Automated removal apparatus, system, and method for selectively removing trimmed portions of a laminated ply in a ply-by-ply fabrication process

An automated removal system for selectively removing one or more trimmed portions of a laminated ply in a ply-by-ply fabrication process, the automated removal system comprising:

• a robot assembly comprising a robot having a robotic arm, and comprising a control unit, and a power unit;
• a carrier apparatus for carrying the one or more trimmed portions;
• an automated removal apparatus attached to the robot assembly, the automated removal apparatus comprising:
• a rotatable reel comprising a plurality of retractable vacuum panels attached around a hub portion of the rotatable reel, each of the plurality of retractable vacuum panels comprising one or more retractable vacuum pad assemblies, each having a vacuum pad with a vacuum port and a self-sealing valve;
• a plurality of piston assemblies attached to the plurality of retractable vacuum panels;
• a plurality of friction reducing elements attached around the rotatable reel, and positioned between the plurality of retractable vacuum panels;
• a drive assembly attached to the rotatable reel;
• a connector assembly attached between the drive assembly and the robotic arm of the robot;
• and
• a pneumatic system attached to the rotatable reel, the pneumatic system comprising a valve manifold operable to control an air flow to actuate the plurality of piston assemblies, and operable to control the air flow to one or more vacuum generators to generate a vacuum flow through one or more of the vacuum ports, and the vacuum flow generating a vacuum force configured to pull up and hold the one or more trimmed portions against one or more of the vacuum pads, when the rotatable reel is rotated over the one or more trimmed portions to be removed.

An automated removal method for selectively removing one or more trimmed portions of a laminated ply in a ply-by-ply fabrication process, the automated removal method comprising the steps of:

• positioning an automated removal apparatus over the one or more trimmed portions of the laminated ply, to be removed, in the ply-by-ply fabrication process, the automated removal apparatus comprising:
• a rotatable reel comprising a plurality of retractable vacuum panels attached around a hub portion of the rotatable reel, each of the plurality of retractable vacuum panels comprising one or more retractable vacuum pad assemblies, each having a vacuum pad with a vacuum port and a self-sealing valve;
• a plurality of actuator assemblies attached to the plurality of retractable vacuum panels;
• a plurality of friction reducing elements attached around the rotatable reel;
• a drive assembly attached to the rotatable reel;
• a connector assembly attached to the drive assembly;
• and
• a pneumatic system attached to the rotatable reel, the pneumatic system comprising a valve manifold operable to control an air flow to actuate the plurality of actuator assemblies, and operable to control the air flow to one or more vacuum generators to generate a vacuum flow through one or more of the vacuum ports;
• rotating the rotatable reel, via the drive assembly, onto the one or more trimmed portions to be removed, wherein piston rods of the plurality of actuator assemblies are in an extended position, to extend the plurality of retractable vacuum panels and the one or more retractable vacuum pad assemblies;
• compressing the one or more retractable vacuum pad assemblies against the one or more trimmed portions, to cause the self-sealing valve to open to an open position from a closed position, for each vacuum pad of the one or more retractable vacuum pad assemblies that is compressed, and to apply a vacuum force from the vacuum flow, to pull up and hold a section of the one or more trimmed portions against the vacuum pad;
• and
• winding the one or more trimmed portions, held by the vacuum force, around an outer circumference of the rotatable reel for removal.