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: A tape delivery end-effector apparatus is, in an exemplary embodiment, a multiple-channel system for applying materials in tape form to a tooling mandrel. The end-effector apparatus is mounted on a multi-axis fiber placement machine and uses the machine's computer controlled guidance system. A preset constant tension is independently applied to each tape unspooled from spool holders by a separate servo motor, servo amplifier and feedback transducer for each spool holder. The transducer continuously measures the tape spool diameter. Two sets of rollers guide the tapes to the mandrel.

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.