Abstract: In one embodiment, an apparatus for removing scrap from tape material on original backing paper includes a supply reel, at least one cutting member, at least one heating member and/or cooling member, and at least one removal member. The supply reel is for supplying and unrolling tape material on original backing paper. The at least one cutting member is for cutting unrolled tape material while on original backing paper. The at least one of a heating member and a cooling member are for at least one of heating and cooling cut unrolled tape material on original backing paper. The at least one removal member is for removing scrap cut unrolled tape material from original backing paper.

Abstract: The present invention provides an apparatus and associated method for removing backing film from tape or tape during the fiber placement process. The present invention uses a passive (non-powered) take-up roller to wind up the backing film that has been separated from the tape.

Abstract: The operation of automated tape heads used to layup a composite structure is optimized in order to reduce layup time and better balance tape head loading. Ply data is generated that defines the ply segments and tape courses for each sequence of the layup. Each sequence is partitioned into groups of either ply segments or tape courses for the sequence. Multiple possible tape head assignments are generated in which the individual tape heads are assigned to the groups A final set of tape head assignments are selected based on the assignments that minimize the time required to complete the layup.

Abstract: To fabricate a composite item, an infrared heat source is energized and a composite material is dispensed. The composite material includes a reinforcement and a resin. In addition, the composite material is applied to a substrate of previously applied composite material. The infrared heat source is configured to emit a wavelength of electromagnetic radiation that is absorbed by the resin to a relatively greater extent than the wavelength of electromagnetic radiation is absorbed by the reinforcement.

Abstract: An automatic composite tape placement head includes a roller for compacting tape on a substrate, and a cutter adjacent the roller for cutting the tape at the roller.

Abstract: An end effector, and methods for constructing composite members, in which a compaction roller and redirect rollers translate synchronously along the compaction axis. Additionally, the end effector includes an advantageous arrangement of spools and rollers that directs tow to the redirect rollers at substantially a right angle. Movement of the compaction roller along the compaction axis induces little, if any, changes in tow tension. The substantially constant tow tension advantageously reduces rewinding of the tow supply spools, which can degrade the quality of the lay up and contribute to despooling problems.

Abstract: A method is provided to compensate for misplacement of tows by a fiber placement machine automatically controlled by programmed instructions. The method includes laying down a test layup of fiber tows using the machine; scanning the test layup to determine the position of the test layup relative to reference standards; determining misplacements in the position of the test layup; and, modifying the programmed instructions to compensate for the misplacements.

Abstract: In one embodiment, an apparatus for removing scrap from tape material on original backing paper includes a supply reel, at least one cutting member, at least one heating member and/or cooling member, and at least one removal member. The supply reel is for supplying and unrolling tape material on original backing paper. The at least one cutting member is for cutting unrolled tape material while on original backing paper. The at least one of a heating member and a cooling member are for at least one of heating and cooling cut unrolled tape material on original backing paper. The at least one removal member is for removing scrap cut unrolled tape material from original backing paper.

Abstract: The off-part motion of an automatic composite tape laydown head is optimized to increase the overall rate at which tape is laid down to form doublers in a composite structure layup. Starting and stopping gates for each doubler are determined based on ply data and course definitions for the doublers. Using the gate locations, multiple possible paths between the doublers are analyzed to determine the best course for optimizing tape head travel. The selected course is used by an NC program that controls the operation of the tape head.

Abstract: To fabricate a composite item, a first end effector is selected from a plurality of end effectors to apply tows to a form. The first end effector includes an integrated creel configured to store spools of the tow on an assembly of spindles. The assembly of spindles is substantially parallel to a longitudinal axis of the first integrated creel. The first end effector is secured to a positioning device. The tows are applied to the form and the tows are compacted on the form with a compaction device. The assembly of spindles are disposed circumferentially about the compaction device.

Abstract: The operation of automated tape heads used to layup a composite structure is optimized in order to reduce layup time and better balance tape head loading. Ply data is generated that defines the ply segments and tape courses for each sequence of the layup. Each sequence is partitioned into groups of either ply segments or tape courses for the sequence. Multiple possible tape head assignments are generated in which the individual tape heads are assigned to the groups A final set of tape head assignments are selected based on the assignments that minimize the time required to complete the layup.

Abstract: A composite item is fabricated with a device. The device includes and end effector and a positioning device. The end effector places a tow. The end effector includes a spindle, compaction device, and a path. The spindle detachably secures a spool of tow and the path is disposed from the spool to the compaction device. The positioning device positions the end effector. The end effector is detachably secured to the positioning device.

Abstract: An end effector, and methods for constructing composite members, in which a compaction roller and redirect rollers translate synchronously along the compaction axis. Additionally, the end effector includes an advantageous arrangement of spools and rollers that directs tow to the redirect rollers at substantially a right angle. Movement of the compaction roller along the compaction axis induces little, if any, changes in tow tension. The substantially constant tow tension advantageously reduces rewinding of the tow supply spools, which can degrade the quality of the lay up and contribute to despooling problems.

Abstract: To fabricate a composite item, an infrared heat source is energized and a composite material is dispensed. The composite material includes a reinforcement and a resin. In addition, the composite material is applied to a substrate of previously applied composite material. The infrared heat source is configured to emit a wavelength of electromagnetic radiation that is absorbed by the resin to a relatively greater extent than the wavelength of electromagnetic radiation is absorbed by the reinforcement.

Abstract: The present invention provides an apparatus and associated method for removing backing film from tape or tape during the fiber placement process. The present invention uses a passive (non-powered) take-up roller to wind up the backing film that has been separated from the tape.

Abstract: A composite item is fabricated with a device. The device includes and end effector and a positioning device. The end effector places a tow. The end effector includes a spindle, compaction device, and a path. The spindle detachably secures a spool of tow and the path is disposed from the spool to the compaction device. The positioning device positions the end effector. The end effector is detachably secured to the positioning device.

Abstract: A method and system compensates for vertical deflection for parts manufactured by a numerically controlled (NC) machine. The (NC) machine has an application head position programmed to a plurality of nominal tool coordinates. Each nominal tool coordinate has a horizontal coordinate, a rotational coordinate, and a vertical coordinate. A tool used to manufacture the part is placed on the NC machine. The tool has a plurality of actual tool coordinates, each actual tool coordinate has a horizontal component, a rotational component, and a vertical sag component. A difference between each vertical sag component and a corresponding one of the nominal tool coordinates is calculated. Each difference is multiplied by a multiplier value providing an adjusted sag value. Each adjusted sag value is subtracted from the application head position for each actual tool horizontal or rotational coordinate to compensate the part for the vertical sag of the tool during manufacture.

Abstract: A method and system compensates for vertical deflection for parts manufactured by a numerically controlled (NC) machine. The (NC) machine has an application head position programmed to a plurality of nominal tool coordinates. Each nominal tool coordinate has a horizontal coordinate, a rotational coordinate, and a vertical coordinate. A tool used to manufacture the part is placed on the NC machine. The tool has a plurality of actual tool coordinates, each actual tool coordinate has a horizontal component, a rotational component, and a vertical sag component. A difference between each vertical sag component and a corresponding one of the nominal tool coordinates is calculated. Each difference is multiplied by a multiplier value providing an adjusted sag value. Each adjusted sag value is subtracted from the application head position for each actual tool horizontal or rotational coordinate to compensate the part for the vertical sag of the tool during manufacture.