SAMPE Journal - November/December 2020 - 40
FEATURE / ONE-OFF COMPOSITE STRUCTURES
A typical work flow looks like this:
* Import product geometries and layup
information
* In case of multiple product; nest the
different shapes to ensure minimal material
usage
* Create an ATL laminate around the nested
products, and generate the ATL code
for production
* Generate code for the cutting of the
individual parts
* Generate pick and place code, to place
and build up a product on a second table.
o The sequence of blank placement is
taken into consideration when generating P&P code, also when multiple ATL
laminates are needed to produce large
complex structure.
Figure 7. Airborne automated tape laying.
Automated Tape Laying (ATL)
The main process within the ALC is the automated tape laying. With this process the approx. 120
different laminates are produced, in sizes up to
6900x1900mm with a thickness of >15 layers. In the
case of the top skin the product is laid up directly,
while for the truss and c-profiles the ATL creates a
base laminates from which shapes are cut.
The ATL works with a 150mm wide UD prepreg,
either based on carbon pitch or PAN fibres. The
tapes are placed with a nominal gap of 1mm, with a
typical accuracy < +/- 1.0mm. The maximum production rate is in the range of ~ 50m2/hour, however for the fragile pitch fibre prepregs the machine is
running at a lower speed in order to prevent damage to the fibres.
Laminate Cutting
In order to create blanks it is necessary to be able
to cut them from a larger laminate. The ALC has
two different methods of cutting the uncured laminates; it can either use a rolling disc cutter, or an
ultrasonic knife, the choice in method depends on
the product and the tooling used.
Typically the ultrasonic knife is faster, able to
cut thicker laminates and more complex geometries.
Pick and Place
Using a quick tool changing system, the robot can
automatically switch end effector within 1-2 minutes. In order to build up a product on the second
table, the robot will switch to a pick & place end
effector. The P&P end effector used for the CCAT
40
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SAMPE JOURNAL
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Figure 8. Laminate cutting using disc cutter.
Figure 9. Pick & place end effector.
N OV E M B E R / D E C E M B E R 2 0 2 0
w w w. s a m p e . o r g
http://www.sampe.org
SAMPE Journal - November/December 2020
Table of Contents for the Digital Edition of SAMPE Journal - November/December 2020
Table of Contents
SAMPE Journal - November/December 2020 - Cover1
SAMPE Journal - November/December 2020 - Cover2
SAMPE Journal - November/December 2020 - Table of Contents
SAMPE Journal - November/December 2020 - 2
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SAMPE Journal - November/December 2020 - Cover3
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