SBIR Phase II: Modular Tensioning Cartridge

这一小型企业创新研究(SBIR)第二阶段项目将致力于复合材料制造业中用于个人张力调节的模块化张力控制装置的设计、原型和测试。复合材料越来越多地应用于关键任务应用中，在这些应用中，材料和产品必须可靠地运行，同时提高生产率、提高产品质量和降低成本。通过精确和一致地控制张力，更少的空隙、跳跃或不均匀的丝束，从而产生更高质量的产品。当安全依赖于材料的结构完整性时，这一点尤其重要。总体而言，复合应用程序更环保，并对环境产生积极影响。由复合材料制造的价格相同但更安全的汽车将更轻，耗油更少。复合材料进一步减少了对化石燃料的依赖，因为它们是利用可再生能源的基石。风叶、太阳能电池板和水下涡轮机都是由复合材料制成的。这是一个快速增长的数十亿美元的市场，预计目标张力控制市场的份额在2亿美元范围内，即使不是更快，也同样快速增长。该项目将解决自复合材料行业成立以来一直困扰该行业的一个问题。张力控制尤其困难(但在复合材料行业中非常重要)，因为具有不同撕裂强度和不同弹性的多种材料被组合在一起，以制造更坚固的产品。到目前为止，缺乏具有成本效益的张力控制限制了成品的速度和质量。第二阶段的目标是制作和开发模块化张紧筒的制造工艺。第二阶段的目标是：1)控制组件设计--目标是创建一个中央基站，为多个模块化张紧筒单元的使用提供电力、通信和中央接口；2)完成--所有成功测试的部件必须组装成一个单独的工业级原型单元，然后进行测试；3)产品发布--在最终原型测试后，将进行现场试验，以验证和最终确定导致全面生产的技术。在第一阶段，成功地证明了单个部件满足性能要求的可行性。在第二阶段，将开发和测试原型单元，以完善设计，以满足客户的性能期望。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。

This Small Business Innovation Research (SBIR) Phase II project will address the design, prototype and testing of a modular tension control device for individual tension regulation in the composite manufacturing sector. Composites are increasingly used in mission critical applications where the material and the product must perform reliably, while at the same time improving productivity, increasing product quality and lowering cost. By precisely and consistently controlling tension, there are fewer voids, skips or uneven tows, resulting in a higher quality product. This is particularly important when safety is dependent on the structural integrity of the materials. Overall, composite applications are greener and have a positive environmental impact. Comparably priced but safer automobiles from composites will be lighter and consume less fuel. Composites further reduce reliance on fossil fuels, as they are the building blocks to harness renewable energy. Wind blades, solar panels and underwater turbines are all made from composites. This is a rapidly growing multi-billion-dollar market, and the projected share of the targeted tension control market is in the range of $200 million, growing equally fast, if not faster. This project will solve a problem that has plagued the composites industry since its inception. Tension control is especially difficult (and yet very important in the composites industry), as multiple materials with different tear strengths and varying elasticity are combined to make stronger products. Lack of cost effective tension control has, up to this point, limited the speed and quality of finished products. Phase II objectives are to prototype and develop the manufacturing process for the Modular Tensioning Cartridge. The Phase II Objectives are: 1) Control package design - the goal is to create a central base station to provide power, communications and a central interface for the use of multiple Modular Tensioning Cartridge units; 2) Finalization - all successfully tested components must be assembled into a singular industrial grade prototype unit and then tested; 3) Product release - upon final prototype testing, field trials will be conducted to validate and finalize technology leading to full production. In phase I, feasibility of the individual components to meet performance requirements was successfully demonstrated. In Phase II, prototype units will be developed and tested refining the design to meet the performance expectations of the customers.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.