Composites system with dockable heads

A composites lamination system comprising a six-axis positioner and multiple removable heads for applying composite material to a tool, the system comprising:

• a gantry and a wrist comprising the six-axis positioner;
• the gantry having two spaced uprights that support a crossbeam, wherein the uprights and the crossbeam are movable in the X-axis;
• a workzone for a tool positioned between the two spaced uprights;
• a movable column supported on the crossbeam, wherein the column is movable relative to the crossbeam in the Y-axis and the Z-axis;
• a wrist mounted on the column, wherein the wrist rotates around an I-axis parallel to the X-axis, around a J-axis parallel to the Y-axis, and around a K-axis parallel to the Z-axis;
• a replaceable head mounted on the wrist on the end of the K-axis, whereby the gantry and the wrist provide six axis of motion for the replaceable head, and removal of the head from the wrist allows the six axis of motion to remain with the positioner;
• a plurality of docking stations in a docking zone;
• at least one of the docking stations comprising a live docking station, whereby the live docking station is able to couple at least one of electrical power, pneumatic power, and signals to a head positioned in the live docking station;
• an upper and lower coupling plate coupling the replaceable head to the wrist, the upper coupling plate being mounted on the end of the sixth axis of the positioner, and the lower coupling plate being mounted on an upper frame portion of the head;
• separable connectors for utilities and signal connections on the upper and lower coupling plates, the separable connectors coupling electrical power, pneumatic power, and signals from the wrist to the head when the head is mounted on the end of the wrist;
• a maintenance plate mounted to the live docking station;
• and
• separable connectors around the perimeter of the maintenance plate, whereby the separable connectors on the maintenance plate mate with the separable connectors on the lower coupling plate of the head in the live docking station, and whereby the maintenance plate couples utilities and signals to the lower coupling plate so that the head can be powered up and run in the live docking station for testing or maintenance purposes.