SBIR Phase I: Highly Tailored Automated Laminate Production for Advanced Composite Infusions.

该SBIR第一阶段项目将开发一种自动复合材料层压装配和缝合机。 该演示机器将能够平行放置，切割和固定6层干燥复合材料。 该工艺的并行性质极大地缩短了制造时间，而机器的卷到卷的布局允许使用相对较小的机器占地面积来制造长的连续层压件。 关键的技术障碍将是软件控制和多个平行层的机械管理。 在这个研究项目中，绿色动力公司将展示拟议的机器控制方案和机械系统布局，该方案允许多个层片平行缠绕，并同时在单个龙门架上切割。 该绿色动力层压配套和缝合机将证明劳动力和成本的节省，可以通过一个单片层压板的自动化制造实现。 这些节省将使复合材料的成本持续降低，并刺激其进入新市场。降低复合材料结构（如风力涡轮机叶片和汽车部件）的成本并提高其质量是降低碳排放的关键途径。拟议的制造机器并行处理多个织物卷，并使用专有的控制算法和织物处理方法，同时切割和固定多达6层材料。由于各个层是独立加工的，因此所产生的层压堆叠是高度定制的，并且仅在需要的地方放置材料。最终产品是可运输的，并且对于非常长的长度部件，可以卷起以最小化运输尺寸。在制造现场，该层压件在单个步骤中被放置在工具中，这大大减少了制造零件的时间和工具中的处理时间。没有其他复合自动化机器可以提供在多个方向上定制的单件层压。所得到的层压材料有效地利用了复合材料的正交各向异性特性，以实现更低的重量，同时实现更低的触摸劳动率。我们的机器的多辊、线性取向允许在小的机器占地面积内对长窄层压板进行卷到卷的处理，并产生卷的、可运输的层压板。

This SBIR Phase I project will develop an automated composite lamination kitting and stitching machine. This demonstration machine will be capable of placing, cutting and securing 6 layers of dry composite material in parallel. The parallel nature of the process greatly improves manufacturing time, while the reel-to-reel capable layout of the machine allows for manufacturing of long continuous laminates using a comparatively small machine footprint. The key technical hurdles will be software control and mechanical management of multiple parallel plies. During this research project Green Dynamics will demonstrate the proposed machine control proposal and mechanical system layout, which allows multiple plies to spool in parallel and be cut on individual gantries simultaneously. The Green Dynamics lamination kitting and stitching machine will demonstrate the labor and cost savings that can be achieved through automated manufacturing of a single piece laminate. These savings will enable the continued reduction in cost for composite materials, and spur their growth into new markets. Decreasing the cost and improving the quality of composite structures such as wind turbine blades and automotive components is a key path to lower carbon emissions. The proposed manufacturing machine handles multiple fabric rolls in parallel and uses proprietary control algorithms and fabric handling methods to cut and secure up to 6 layers of material simultaneously. As individual layers are processed independently the resulting laminate stack is highly tailored and places material only where it is needed. The final product is transportable, and for very long length parts, can be rolled up to minimize transport size. At the manufacturing location this laminate is placed in the tool in a single step, which greatly reduces the time to manufacture the part and the process time in the tool. No other composite automation machine can provide a single piece lamination which is tailored in multiple directions. The resulting laminate effectively uses the orthotropic properties of composite materials to achieve lower weights while enabling much lower touch labor rates. The multi-roll, linear orientation of our machine allows for reel to reel processing of long narrow laminates in a small machine footprint, and results in a rolled, transportable laminate.