Abstract: A composite placement machine has a simplified fiber delivery path from a creel to a lay-up table. A carriage is mounted for motion in the Y-axis along the length of an overhead beam. A composite placement head having a shiftable compaction roller is supported by the carriage. A stationary creel at one end of the overhead beam forms a band of composite material having a width that extends in the X-axis. A lay-up table is mounted for motion in the X-axis and rotary motion about a C-axis that is perpendicular to the X and Y-axes. The motion of the head in the Y-axis, the shiftable compaction roller, and the motion of the lay-up table X-axis and the C-axis allows the head to apply composite material to the lay-up table in both Y-axis directions in any orientation without twisting the band of composite material relative to the X and Y-axes.

Abstract: A composite placement machine has a simplified fiber delivery path from a creel to a lay-up table. A carriage is mounted for motion in the Y-axis along the length of an overhead beam. A composite placement head having a shiftable compaction roller is supported by the carriage. A stationary creel at one end of the overhead beam forms a band of composite material having a width that extends in the X-axis. A lay-up table is mounted for motion in the X-axis and rotary motion about a C-axis that is perpendicular to the X and Y-axes. The motion of the head in the Y-axis, the shiftable compaction roller, and the motion of the lay-up table X-axis and the C-axis allows the head to apply composite material to the lay-up table in both Y-axis directions in any orientation without twisting the band of composite material relative to the X and Y-axes.

Abstract: A process uses predictive modeling software for selectively applying relief cuts and tension to the fibers in a 2-dimensional panel prior to shaping the panel into a 3-dimensional part. The predictive modeling software identifies areas of fiber tension in the final molded product, and relief cuts are made in those areas. The plies are loaded into grippers attached to a supporting frame and predictive modeling software is used to identify areas of fiber compression in the final molded product. Tension is applied to the identified areas of fiber compression. The panel is molded in a form and cure press, and the tension is maintained on the material while closing the mold halves. The molded part is able to conform to the final mold shape without tearing in areas of tension and without material buildup in areas of compression in the final molded part or post mold distortion.

Abstract: A method of forming a reinforced pressure vessel includes the steps of providing a thin wall cylinder, wrapping the cylinder with at least one layer of prepreg reinforcing fiber, wrapping the cylinder with at least one layer of perforated shrink tape, applying heat to the shrink wrapped cylinder to squeeze the at least one prepreg fiber layer to force resin to weep through the perforated shrink tape and cure the resin, and allowing the resin to remain on the outer surface of the shrink tape to form a protective layer on the pressure vessel.

Abstract: A method for molding a composite structure includes the steps of infusing a fabric with a resin to form a ply of composite material, transferring the ply of composite material to a preheat station, and preheating the ply of composite material to a temperature that renders the composite material more drapable, but is less than a temperature that causes the resin in the material to initiate polymerization. The ply of composite material is then transferred to a press station where it is heated to a temperature that causes the resin to initiate polymerization, whereby the curing time for the composite material is substantially less than the curing time of a fabric that is infused with an epoxy resin.

Abstract: A fiber placement system for producing small sized flat laminates having a length and width that extends in the X and Y axes, and a constant height measured in the Z-axis includes a fixed creel for delivering fiber used by the system, and a fixed bracket attached to the creel. A fiber placement head is supported by the fixed bracket and a movable table for supporting a tool is positioned under the fiber placement head. The fiber placement head is fixed in the X, Y, and Z-axis during the application of fiber to the tool.

Abstract: A method of wireless communication uses a fiber composite structure including a first conductive fiber composite layer comprising carbon fiber, a second conductive fiber composite layer comprising carbon fiber, and an insulating layer electrically isolating the first composite layer from the second composite layer. Communication devices such as transceivers are connected to the first and second composite layers and signals may be communicated to and from the communication devices through the composite layers. An AC or DC voltage may be applied to the first and second composite layers to conduct electrical power to the electrical devices without the requirement of separate wires.

Abstract: A fiber placement system for producing small sized flat laminates having a length and width that extends in the X and Y axes, and a constant height measured in the Z-axis includes a fixed creel for delivering fiber used by the system, and a fixed bracket attached to the creel. A fiber placement head is supported by the fixed bracket and a movable table for supporting a tool is positioned under the fiber placement head. The fiber placement head is fixed in the X, Y, and Z-axis during the application of fiber to the tool.

Abstract: A method for determining an “effective” thermal coefficient of a machine comprises the steps of installing one or more temperature sensors (110) at various locations on the machine, positioning a first machine member (60) at a “known” reference location, relative to a second machine member (42), installing a linear position measuring device (120) to detect changes in position of the first machine member (60) relative to the second machine member (42) along a first axis of movement, periodically acquiring readings from each of the temperature sensors (110) and from the linear position measuring device (120) during a test cycle and compiling the temperature and linear position data into a table.

Abstract: Analog signals are generated in response to one or more operating parameters of a machine such as vibration and used to provide a log of the operating history of the machine. The analog signals are converted into root mean square (rms) values which are periodically sampled. The sampled signals are sorted into predefined rms value bands. Each occurrence of a signal in an rms value band is used to increment a counter in order to keep track of the number of occurrences of signals in a particular rms value band. The number of accumulated signals in each of the rms value bands provides an indication of the usage and condition of the machine.

Abstract: Analog signals generated in response to operating parameters of a machine are converted into rms signals that are periodically sampled, sorted into defined rms value bands and saved as an evolving history of the operation of the machine.

Abstract: A method for determining an “effective” thermal coefficient of a machine comprises the steps of installing one or more temperature sensors (110) at various locations on the machine, positioning a first machine member (60) at a “known” reference Location, relative to a second machine member (42), installing a linear position measuring device (120) to detect changes in position of the first machine member (60) relative to the second machine member (42) along a first axis of movement, periodically acquiring readings from each of the temperature sensors (110) and from the linear position measuring device (120) during a test cycle and compiling the temperature and linear position data into a table.

Abstract: A damped, cantilevered support arm for a machine tool position monitoring device rigidly attached to the machine tool by a pair of spaced bolts for relative movement with a machine part along a longitudinal axis. The line of centers through the bolts is oriented along the longitudinal axis and the arm is mounted with shims located between its base and the machine tool part to allow limited effective freedom of movement of the support arm around the line of centers in a direction normal to the longitudinal axis. A squeeze-film damping chamber is provided between the spaced shims for reducing the response of the support arm in the normal direction during relative movement along the longitudinal axis. A boundary O-ring seal together with the thickness of the spacers, defines the damping chamber.

Abstract: A rotary deck for interchanging a pair of pallets in a machining center is partially enclosed within a guard housing surrounding the machining zone. The deck sweeps a predetermined diameter with the pallets. An operator access door is mounted to cover an opening in the housing, adjacent the machining zone. The door slides into the sweep diameter when opened and the deck is stationary; an interlock prevents deck rotation when the door is opened.