Features:

• Modular design
• Fully wraps elastomeric tool
• Heats and cools seam
• 50 feet long using 5 10-foot modules
• Wrap ply thickness up to ~ 0.5 mm (0.020 inches)
• All actions automated
• Touch screen interface
• Easy to clean & maintain
• 10 second die change
• 2 minutes per part

Situation:

In the manufacture of advanced composite structures, some tools must be wrapped with a tight fitting ply of material prior to placement in the curing tool.

Problem:

This process has traditionally been done by hand which struggles to meet production requirements and introduces quality issues.

Implication:

High cost of manufacturing.

Solution:

This machine automates the wrapping of a long trapezoid cross-section tool and seaming of the overlapped edge. Tools are initially placed in the forming cavity to be centered. The tool is then automatically lifted from the cavity and the operator is instructed to align the wrapping ply with the machine positioned back stops. With that done, the machine lowers the tool onto the wrapper and presses it into the forming die. A set of articulating surfaces then forms the inner and outer folds. Once the tool is wrapped, the overlapped wrapper is heated and cooled under pressure to bond the two edges. The finished part is then ejected to allow easy removal by the operator.

The machine is made as a series of 10 foot modules that allow the overall length to be easily changed. The present machine is capable of wrapping a 50 foot long tool in 2 minutes. A unique multi-piece forming cavity allows for die changeover in less then 10 seconds. All machine actions are prompted from a simple touch screen user interface. A cleaning mode exposes all machine surfaces to simplify periodic maintenance and cleaning.