Method for laying up a tape of material and device for implementing same

Abstract

A method of laying up a segment on a layup surface using a layup head that is mobile with respect to the layup surface, the layup head supporting a spool of a tape of material which includes at least one layer to be laid up from which said segment is cut and at least one interliner, the method including applying the tape of material against the layup surface and removing the interliner using a separator. The tape of material is pressed firmly by a press roller against the layup surface before the interliner is removed as the layup head moves in an advancing movement. A layup head for implementing the method and a layup machine including the layup head are also described.

Claims

1. A method of laying up a segment on a layup surface using a layup head that is mobile with respect to the layup surface, said layup head supporting a spool of a tape of material which comprises at least one layer to be laid up from which said segment is cut and at least one interliner, the at least one layer having a first surface and a second surface, said method comprising: applying the tape of material against the layup surface with the first surface facing the layup surface; and removing the interliner using a separator from the second surface to expose the second surface; firmly pressing, by a press roller, the tape of material against the layup surface before the interliner is removed as the layup head moves in an advancing movement; firmly pressing, by a compaction roller, directly on the exposed second surface of the at least one layer against the layup surface after the interliner has been removed; and directing, by the separator, the interliner toward a recovery spool.

2. The method as claimed in claim 1, wherein, when the segment to be laid up and a following segment are configured in such a way as to be able to be in contact simultaneously with the press roller, the press roller is moved away from the layup surface before coming into contact with the next segment so as no longer to press the tape of material against the layup surface, and wherein the tape of material is paid out from the spool in a manner that is synchronized with the advancing movement of the layup head.

3. The method as claimed in claim 1, wherein the separator is positioned just ahead of the compaction roller so that when the segment is completely detached from the interliner, said segment comprises a part situated ahead of the compaction roller with a reduced length.

4. The method as claimed in claim 1, wherein a shoe is positioned ahead of the compaction roller so that when the segment is completely detached from the interliner, the layer to be laid up does not wrinkle ahead of the compaction roller.

5. A layup head for implementing a method of laying up a segment on a layup surface, said layup head comprising: a spool of a tape of material comprising at least one layer to be laid up from which a segment to be laid up on a layup surface is cut and at least one interliner; a separator configured to separate the interliner from the layer to be laid up to expose a surface of the at least one layer; a press roller positioned between the spool and the separator in a direction of travel of the tape of material and configured to press said tape of material firmly against the layup surface when, in operation, the layup head is moving in an advancing movement; and a compaction roller positioned after the separator in the direction of travel of the tape of material and configured to directly press on the exposed surface of the at least one layer that is to be laid up firmly against the layup surface when, in operation, the layup head is moving in an advancing movement, the separator being configured to direct the interliner toward a recovery spool.

6. The layup head as claimed in claim 5, wherein the press roller is configured to move between a deployed position in which the press roller is moved closer in operation to the layup surface so as to press the tape of material firmly against said layup surface, and a retracted position in which the press roller is moved further away in operation from the layup surface.

7. The layup head as claimed in claim 6, further comprising a synchronization system configured to synchronize the paying-out of the tape of material with the advancing movement of the layup head in operation.

8. The layup head as claimed in claim 7, wherein the synchronization system comprises: at least one motorized drive to control the rotational movement of the spool; and a sensor configured to measure the paying-out of the tape of material.

9. The layup head as claimed in claim 5, wherein the separator is positioned just ahead of the compaction roller so that when the segment is completely detached from the interliner, said segment comprises a part situated ahead of the compaction roller with a reduced length.

10. The layup head as claimed in claim 5, further comprising a shoe positioned ahead of the compaction roller.

11. A layup machine comprising a layup head comprising: a spool of a tape of material comprising at least one layer to be laid up from which a segment to be laid up on a layup surface is cut and at least one interliner; a separator configured to separate the interliner from the at least one layer to be laid up to expose a surface of the at least one layer; a press roller positioned between the spool and the separator in a direction of travel of the tape of material and configured to press said tape of material firmly against the layup surface when, in operation, the layup head is moving in an advancing movement; and a compaction roller positioned after the separator in the direction of travel of the tape of material and configured to directly press on the exposed surface of the at least one layer that is to be laid up firmly against the layup surface when, in operation, the layup head is moving in an advancing movement, the separator being configured to direct the interliner toward a recovery spool.

12. The layup machine as claimed in claim 11, further comprising a tool with a layup surface.

13. The layup machine as claimed in claim 12, further comprising a recovery table on which any offcuts may be laid.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features and advantages will become apparent from the following description of the invention, which description is given solely by way of example with reference to the attached drawings in which:

(2) FIG. 1 is a diagram of a layup head illustrating the prior art,

(3) FIG. 2 is a diagram of the layup head of FIG. 1, illustrating the risks of wrinkling of a layer that is to be laid up ahead of a layup roller,

(4) FIG. 3 is a plan view of part of a tape of material with part of an interliner cut away,

(5) FIG. 4 is a diagram of a layup head illustrating one embodiment of the invention,

(6) FIG. 5 is a plan view of a tape of material laid up by the layup head visible in FIG. 4,

(7) FIGS. 6A to 6F are diagrams of a layup head illustrating the various steps in laying up a segment of tape,

(8) FIGS. 7A to 7F are plan views of the segment of tape laid up by the layup head and illustrating the position of the rollers of the layup head at the various steps illustrated in FIGS. 6A to 6F.

DETAILED DESCRIPTION

(9) FIG. 3 depicts a tape of material 32. This tape of material 32 comprises at least one layer 34 to be laid up and at least one interliner 36 applied against one of the faces of the layer 34 that is to be laid up.

(10) According to one embodiment, the interliner 36 is a backing paper and the layer 34 that is to be laid up is suited to affording lightning protection. By way of example and non limitingly, the layer 34 to be laid up is a layer of fiber glass fabric and/or a fine metal gauze. Whatever the embodiment, the interliner 36 is suited to absorbing tensile load in excess of that which the layer 34 that is to be laid up is capable of absorbing. In addition, the tack between the layer 34 and interliner 36 is lower than that between the layer 34 that is to be laid up and a layup surface. To achieve that, the interliner 36 preferably comprises a non-stick treatment.

(11) According to one embodiment, the layer of material 32 comprises a film applied against the opposite face of the layer 34 that is to be laid up to the interliner 36.

(12) According to one embodiment, the tape of material 32 has a given width of the order of 150 or 300 mm.

(13) The layer 34 and interliner 36 have the same width as the tape of material 32.

(14) According to one type of packaging, the tape of material 32 is packaged in the form of a spool 38 (visible in FIG. 4).

(15) The tape of material 32 is not described further because it is known to those skilled in the art. Thus, the materials of which it is made, and the width thereof may vary from one tape to another.

(16) The tape of material 32 comprises a plurality of segments 40, 40, 40 to be laid up, each of them delimited in the layer 34 that is to be laid up by an upstream cut 42 and a downstream cut 44, the upstream cut 42 being the first to be laid up.

(17) According to a first configuration, for two adjacent segments 40 and 40, the downstream cut 44 of the segment 40 coincides with the upstream cut 42 of the segment 40.

(18) In the second configuration, for two adjacent segments 40 and 40, the downstream cut 44 of the segment 40 is separate from the upstream cut 42 of the segment 40. In that case, there is a portion of tape referred to as an off cut 46 between the two adjacent segments 40 and 40.

(19) The segments have lengths and shapes of cut suited to allowing the various segments to be laid up one after another and/or one beside the next so that they cover an entire surface, for example an exterior surface of a component made of composite comprising lightning protection.

(20) According to a first alternative form, the tape of material 32 is precut and the segments are already delimited before the tape of material 32 is packaged in the form of a spool 38.

(21) According to another alternative form, the tape of material 32 is cut at a layup head 50 just before the layer 34 that is to be laid up is laid up onto a layup surface 48.

(22) Advantageously, only the layer 34 that is to be laid up is cut to delimit the segments 40, 40, 40, the interliner 36 remaining continuous over the entire length of the tape of material 32.

(23) According to one application, the layer 34 to be laid up is a lightning protection layer laid up on the exterior surface of a component made of composite forming part of an aircraft fuselage.

(24) According to one procedure, the various layers that form the component made of composite are laid up on a tool the geometry of which is adapted to that of the component that is to be produced and are then consolidated or polymerized in order to obtain a rigid component.

(25) Because the layer 34 that is to be laid up is situated on one of the faces of the component, it is laid up either directly onto the tool or onto the last of the layers. For the remainder of this description, a layup surface 48 corresponds to the surface of a tool or to the surface of a layer already laid up.

(26) FIG. 4 depicts part of a tape layer machine which comprises a layup head 50 supported by a movement mechanism 52 configured to move the layup head 50, notably with respect to the layup surface 48.

(27) According to one embodiment, the movement mechanism 52 is a robotic arm.

(28) The movement mechanism 52 is configured to move the layup head 50 in at least one direction of advance Da parallel to the layup surface 48, in a normal direction Dn (visible in FIG. 6B) perpendicular to the layup surface 48 and/or a combination of these two directions.

(29) The movement mechanism 52 is not described further because it may be identical to those of the prior art.

(30) The layup head 50 comprises:

(31) a chassis 54 connected to the movement mechanism 52,

(32) a first spool support 56 connected to the chassis 54 and configured to accept a spool 38 of tape of material 32,

(33) a second spool support 58 connected to the chassis 54 and configured to accept a recovery spool 60 for recovering the interliner 36,

(34) a first roller 62 connected to the chassis 54 and configured to press the layer 34 that is to be laid up firmly against the layup surface 48,

(35) a separator 64 connected to the chassis, positioned between the spool 38 and the first roller 62 and configured to separate the interliner 36 from the rest of the tape of material 32 and direct it towards the recovery spool 60.

(36) The spools 38 and 60 and the first roller 62 are positioned on the chassis in such a way that their axes of rotation are substantially parallel.

(37) The first spool support 56 is positioned at the front of the layup head 50 and the first roller 62 is placed at the rear in the direction of advance Da.

(38) The spool 38 is configured and positioned on the first spool support 56 in such a way that, when the tape of material 32 is paid out, the layer 34 that is to be laid up is positioned between the interliner 36 and the layup surface 48.

(39) According to one embodiment, the separator 64 is a separation roller the axis of rotation of which is substantially parallel to the first roller 62. The separator 64 is fixed relative to the chassis 54 of the layup head 50.

(40) Advantageously, the layup head 50 comprises a means for adjusting the compaction force 66 exerted by the first roller 62 on the layer 34 to be laid up in the direction of the layup surface 48. With this configuration, the first roller 62 is referred to as a compaction roller 62.

(41) According to one embodiment, the layup head 50 comprises a first actuator 68 connected to the chassis 54, said actuator 68 comprising a rod 70 mobile translationally in a direction perpendicular to the layup surface 48 to which the compaction roller 62 is connected.

(42) For preference, the layup head 50 comprises a cutting system 72 configured to at least partially cut the tape of material 32 so as to delimit segments 40, 40, 40 that are to be laid up. Advantageously, the cutting system 72 is configured to cut only the layer 34 that is to be laid up and to delimit within this layer 34 the various segments 40, 40, 40 that are to be laid up, the interliner 36 not being cut and remaining continuous.

(43) According to one embodiment, the cutting system 72 is an ultrasound cutting system connected to the chassis 54 and positioned under the spool 38 at the front of the tape of material 32.

(44) According to one feature of the invention, the layup head 50 comprises a second roller 74 connected to the chassis, positioned between the spool 38 and the separator 64 in the direction of travel of the tape of material and configured to press the tape of material 32 firmly against the layup surface 48 before the interliner 36 is separated from the layer 34 that is to be laid up. Because this second roller 74 is situated ahead of the separator 64, the layer 34 that is to be laid up is never subjected to tensile loading when separated from the interliner 36. Between the spool 38 and the second roller 74, the tape of material 32 is subjected to tensile loading. However, this tensile loading is absorbed by the interliner 36 which is always closely bonded to the layer 34 that is to be laid up.

(45) For preference, the second roller 74 is capable of translational movement between a deployed position in which the second roller 74 is moved closer in operation to the layup surface 48 so as to apply a force pressing the tape of material 32 firmly against the layup surface 48, and a retracted position in which the second roller 74 is moved away from the layup surface 48 and applies no firm pressing force. This configuration makes it possible to lay up segments 40 that have at least one cut to a point.

(46) For the remainder of the description, the second roller 74 is referred to as a press roller 74.

(47) Advantageously, the layup head 50 comprises a second actuator 76, connected to the chassis 54, which supports the press roller 74 to render same mobile. According to one embodiment, the actuator 76 comprises a rod 78 mobile translationally in a direction perpendicular to the layup surface 48 to which the press roller 74 is connected.

(48) For preference, the separator 64 is positioned just ahead of the compaction roller 62 so that it is spaced only a small distance away from said compaction roller 62. As an idea of an order of magnitude, the point of contact of the compaction roller 62 with the layer 34 that is to be laid up and the zone at which said layer 34 is separated from the interliner 36 are separated by a distance of less than 10 cm.

(49) This configuration makes it possible to limit the extent of the portion of segment unsupported ahead of the compaction roller 62 when said segment is completely separated from the interliner 36.

(50) Advantageously, the layup head 50 comprises a shoe 80 positioned between the separator 64 and the compaction roller 62. According to one embodiment, the shoe 80 has a length such that its first end is spaced only a small clearance away from the point of contact of the compaction roller 62 with the layer 34 that is to be laid up and its second end is spaced only a small clearance away from the zone of separation of the layer 34 from the interliner 36. A small clearance here means a clearance of less than 1 cm.

(51) In addition, the shoe 80 is positioned heightwise with respect to the separator 64 in such a way as to be spaced away from the layer 34 that is to be laid up by a clearance of the order of 1 to 4 mm. This configuration makes it possible to prevent wrinkling in the layer 34 that is to be laid up ahead of the compaction roller 62.

(52) The various rollers 62, 64, 74 and the shoe 80 have a width slightly greater than that of the tape of material 32. They are preferably centered with respect to said tape of material 32.

(53) According to another feature of the invention, the layup head 50 comprises a system for synchronizing the payout movement of the spool 38 with the advancing movement of said layup head 50, at least when the press roller 74 is not in contact with the tape of material 32. This configuration makes it possible to prevent the layer 34 that is to be laid up from being subjected to tensile force when the press roller 74 is spaced away from the tape of material for example at the end of the laying-up of a segment that has a pointed end.

(54) This synchronization system comprises at least one motorized drive 82 to control the rotational movement of the spool 38, the rotational movement of said motorized drive being slaved to the advancing movement of the layup head.

(55) For preference, the synchronization system comprises a motorized drive to control the rotational movement of the recovery spool 60, the rotational movement of said motorized drive being slaved to the advancing movement of the layup head.

(56) In order accurately to determine the advancing movement of the layup head 50, the synchronization system preferably comprises a sensor 84 configured to measure the paying out of the tape of material 32 when it is in contact with the layup surface 48 or just before it comes into contact with the layup surface 48. According to one embodiment, this sensor 84 is an encoder wheel in contact with the surface of the tape of material 32 that is covered by the interliner 36. This encoder wheel is connected to the chassis 54 and positioned ahead of the compaction roller 62. In one configuration, the encoder wheel is positioned just ahead of the press roller 74.

(57) For preference, the layup head 50 comprises a guide 86 connected to the chassis 54 and positioned in such a way as to be in contact with that surface of the tape of material 32 that is covered by the interliner 36 and guide said tape of material 32 between the spool 38 and the press roller 74. This guide 86 makes it possible to improve the positioning of the tape of material 32 with respect to the cutting system 72 and/or to the sensor 84.

(58) The layup machine comprises, in addition to the layup head 50, a command/control system which allows control over the movements of the layup head 50 and of the press roller 74, and the compaction force applied by the compaction roller 62. This command/control post also allows control over the rotational movement of the motorized drive 82, as a function of measurements from the sensor 84.

(59) For preference, the layup machine comprises a supporting structure to which a tool with a layup surface the geometry of which is tailored to that of the component that is to be produced and a recovery table on which any off cuts 46 may be laid can be secured removably.

(60) The principle of operation of the layup machine is now described with reference to FIGS. 6A to 6F and 7A to 7F for the laying-up of a segment 40 with an upstream cut 42 and downstream cut 44.

(61) That portion of the upstream cut 42 of the segment 40 that is situated furthest to the rear of the layup head 50 is positioned level with the lower generatrix of the press roller 74, as illustrated in FIGS. 6A and 7A. This upstream cut 42 may have been obtained using the cutting system 72.

(62) The layup head 50 is moved so as to position the upstream cut 42 vertically in line with a mating position 88 which corresponds to the position of the upstream cut 42 on the layup surface 48.

(63) Next, the layup head 50 is moved in the direction Dn in such a way as to grip the tape of material 32 between the press roller 74 and the layup surface 48, as illustrated in FIG. 6B. The position of the layup head 50 with respect to the layup surface 48 is adjusted in such a way that the press roller 74 applies a force of the order of 5 N per mm of width of tape 32.

(64) As illustrated in FIG. 6C, the layup head 50 is moved in the direction of advance Da. During this movement, because the tape of material 32 is pressed firmly against the layup surface 48, the segment 40 of the layer 34 that is to be laid up adheres to the layup surface 48. At the separator 64, the interliner 36 is removed so that it can be wound onto the recovery spool 60. Once it has begun, the separation of the layer 34 and interliner 36 spreads laterally (at right angles to the length of the tape of material 32) and longitudinally (parallel to the length of the tape of material 32) from the initial point of detachment, as the layup head 50 gradually advances.

(65) Behind the separator 64, the compaction roller 62 applies a compaction force to the layer 34 that is to be laid up.

(66) During this phase, the press roller 74, in contact with the interliner 36, firmly presses the tape of material 32 against the layup surface 48. As a result, the tape of material 32, via the layer 34 that is to be laid up, adheres to the layup surface 48. The paying-out of the tape of material 32 is brought about by the combination of the adhesion of the tape of material 32 to the layup surface 48 and of the advancing movement of the layup head 50. The layer 34 that is to be laid up experiences no tensile force, as such force is absorbed by the interliner 36.

(67) Depending on the downstream cut 44, the press roller 74 may be in contact with the segment 40 but also with another segment 40 or with an off cut 46, for example when said segment 40 has a pointed shape 90. As illustrated in FIGS. 6D and 7D, just before reaching this pointed shape 90, the press roller 74 is moved toward the retracted position by the actuator 76. Thus, the press roller 74 is moved a few millimeters away from the layup surface 48 so that the end 92 of the next segment 40 is not pressed firmly against the layup surface 48.

(68) Next, as illustrated in FIG. 6E, the layup head 50 continues its advancing movement to complete the laying-up of the segment 40. As soon as the press roller 74 is no longer in contact with the tape of material 32, the paying-out from the spool 38 is synchronized by the advancing movement of the layup head 50 by the motorized drive 82 and the sensor 84. For preference, the rotational movement of the recovery spool 60 is likewise synchronized with the advancing movement of the layup head. This synchronization avoids any tensile force in the layer 34 that is to be laid up.

(69) The compaction roller 62 applies firm pressure to said layer 34.

(70) Because the separator 64 is spaced only a small distance away from the compaction roller 62, the length of segment 40 situated ahead of the compaction roller 62 is reduced when the segment 40 is completely detached from the interliner 36. As a result, because the unsupporting portion of the segment 40 is short, the risks of it curling up on itself ahead of the compaction roller 62 are limited. Finally, the shoe 80 prevents any risk of curling of said portion on itself.

(71) During this advancing movement, the compaction roller 62 allows the segment 40 to be separated from the interliner 36. The fact of moving the press roller 64 away means that the end of the next segment 40 can be kept still pressed firmly against the interliner 36. This then causes the two segments 40 and 40 to separate.

(72) As illustrated in FIG. 6F, as soon as the entire segment 40 has been pressed firmly against the layup surface 48, the layup head 50 is moved away from the layup surface 48.

(73) The tape of material 32 is wound on so that the upstream cut 42 of the next segment 40 is positioned in vertical alignment with the lower generatrix of the press roller 74. This press roller 74 is repositioned in the deployed position.

(74) It is therefore possible to proceed to layup the next segment 40 as described hereinabove. If the next segment is an offcut 46, the latter is laid onto the recovery table in the same way as the segments that are to be laid up are laid up on the layup surface, the offcut 46 corresponds to a segment that is not to be laid up on the layup surface 48.

(75) While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.