SBIR Phase I: Modular Tensioning Cartridge

该小型企业创新研究第一阶段项目将开发一种颠覆性的丝束张力控制技术，专门针对复合材料制造的独特工艺变量而设计，以解决该行业目前面临的张力控制限制因素。在复合材料制造中，将具有不同拉伸强度和弹性的多种材料组合在一起以制造更坚固的产品，并且缺乏负担得起的张力控制限制了行业内成品的速度和质量。通过控制张力，减少了间隙、不均匀丝束和断裂，从而提高了最终产品的质量并降低了废品率。尽管存在这些制造限制，但复合材料行业预计将以7%的复合年增长率增长至2018年的109亿美元。通过消除张力控制的限制因素，估计产量可以扩大15%-25%，进一步促进该行业的增长。复合材料？在可再生能源，航空航天，建筑，汽车，管道和坦克，消费品，制造商的主要和日益增长的作用？公司能否在不牺牲质量的情况下消除限制，有效地满足需求，将是至关重要的。扩大生产力将使现有行业中的复合材料实现更大的创新，并促进其在新行业中的应用。该项目的智力价值集中在确定用于复合材料制造的模块化拉伸盒的可行性上。本项目的目标是：1）确定张力是否可以控制在零附近或零处; 2）实现装置的小型化，以满足多用途应用; 3）确定成本目标和经济可行性。将进行研究，通过测试多种设计、形状和材料组合，开发一种能够检测与梁加载和传感能力的关键考虑因素相关的输出微小（克）变化的测力传感器（传感单元）。将进行进一步的研究和测试，以发现散热要求，模糊风险和解决方案，并确定设计和材料要求，以实现整个单元的适当小型化。将进行最终研究，以根据机组质量、尺寸、性能和使用寿命与成本和额外产出/生产力的关系，验证机组对客户的经济价值主张。该团队将确定称重传感器技术作为传感设备的可行性，以及满足尺寸，性能和成本要求的材料和设计的组合。

This Small Business Innovation Research Phase I project will develop a disruptive tow tension control technology specifically designed for the unique processing variables of composite material manufacturing to solve the limiting factor of tension control the industry currently faces. In composites manufacturing multiple materials with different tensile strengths and elasticity are combined to make a stronger product, and the lack of affordable tension control has up to this point limited the speed and quality of finished products within the industry. By controlling tension there are fewer gaps, uneven tows, and breaks, resulting in higher quality end product and reduced scrap rates. The composites industry is forecasted to grow at a 7% compound annual growth rate to $10.9 billion in 2018 despite these manufacturing limitations. By removing the limiting factor of tension control it is estimated that production could expand 15%-25%, increasing the growth of this industry even further. With composites? primary and growing role in renewable energy, aerospace, construction, automobiles, pipe and tank, and consumer goods, a manufacturer?s ability to remove limitations to effectively meet demand without sacrificing quality will be critical. Expanded productivity will allow for greater innovation with composites within existing industries and promote their use in new industries.The intellectual merit of this project centers on determining the feasibility of a Modular Tensioning Cartridge for composites manufacturing. The objectives of this project are 1) to determine if tension can be controlled near or at zero, 2) to achieve miniaturization of the unit for multiple use applications, and 3) to determine cost targets and economic feasibility. Research will be conducted to develop a load cell (sensing unit) capable of detecting minor (gram) changes in output in relation to key considerations of beam loading and sensing capability, through testing of multiple design, shape, and material combinations. Further research and testing will be conducted to discover heat dissipation requirements, fuzzing risks and solutions, and determine design and material requirements in order to achieve proper miniaturization of the full unit. Final research will be conducted to validate the economic value proposition of the unit to customers based on unit quality, size, performance, and service life in relation to cost and additional output/productivity generated. The team will determine the viability of load cell technology as a sensing device, and the combination of materials and design that will meet sizing, performance, and cost requirements.