Automated Fiber Placement Solutions for Constrained Internal Geometries : A Design Exploration

Sammanfattning

In the composite manufacturing industry, Automated Fiber Placement (AFP) is a standard method used to automate the production of complex fiber composite structures. However, because current AFP techniques typically rely on large, spatially inefficient robotic systems, they are incompatible for manufacturing within confined internal geometries. Navigating these internal spaces introduces severe physical and kinematic constraints. To address this limitation, this thesis explores the design and feasibility of an Internal Access System (IAS) to automate this process. The primary focus of this study was to investigate system architectures capable of performing AFP within a 3-meter-long curved circular tube with diameters ranging from 640 mm to 960 mm, covering fiber orientations of 0°, 45°, and 90°. To evaluate potential solutions, a structured product development process was followed to generate and screen candidate system architectures. The most promising concept emerging from this process featured an articulated robot mounted on a linear beam that guides the system into the tube geometry. This configuration was evaluated through kinematic simulations within a virtual environment using DELMIA V5 and MotoSim to investigate its feasibility and operational limitations. The simulations demonstrated that while different robot models performed well in specific tube geometries, additional software functionality is required to fully and accurately validate the complete system configuration. The simulations explored the feasibility of performing fiber layup using three distinct robotic arms across a range of tube diameters and curvatures. These simulations provide a comprehensive mapping of each robotic arm's performance across the various tube configurations. Furthermore, the study investigated the spatial constraints of integrating an AFP end effector within confined spaces, focusing on the hardware limitations of an on-board material supply versus a remote creel system.