Patent Application
20190263615
The present invention relates to a device which allows collecting the ancillary material used as a protective coating and originally adhered to a sheet of composite material wound on a reel. More particularly, the device facilitates the extraction of the ancillary material wound on the device itself, once it has been collected after the placement of the composite material.
This invention likewise relates to a system and a method which allow the separation, storage by winding and extraction of the ancillary material adhered to a composite material supplied in the form of a reel.
Composite material, such as carbon fibre (CFRP) or glass fibre (GFRP) for aeronautic use, for example, is usually supplied in the form of a sheet or tape wound in a reel. In these composite materials, the fibre (carbon or glass) is already embedded in a generally thermosetting resin matrix, such as epoxy, for example.
Generally, the sheet or tape of composite material is presented with a protective coating or ancillary material adhered to its surface, which prevents said composite material wound on the reel from adhering to itself. This ancillary material is usually a protective polyethylene film. The ancillary material must be removed before the composite material is placed to prevent exposing the ancillary material to the curing treatment (high temperature and pressure) to which the composite material is subjected for consolidation.
Due to the delicate conditioning and cleaning conditions of the atmosphere in which the composite material is going to be handled, the tooling and machinery conventionally used to separate the protective film from the tape of composite material is complex and costly in terms of energy consumption, maintenance, and skilled labour.
There are various solutions in the state of the art today for carrying out this process. The most widespread solution consists of applying a vacuum on the protective film through conduits which separate, extract, and conduct the protective film as waste material to chambers or bags for subsequent storage.
This solution of the state of the art presents certain problems, such as the need to frequently empty the waste material from the chambers/bags, the high power consumption of the vacuum pumps and ancillary cooling systems, the loud noise generated by said vacuum pumps with the subsequent associated safety problems, numerous micro-shutdowns during operation due to the saturation of waste material in the extraction conduits, numerous interruptions in the production chain due to the need for multiple cleaning and maintenance hours dedicated to taking care of all the subsystems, among others.
The present invention proposes a solution to the aforementioned problems by means of a device configured for winding an ancillary material according to claim 1, a system for the placement of composite material according to claim 16, and a method for the separation, winding, and extraction of an ancillary material according to claim 20. Preferred embodiments of the invention are defined in the dependent claims.
A first inventive aspect provides a device for winding an ancillary material, wherein the device is characterised in that it comprises:
The at least two slats are arranged such that they substantially form a tubular element. Said tubular element is not necessarily continuous in section along its entire length, but rather the slats can be arranged with a space between contiguous slats. Optionally, the at least two slats can be arranged adjacent without leaving any space between contiguous slats, but allowing relative movement between slats.
The ancillary material which is to be wound on the device is originally adhered to a sheet or tape of composite material. However, the device of the invention can also be used for winding other types of ancillary material.
The slats can be connected to the support mechanism directly or indirectly. Indirect connection will be understood to mean the connection made by means of one or several elements.
The slats are elongated and arranged with their longest dimension parallel to the bar.
The device of the invention allows winding the ancillary material on the device and facilitates the removal thereof once wound.
Advantageously, this device prevents the use of additional elements for the separation and storage of the ancillary material (e.g. vacuum pumps).
By preventing additional elements, and since the device according to the invention only has mechanical elements, the following are also achieved:
It should be pointed out that unlike the conventional vacuum pump solution, which exceeded 80 dB and made it mandatory to use PPE (personal protective equipment) which can be burdensome when working, the device of the invention allows collecting the ancillary material in a simpler and easier to use manner.
A fundamental aspect of the present invention is the easiness of the extraction of the ancillary material once a volume of ancillary material has been wound on the device. At the same time the ancillary material is being wound around the slats, certain tension is produced in the material winding direction, which exerts a pressure on the outer face of the slats and tries to shrink the internal section between them. Once a desired volume of ancillary material is wound on the device, when the end part is uncoupled, the internal section between the slats decreases, at least in part of the device, releasing the tension in the wound ancillary material and facilitating the removal of the ancillary material from the device.
As discussed, since the internal section between the slats decreases, it greatly facilitates the removal or extraction of said ancillary material from the device by the operator. Once it is off the device, the ancillary material can be placed in a waste container for this purpose, while the operation continuous without additional shutdowns or jams.
In a particular embodiment, the at least two slats have a curved cross section. Advantageously, this allows better winding of the ancillary material.
In a particular embodiment, at least one of the slats is fixed at the first end to the support mechanism and supported at the second end on the end part such that the support on the end part determines the size of the internal section defined by the slats in the region of the second end.
In a particular embodiment, the slats are fixed by fasteners hidden from view.
In a particular embodiment of the invention, the connection mechanism of the end part is configured for increasing and reducing the section defined by the at least two slats, such that:
Advantageously, the end part provides rigidity to the device as the slats are better secured as a result of the coupling thereof.
In a particular embodiment, the end part comprises a reduction in section on which the second end of the at least one of the slats is supported. This means an improvement in the arrangement of the slats during the coupling/uncoupling of the end device, allowing the slats to slide smoothly along the reduction in section, preventing jerking. Preferably, the reduction in section is a substantially frustoconical shape.
In a particular embodiment, the configuration of the slats is such that when the connection mechanism is uncoupled from the second end of the bar, the slats bend in the region of the second end, producing a progressive decrease in the internal section defined by the slats in the longitudinal direction of the bar. The bending of the slats can be induced by the ancillary material winding tension and/or because the slats are configured such that they tend to bend towards the bar in the absence of an element preventing it.
In a particular embodiment, the at least two slats form a tubular element having a substantially cylindrical internal section.
In a particular embodiment, the slats are arranged spaced from one another, such that there is a through slot between contiguous slats.
In a preferred embodiment, the number of slats is eight.
In a particular embodiment, the at least two slats include at least one first slat fixed at its first end to the support mechanism, and at least one second slat fixed at its second end to the end part, such that the uncoupling of the end part with respect to the bar causes the disconnection of the at least one second slat with respect to the support mechanism. In a preferred embodiment, the uncoupling of the end part causes the movement of the at least one second slat with respect to the at least one first slat. Preferably, the movement is a longitudinal movement parallel to the longitudinal axis of the bar.
In a particular embodiment, the at least one first slat fixed at its first end to the support mechanism comprises rails on its edges along which the at least one second slat moves longitudinally. Additionally, said rails serve as a guide for the movement of the at least one second slat.
In a particular embodiment, the connection mechanism of the end part comprises a housing adapted for inserting the second end of the bar.
In a particular embodiment, the second end of the bar is threaded and the connection mechanism of the end part comprises a threaded housing adapted for inserting said second end.
In a particular embodiment, the device comprises at least two plates and the bar comprises at least two slots parallel to the longitudinal axis of the bar,
wherein said at least two slots comprise in at least part of their extension at least one inclined plane, each slot being configured for housing a plate,
wherein each plate comprises at least one inclined plane configured for being supported on the at least one complementary inclined plane of the slot which houses it, the plates being fixed to the bar in a sliding manner by means of retaining elements,
wherein each slat is fixed to a plate,
wherein the end part comprises a pushing element movable in the longitudinal direction of the bar and pushing means configured for moving the pushing element,
wherein
In a particular embodiment, the pushing element has an annular shape and the connection mechanism of the end part comprises a pin configured for being coupled with the second end of the bar, the pin being inserted through the pushing element, such that the pushing element is linearly movable in the longitudinal direction of the bar.
In a particular embodiment, the pushing means comprise:
In this embodiment, the rotary motion of the drive is converted into linear motion for pushing the pushing element due to the eccentric shape of the drive.
In one embodiment, the pin is a threaded pin comprising a threaded surface in at least a portion of its extension and a head configured for pushing the pushing element.
In one embodiment, the pin is configured for being coupled with the second end of the bar in a manner which can be uncoupled.
In a particular embodiment, the device additionally comprises an arm attached by means of a rotational attachment to the support mechanism. Advantageously, this arm allows fixing the device such that in a use situation, the surfaces of the slats are supported on a reel of composite material, keeping the axis of the device parallel with respect to the axis of the reel.
In a particular embodiment, the arm is a swivel arm comprising a pressure spring. Advantageously, in a use situation this arm allows the device to swivel and be arranged supported on the reel of composite material at all times. Therefore, as the level of composite material decreases, and the level of wound ancillary material increases, the pressure spring of the swivel arm allows the surfaces of the device and of the reel to be in contact at all times.
In a particular embodiment, the at least two slats are manufactured from aluminium with an anti-adhesion surface treatment. This allows preventing the ancillary material from sliding as it is wound on the slats, and therefore prevents the lack of coordination of the turning of the device with the turning of the reel of composite material. Furthermore, clusters of material are not created as a result of possible creases produced during the initial winding.
In a second inventive aspect, a system for the placement of composite material wound on a reel is provided, characterised in that the system comprises:
In one embodiment, the machine is configured such that it allows the support of the device on a reel installed in said machine, such that the turning of the reel causes the turning of the device at the same linear velocity and in counter-rotating direction with respect to the turning direction of the reel. It is understood that the at least two slats of the device are supported and roll on the reel, causing both reel and device to turn at the same linear velocity in counter-rotating direction.
In another embodiment, the system comprises a belt or gear configured for connecting the support mechanism of the device and a reel, causing them both to turn at the same linear velocity in counter-rotating direction.
In these embodiments, the machine and the device are configured so that as the machine turns the reel, the device turns in a coordinated manner with respect to the reel, driven by the turning of the reel. Therefore, as the composite material wound on the reel is placed, the ancillary material adhered to its surface is progressively detached and wound on the device.
Advantageously, as the turning is completely integral between device and reel, the turning of the device efficiently assumes the accelerations/decelerations in the process of unwinding ancillary material, without having to use ancillary equipment such as motors, variable speed or frequency drives, servo controllers, or programming, among others. Furthermore, additional energy consumption for turning the device synchronously with the reel is not required.
Additionally, this system significantly reduces maintenance hours and power consumption, as it allows working with air handling units (or ancillary cooling systems) at less than 50% in comparison with the solutions of the state of the art. That is because the device according to any of the embodiments of the first inventive aspect only has mechanical elements.
In a particular embodiment, the machine configured for placing the composite material is an automatic fibre placement machine.
In a third inventive aspect, a method for the separation, winding, and extraction of an ancillary material adhered to a composite material wound on a reel is provided, characterised in that it comprises the following steps:
Advantageously, the present invention allows a substantial increase in the performance speed, increasing process efficiency and reducing production costs. Another additional advantage is that this solution does not cause the tangling of ancillary material on the reel of composite material and increases placement capacity, with the system of the present invention reaching a placement capacity of 100%. In contrast, the solutions of the state of the art only reach a composite material placement capacity of 70%.
All the features and/or steps of the methods described in this specification (including the claims, description and drawings) can be combined in any combination, with the exception of combinations of mutually exclusive features.
These and other features and advantages of the invention will become more apparent based on the following detailed description of a preferred embodiment, given only by way of non-limiting illustrative example in reference to the attached figures.
The present invention defines a device (10) for winding an ancillary material (21). The device (10) comprises a support mechanism (1), at least two slats (2), a bar (3), and an end part (4).
The at least two slats (2) are connected to the support mechanism (1) and arranged such that they substantially form a tubular element, thereby defining an internal section between the slats (2). The slats (2) comprise a first end (2.1) and a second end (2.2).
The bar (3) is rigidly attached at a first end (3.1) to the support mechanism (1), arranged longitudinally along the inside of the internal section defined by the at least two slats (2), and configured for being connected at a second end (3.2) to the end part (4).
The end part (4) comprises a connection mechanism (4.2) configured for being coupled, in a manner which can be uncoupled, with the second end (3.2) of the bar (3), such that in the coupled state of the end part (4) the internal section defined by the at least two slats (2) is larger than it is in the uncoupled state of the end part (4).
In this embodiment, the end part (4) is a body of revolution at the end of which the connection mechanism (4.2) is located. The connection mechanism (4.2) is a housing adapted for inserting the second end (3.2) of the bar (3). Preferably, the connection mechanism (4.2) is a threaded housing and the second end (3.2) of the bar (3) is also threaded to allow said coupling.
Additionally, the end part (4) comprises a reduction in section (4.1) on which the second end (2.2) of the at least one of the slats (2) is supported. Said reduction in section (4.1) is substantially frustoconical so as to allow the slats to slide smoothly along this reduction in section during the coupling/uncoupling of the end part.
In this embodiment, the slats (2) form a tubular element, defining a substantially cylindrical internal section along their entire length between their first end (2.1) and second end (2.2). Said tubular element furthermore can be divided by means of through slots (2.3) extending from the first end (2.1) to the second end (2.2), thereby forming the separation between slats (2).
Said slats are connected, preferably adhered, to the support mechanism (1) through an annular projection (1.1) thereof. Said annular projection (1.1) defines the cross-section shape of the internal section between slats in the region of the first end (2.1), being substantially circular in this particular example. Nevertheless, other cross-section shapes are allowable, such as polygonal, for example, being defined by the number, shape, and arrangement of the slats (2).
In this embodiment, the support of the slats (2) at their second end (2.2) on the end part (4), in particular on the reduction in section (4.1), determines the size of the internal section defined by the slats in the region of the second end (2.2). In this embodiment, when the end part (4) is uncoupled, the slats (2) remain fitted at their first end (2.1) to the support mechanism (1), and are cantilevered at their second end (2.2).
Preferably, the slats (2) are manufactured from aluminium with an anti-adhesion surface treatment.
In this embodiment, the device (10) includes an arm (5) attached in a rotational manner to the support mechanism (1). Therefore, the support mechanism (1) can freely turn with respect to the arm (5). This allows providing rotary motion to the whole device. In this embodiment, the arm (5) is a swivel arm comprising a pressure spring (5.1).
In a use situation of the device (10), when the ancillary material (21) is wound around the slats (2), certain tension is produced in the winding direction of the ancillary material (21), which therefore exerts a pressure on the outer face of the slats (2) and tends to reduce the internal section between them.
Given that these slats (2) are fixed to the support mechanism (1) at their first end (2.1) and supported on the end part (4) at their second end (2.2), the slats (2) try to maintain their substantially tubular arrangement with a substantially cylindrical internal section. However, given the pressure exerted by the ancillary material (21) being wound on the slats (2), the slats (2) may bend at a certain degree and acquire the arrangement of a hyperboloid of one sheet.
Upon uncoupling the connection mechanism (4.2) of the end part (4) from the second end (3.2) of the bar (3), the slats (2) are no longer supported on the end part (4) in the region of the second end (2.2). Therefore, the pressure of the ancillary material causes the bending of the slats (2) in the region of their seconds ends (2.2) and a progressive decrease in the internal section defined by the slats (2) is produced in the longitudinal direction of the bar (3).
In this embodiment, the uncoupling of the connection mechanism (4.2) of the end part (4) with respect to the bar (3) causes the movement of the at least one second slat (2.6) with respect to the at least one first slat (2.5), the second slat (2.6) thereby being extractable.
Preferably, the first slats (2.5) comprise rails on its edges adjacent to the edges of the second extractable slat (2.6). The extractable second slat (2.6) moves along these rails longitudinally. Additionally, said rails serve as a guide for the movement of the at least one second slat (2.6).
Preferably, the device of this embodiment has three slats (2), particularly:
In this embodiment, the second slat is connected to the support mechanism (1) indirectly, by means of the fixing thereof with the end part (4).
In a use situation of the device, once a suitable volume of ancillary material has been wound or the maximum storage level in the device (10) has been reached, it is then extracted. In this embodiment, upon uncoupling the end part (4), the end part (4) is extracted together with the second extractable slat (2.6). After this, the internal section between slats is reduced due to the separation of the second slat (2.6), which facilitates extraction of the ancillary material by an operator.
The plates (3.4) are fixed in a slidable manner to the bar (3) by means of retaining elements (3.5). Furthermore, the plates (3.4) comprise fixing means (3.4.2) configured for fixing the slats (2), so the connection of the at least two slats to the support mechanism is indirect through the bar (3) in this particular example.
Furthermore, the end part (4) of the device (10) comprises:
In the embodiment of
Furthermore, the pin (4.3) is inserted through a hole of the pushing element (4.4), such that the pushing element (4.4) is linearly movable along the axis of the bar (3) according to the coupling of the pin (4.3).
The pushing means comprise:
The transition between the coupled/uncoupled state, or vice versa, is schematically shown in
In the embodiment of
In this sense, after the pin (4.3) is inserted a given distance in the bar (3), starting from the position shown in
In a preferred embodiment, the 90° turn of the drive (4.5.1) produces a forward movement of the pushing element (4.4) of 5 mm.
The threaded pin (4.3) is inserted through a hole of the pushing element (4.4), such that the pushing element (4.4) is linearly movable along the axis of the bar (3) according to the coupling of the threaded pin (4.3). In other words, as the threaded pin (4.3) is coupled to the bar (3), said bar cooperates and coaxially pushes the pushing element (4.4) so it can in turn push the ends (3.4.3) of the plates (3.4) towards the support mechanism (1), causing the sliding of the inclined planes (3.4.1) of the plates (3.4) over the inclined planes (3.3.1) of the slots (3.3). The coupling of the end part (4) is produced in that manner in this particular example.
In the embodiment of
In this embodiment, the uncoupling and the decrease in internal section defined between slats are achieved by means of the turning of the threaded pin (4.3) in the opposite direction, which causes the threaded pin (4.3) to become unscrewed from the bar (3) and the inclined planes of the plates and the slots to slide, also as a result of the action of the retaining elements (3.5) which try to shrink the internal section defined by the plates.
In a variation of the embodiment of
As it has been seen, in the embodiments of
In one embodiment, in the uncoupled state, the slats (2) substantially form a tubular element having a circular section and diameter of 59 mm, whereas in the coupled state they form a tubular element having a circular section and diameter of 64 mm.
Therefore, once a suitable volume is wound or the maximum storage level of ancillary material in the device (10) has been reached, upon uncoupling the end part the internal section between the slats decreases. Like in the devices of the other embodiments, as the internal section defined between slats decreases, winding tensions are released, facilitating the removal or extraction of said ancillary material from the device by the operator.
Finally, in the embodiment of the device (10) shown in
In particular, the system (100) for the placement of composite material (22) shown in said figures comprises:
The composite material (22) has ancillary material (21) originally adhered thereto, i.e., when it is wound on the reel (20).
In the system (100), the device (10) is configured for turning at the same linear velocity of the reel (20), in counter-rotating direction. This may be by both supporting and bearing both, and by using belts or gears. In any of the preceding cases, the use of variable speed drives or servo controllers is eliminated.
Preferably, the slats (2) of the device (10) are supported and roll on the reel (20), causing them both to turn at the same linear velocity in counter-rotating direction. That is, the device (10) and the reel (20) have a rolling contact point which does not slide with respect to the other, or said otherwise, the relative speed between device (10) and reel (20) at that point is 0.
The device (10) comprises a support mechanism (1) which can freely turn with respect to an arm (5), to which it is attached by means of rotational attachment. This allows providing rotary motion to the whole device. Preferably, the arm (5) is a swivel arm comprising a pressure spring (5.1), so the arm (5) swivels between a position where the device (10) is separated from the reel (20), and another position where both are supported at all times on one another as a result of the pressure spring (5.1).
In a preferred embodiment, the machine (30) is an automatic fibre placement machine.
Furthermore,
In
In
Like in the devices of the previous figures, as the section between slats decreases, winding tensions are released, facilitating the removal or extraction of said ancillary material of the device by the operator.
In a particular embodiment not shown, the system (100) comprises a machine (30) and several devices (10), which can wind ancillary material (21) wound on the same reel (20) or simultaneously, without having to perform shutdowns for the placement of composite material (22) between interchanges of the device (10) while working.
| Number | Date | Country | Kind |
|---|---|---|---|
| P201830190 | Feb 2018 | ES | national |
