Integrated, automted composite material manufacturing system for pre-cure processing of preimpregnated composite materials

An integrated, automated composite material manufacturing system for pre-cure processing of preimpregnated composite material having at least one tacky surface, comprising:

• control subsystems means for controlling and synchronizing the pre-cure processing operations effected by said integrated, automated composite material manufacturing system;
• cutting means operative in response to first control signals from said control subsystems means for controlled cutting of the preimpregnated composite material into individual composite plies of predetermined size and shape based upon predetermined composite ply configurations stored in said control subsystem means;
• ply loading means operative in response to second control signals from said control subsystems means for providing automatic pickup, transfer and placement operations to load the individual composite plies, said ply loading means including
• a numerically controlled carriage subassembly having a ply transfer end effector that includes an array of bi-functional transfer feet, and
• a numerically controlled tray handling apparatus disposed in combination with and movable with respect to said numerically controlled carriage subassembly, said numerically controlled tray handling apparatus having a stacking tray mounted in combination therewith,
• said numerically controlled carriage subassembly and said ply transfer end effector being operative in response to said second control signals to position said ply transfer end effector over the individual composite plies,
• said ply transfer end effector being operative in response to said second control signals to selectively activate a multiplicity of said bi-functional transfer feet to form a predetermined combination corresponding to the predetermined size and shape of the individual composite plies, said selectively activated bi-functional transfer feet being operative to engage and retain and to mechanically disengage and release the tacky surface of the individual composite plies to load the individual composite plies onto said stacking tray, and wherein
• said numerically controlled tray handling apparatus is operative in response to said second control signals for synchronized movement with respect to said ply transfer end effector for positioning said numerically controlled tray handling apparatus beneath said ply transfer end effector to load the individual composite plies onto said stacking tray;
• means for automatically transferring said loaded stacking tray of individual composite plies for subsequent precure processing;
• ply conforming subsystem means operative in response to fourth control signals from said control subsystems means for conforming layed-up individual composite plies, said ply conforming subsystem means including
• a support table,
• said support table including a composite article mold having a predetermined mold surface,
• a frame member having a flexible impervious membrane disposed in combination therewith, and
• a mounting assembly structurally and functionally interconnecting said frame member with said support table,
• said mounting assembly being alternatively operative in response to said fourth control signals to rotate said frame member to a contact position wherein said flexible impervious membrane is adjacent said predetermined mold surface and operative to conform layed-up individual composite plies to said predetermined mold surface and to rotate said frame member to a displaced position wherein said frame member is stowed below said predetermined mold surface to facilitate lay-up of the individual composite plies;
• and
• ply transfer/layup means operative in response to third control signal means from said control subsystem means for providing automatic pickup, transfer and placement operations to lay-up the individual composite plies from said loaded stacking tray onto said predetermined mold surface of said composite article mold, said ply transfer/layup means including
• a ply transfer end effector having an array of bi-functional transfer feet, and
• means operative in response to said third control signals for positioning said ply transfer end effector with respect to the individual composite plies from said loaded stacking tray, wherein
• said ply transfer end effector is operative in response to said third control signals to selectively activate a multiplicity of said array of bi-functional transfer feet to form a predetermined combination corresponding to the predetermined size and configuration of the individual composite plies from said loaded stacking tray, said selectively activated bi-functional transfer feet being operative to engage and retain and disengage and release the individual composite plies in layed-up combination with said predetermined mold surface of said composite article mold.