Automated bi-stable valve system and method of using the same for composite manufacturing

An automated material handling system for a material handling process in composite manufacturing, the automated material handling system comprising:

• one or more cut plies to be selectively picked up and removed from a work surface;
• a robot having an arm with an end effector;
• a vacuum system coupled to the end effector;
• and
• an automated bi-stable valve system coupled to a first end of the end effector, the automated bi-stable valve system comprising:
• (a) a bi-stable valve mechanism comprising a plurality of bi-stable valves, wherein each of the plurality of bi-stable valves is configured to switch between a valve closed state and a valve open state;
• and
• (b) a control system coupled to the bi-stable valve mechanism and configured to operably control the bi-stable valve mechanism, the control system comprising:
• (i) at least one traversable bridge apparatus;
• and
• (ii) a valve switch mechanism attached to the at least one traversable bridge apparatus, and movable, via the at least one traversable bridge apparatus, over the plurality of bi-stable valves, the valve switch mechanism comprising a plurality of control actuators, wherein the plurality of bi-stable valves comprises a plurality of rows of bi-stable valves, and wherein each control actuator of the plurality of control actuators is configured to actuate one or more different rows of the plurality of rows of the plurality of bi-stable valves, and each of the plurality of control actuators correspond to the respective plurality of rows,
• wherein the valve switch mechanism is configured to switch one or more of the plurality of bi-stable valves between the valve closed state and the valve open state, to allow for selective control of one or more adhesion zones on the bi-stable valve mechanism, the one or more adhesion zones corresponding to one or more adhesion areas on a surface of the one or more cut plies to be selectively picked up and removed from the work surface during the material handling process in the composite manufacturing.

A method of using an automated bi-stable valve system in a material handling process for composite manufacturing, the method comprising the steps of:

• providing the automated bi-stable valve system comprising:
• (a) a bi-stable valve mechanism comprising a plurality of bi-stable valves, wherein each of the plurality of bi-stable valves is configured to switch between a valve closed state and a valve open state;
• and
• (b) a control system coupled to the bi-stable valve mechanism and configured to operably control the bi-stable valve mechanism, the control system comprising:
• (i) at least one traversable bridge apparatus;
• and
• (ii) a valve switch mechanism attached to the at least one traversable bridge apparatus, and movable, via the at least one traversable bridge apparatus, over the plurality of bi-stable valves, the valve switch mechanism comprising a plurality of control actuators, wherein the plurality of bi-stable valves comprises a plurality of rows of bi-stable valves, and wherein each control actuator of the plurality of control actuators is configured to actuate one or more different rows of the plurality of rows of the plurality of bi-stable valves, and each of the plurality of control actuators correspond to the respective plurality of rows;
• coupling the automated bi-stable valve system to an end effector attached to a robot and attached to a vacuum system;
• and
• selectively picking up and removing, with the automated bi-stable valve system, one or more cut plies from a work surface, by selectively switching, with the valve switch mechanism, one or more of the plurality of bi-stable valves from the valve closed state to the valve open state, to allow for selective control of one or more adhesion zones on the bi-stable valve mechanism, the one or more adhesion zones corresponding to one or more adhesion areas on a surface of the one or more cut plies, and to increase valve densities.