Abstract: A method and system for a fiber compaction device with interdependent segment travel is described. A compaction device structure supports a series of individual interdependent segments including a compaction surface. Each segment also includes an opening in which a presser member can be located. The presser members consist of either an elastomeric bladder filled with an incompressible fluid or individual pistons that are manifolded together with a fixed volume of incompressible fluid. The presser members create an interdependence in segment positions such that if one or more segments are displaced the others move to balance the segment positions. Having a fixed volume of incompressible fluid allows the segments to work interdependently, thus guaranteeing that the average section position will be the nominal position and eliminating the need for a fixed center section.

Abstract: Apparatus and method for controlling tension of one or more fiber tows preferably including a support frame having a spool holder, a motor for driving the spool holder, a dancer arm having a free end with a redirect roller mounted thereon and a fixed end pivotally mounted to coact with an angular-position sensor, a low-friction pneumatic cylinder mounted to the dancer arm and a support plate to exert a force thereon, a second redirect roller mounted to coact with a second angular-position sensor, and a controller and associated circuitry to control the tension of the fiber by controlling the motor in response to the position of the dancer arm. Preferably, a microcontroller mounted on a single printed circuit board (PCB) having signal buffering circuitry to control a plurality of individual tensioners is provided. The PCB preferably plugs into a backplane which allows communication between several microcontrollers, thereby allowing the control of at least 32 individual tensioners.

Abstract: Method and apparatus for the manufacture of fiber reinforced structures wherein tooling and a delivery head are employed for the placement of discrete, elongated fiber elements in mutually superimposed relationship to define reinforcement or stiffening members on fiber elements for the interiors or exteriors of composite shells and the consolidation of the fibers to form the cured composite structure. A consolidation medium is provided for the positioning and control of the fiber elements on the hard tooling and during the curing of the fiber elements.

Abstract: Method and apparatus for the manufacture of fiber reinforced structures wherein tooling and a delivery head are employed for the placement of discrete, elongated fiber elements in mutually superimposed relationship to define reinforcement or stiffening members on fiber elements for the interiors or exteriors of composite shells and the consolidation of the fibers to form the cured composite structure. A consolidation medium is provided for the positioning and control of the fiber elements on the hard tooling and during the curing of the fiber elements. Method and apparatus for the manufacture of fiber reinforced structures.

Abstract: A self-contained apparatus for placement of discrete fiber element tows on a mandrel or other tooling. The apparatus carries a spooled fiber element supply, which is directed to a compaction roller over a short, non-convoluted path through a cut/add module having a knife assembly for severing a discrete tow from a continuous fiber element filament, and a drive assembly for feeding the tow and restarting feed of a new tow after severance of the prior one from the filament. The apparatus is particularly suitable for sequentially laying up superimposed, or stacked, tows to define rib-like stiffeners of composite material for reinforcing composite shell structures, and grids of such stiffeners. Methods of using the apparatus are also disclosed.

Abstract: A delivery head assembly is provided for forming a tape band from a plurality of tows and applying the band as superimposed layers in a helical pattern on to a mandrel to produce non-uniform cross sectional articles. This head assembly is composed of a distribution section, ribbonizing section, coating section, add section, and compaction roller.

Abstract: A delivery head is adapted for use in a fiber placement system for laying a plurality of tows, forming a band, onto a mandrel to form an irregular shaped object. The delivery head has cut and add sections and includes a plurality of pathways for guiding a respective plurality of tows from an inlet to an outlet of the delivery head. The cut and add section is provided in the form of a module which includes apparatus for selectively actuating any of a plurality of cutting elements and for selectively actuating any of a plurality of advancing devices for advancing respective ones of the tows toward the outlet of the delivery head.

Abstract: A filament winding system includes a head that selects the number of tows to be within a winding band while winding and positioning the winding band directly on the mandrel according to contours of the mandrel. Half of the tows are conveyed in an upper portion of the head and the remaining half are conveyed in a lower portion of the head with both halves meeting at an applicating roller at the discharge end of the tows. The head includes cut and add assemblies wherein the individual tows are selectively cut and later can be added to the band.