Abstract
Abstract In this study an automated composite layup end effector is presented which is the first to be able to find defects in real time during layup using tactile shape sensing. Based around an existing sensor concept developed by the Bristol Robot Laboratory known as the ‘TacTip’, a new end effector is developed, replacing the soft gel core of the original sensor was replaced by a much firmer elastomer, enabling it to apply up to 400N of compaction force. In this paper it is shown to successfully detect typical defects such as wrinkles, foreign objects, layup errors or incorrect material types while simultaneously compacting preimpregnated composite materials over complex mould shapes.
Highlights
Composite materials generally consist of thousands of carbon or glass fibres which individually have excellent specific structural properties
They present a concept for an Automated Fibre Placement (AFP) or Automated Tape Laying (ATL) roller equipped with pressure sensing piezo-electric transducers to give real time feedback
A new version of the ‘TacTip’ tactile shape sensor featuring an elastomer core rather than the original soft gel core has been shown to be capable of detecting a range of composite defects while simultaneously compacting prepreg material onto a mould surface
Summary
Composite materials generally consist of thousands of carbon or glass fibres which individually have excellent specific structural properties. In order to make the most of these properties in structural applications the fibres need to be strongly bonded together and remain as straight and aligned as possible in the finished product Defects such as wrinkles, bridges across concave corners, foreign objects or misplaced plies can severely compromise the integrity of the material [1]. It was concluded that one of the main advantages of manual layup was the ability of the human workers to gather real time feedback from their work via both visual and tactile sensing to ensure the products are defects free. This allows them to constantly adjust their actions in a closed-loop feedback system, correcting any defects or unwanted features as soon as they begin to arise. Tactile sensing remains a relatively untouched area for automated systems
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