable guide 62, material clamp 63, and movable belt deflector 64 on the carriage 58.

The material clamp 63 and the movable belt deflector 64 on the carriage 58 are extended to hold the fresh material fixed while the material drive 52 waits for the next material change and splicing operation.

The event sequence described above may continue indefinitely as long as the material drives 51 and 52 alternate between the active supply of material and the position in a standby / standby state.

The material drives 53 and 54 are identically configured and operated in an identical manner to ensure a more or less continuous supply of the alternative strip material via the belt 56 through the car loader 67 in the laying machine 68.

By providing a more or less continuous supply of two different types of material to a laying machine 68 and a means for an employee to safely reload material spools or perform maintenance and / or repair tasks during production, the autospline embodiments described above provide a significant reduction the unproductive time in connection with the lay-up process for the production of multilayer composite parts.

The foregoing disclosure of the embodiments is provided for purposes of illustration and description. It is not intended to be exhaustive of the subject matter hereof or to set forth other embodiments in a restrictive manner with respect to the precise forms as disclosed. Numerous variations and modifications of the embodiments described herein will become apparent to those skilled in the art in light of the foregoing disclosure. The scope of the embodiments may be determined solely by the claims and their equivalents.

In describing representative embodiments of the present embodiments, the specification may have represented the method and / or method of the present embodiments as a particular sequence of operations. Meanwhile, the method or the method in the The extent to which the method or method does not rely on the particular sequence of operations as specified herein is not limited to the exact sequence of operations described. As one skilled in the art will readily recognize, other sequences of steps are possible. For this reason, the sequence of work steps specified in this specification may not be interpreted as limiting the claims. In addition, the claims directed to the method and / or method of the present embodiments should not be limited to the performance of their operations in the formulated order; One of ordinary skill in the art readily recognizes that the sequences may be varied without departing from the spirit and scope of the present embodiments. List of Reference Numerals: P0162WO 1 material drive 32 chuck 2 material drive 33 tape path 3 material drive 34 pinch roller 4 material drive 35 material coil 5 material coil 36 chuck 6 material coil 37 tape path 7 support arm 38 pinch roller 8th support arm 39 material coil 9 tape path 40 chuck 10 tape path 41 tape path 11 tape path 42 pinch roller 12 tape path 43 material coil 13 rotary drive 44 chuck 14 rotary drive 45 linear actuator 15 system 46 linear actuator 16 Auflegemaschine 47 Underlay base structure 17 Underlay base structure 48 maintenance zone 18 pinch roller 49 feed 19 pinch roller 50 maintenance zone 20 pinch roller 51 material drive 21 pinch roller 52 material drive 22 chuck 53 material drive 23 chuck 54 material drive 24 chuck 55 tape path 25 chuck 56 tape path 26 system 57 carriage 27 carriage means 58 carriage 28 carriage means 59 guide rollers 29 tape path 60 sliding mechanism 30 pinch roller 61 cutter 31 material coil 62 guide means 63 Material clamp 67 Autoloader 64 Strap deflecting means 68 Auflegemaschine 65 Welding lifeline 69 system 66 welding equipment 70 cutting mechanism

Claims (7)

1. A system (15; 26) for feeding material to a lay-up machine (18), wherein the system comprises first to fourth material drives (1, 2, 3, 4;), which can each be loaded with a material roll (5, 6, 7, 8; 31, 35, 39, 43) and which each comprise a motor-driven clamping apparatus (22, 23, 24, 25; 32, 36, 40, 44), deflection pulleys and a motor-driven pressure-roller device (18, 19, 20, 21; 30, 34, 38, 42);
   each of the first to fourth material drives (1, 2, 3, 4) can supply material from the respective material roll (5, 6, 7, 8; 31, 35, 39, 43) via a respective tape path (9, 10, 11, 12; 29, 33, 37, 41) to a feed (49) of the lay-up machine (16);
   characterized in that
   the first and the second material drive (1, 2) form a first pair of material drives (1, 2) which is mounted on a first common retainer which is driven by a first drive device, wherein the first and the second material drives (1, 2) can be loaded with material rolls (5, 6; 31, 35) of different types and/or widths of material;
   the third and the fourth material drive (3, 4) form a second pair of material drives (3, 4), which is mounted on a second retainer which is driven by a second drive device, wherein the third and the fourth material drive (3, 4) can be loaded with material rolls (7, 8; 39, 43) of different types and/or widths of material, wherein the type of material of the third material roll (7; 39) corresponds to the type of material of the first material roll (5; 31) and the type of material of the fourth material roll (8; 43) corresponds to the type of material of the second material roll (8; 35),
   wherein, when the first or the second pair of material drives (1, 2, 3, 4) is in an active zone in the active mode of supplying the lay-up machine (16), the other, second or first pair of material drives (3, 4, 1, 2) is positioned in a maintenance zone (48, 50), in an inactive state, in order to allow access for workers for new loading, maintenance or repair work, and wherein the system (15; 26) is set up, when a material roll (5, 6, 31, 35) of one of the material drives (1, 2) of the pair material drives (1, 2) is consumed in the active zone, to actuate the first and the second drive device in order to exchange the position of the first and the second pair of material drives (1, 2, 3, 4) so as to shift the pair of material drives (1, 2) in the active zone to the maintenance zone (48, 50), and to shift the inactive pair of material drives (3, 4) disposed in the maintenance zone (48, 50) to the active zone for supplying the lay-up machine (16).
2. A system (15; 26) according to claim 1, characterized in that the system (15; 26) is designed to actively supply the lay-up machine (16) at all times by one of the first to fourth material drives (1, 2, 3, 4) of the first or second pair, while the other material drive (2, 1, 4, 3) of the respective pair remains in the idle/readiness position until a part laying program demands a change in material, and when the part laying programme demands a change in material the other material drive (2, 1, 4, 3) of the respective first or second pair is positioned in an aligned manner on the feed (49) by actuating the first drive device on the lay-up machine (16).
3. A system (15) according to claim 1 or 2, characterized in that the first and the second common retainer are formed by a first and second support arm (7, 8), and the first and the second drive device are formed by a first and the second rotary drive (13, 14), wherein the first and the second rotary drive (13, 14) are mounted on a base substructure (17), wherein the first and the second rotary drive (13, 14) are coaxially positioned in such a way that each pair of the material drives (1, 2, 3, 4) can move independently of the respective other one about the same point of rotation, and wherein a rotational axis is arranged in such a way that each of the material drives (1, 2, 3, 4) can be positioned in alignment to the feed (49) of the lay-up machine (16).
4. A system (26) according to claim 1 or 2, characterized in that the first and second common retainer are formed by a first and a second carriage device (27, 28), and the first and second drive device are formed by a first and second linear drive (45, 46), wherein the first and second linear drive (45, 46) are positioned in parallel and offset with respect to each other so that each pair of the material drives (1, 2, 3, 4) can move along the same linear path independently of the other drive, wherein the first and the second linear drive (45, 46) are carried by a series of base substructures (47), and wherein the linear drives (45, 46) are arranged in such a way that each of the material drives (1, 2, 3, 4) can be positioned in alignment to the feed (49) of the lay-up machine (16).
5. A method for supplying material to a lay-up machine (16), wherein the method is carried out by a system (15; 26) according to one of the claims 1 to 4, comprising:

   the feeding of material of a first type of material from the first material drive (1) to the lay-up machine (16);

   if one of the material rolls (5, 6) is used up on the first material drive (1) or second material drive (2) or a malfunction is determined:

   depending on which of the material drives (1, 2, 3, 4) actively supplies the lay-up machine (16) with material, actuation of the pressure-roller device (18, 19) and the motor-driven clamping apparatus (22, 23) on the respective material drive (1, 2) in order to rewind the tape material still connected to the feed (49) on the lay-up machine (16);

   actuation of the first and the second drive device so that simultaneously the first and the second material drive (1, 2) are displaced from the active zone to the maintenance zone and the third and the fourth material drive (3, 4) are displaced from the maintenance zone (48, 50) to the active zone;

   resuming the production in that the third and the fourth material drive (3, 4) alternate in the role of the supplier of the lay-up machine (16) within the terms of the requirements of the part laying program, and

   new loading, cleaning and/or maintaining the first and/or the second material drive (1 2).
6. A method according to claim 5, characterized in that the method further comprises:

   continuation of production until the part laying program demands a change to a second type of material;

   actuation of the pressure-roller device (18) and the motorised clamping apparatus (22) on the first material drive (1) in order to wind up the tape material of the first material type along the first tape path (9), which tape material is still connected to the feed (49) of the lay-up machine;

   actuation of the first drive device in order to align the second material drive (2) to the feed (49) on the lay-up machine (16);

   actuation of the pressure-roller device (19) and the motorised clamping apparatus (23) on the second material drive (2) in order to further move the tape material of the second type of material along the tape path (10) to the feed (49) on the lay-up machine (16), and

   resuming the production by supplying the lay-up machine (16) with tape material by the second material drive (2).
7. An automated lay-up system, comprising:

   a lay-up machine (16; 68), and

   a system (15, 26, 69) according to one of the claims 1 to 4.

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