Research ArticleThe AFP machines have brought significant improvement on the manufacture of composite in terms of speed of material deposition, repeatability, good compaction, and reduction of waste [5]. But most AFP machines are designed for the manufacture of airframe components, which are usually shallow shells or tubes, and are not capable of handling some applications with more complex shapes. To be able to expand the manufacture capabilities of AFP machines in a simple and low cost way, it is necessary to increase the number of degrees of freedom of the robotic system. One way is using another manipulator to hold the mandrel to be manufactured. The advantages of the integrated AFP manufacturing work cell using two serial manipulators are the large workspace and the dexterity to lay the fiber to manufacture the more complex geometry like human arms. But the load carrying capacity and the precision positioning capability are rather poor due to the cantilever structure of the serial manipulator [6]. For the applications of AFP machine where high load carrying capacity and precise positioning are of paramount importance, an alternative to such serial manipulators manufacturing work cell is desirable.With the better stiffness and precise positioning capability [7], a 6 degree of freedom (DOF) parallel robot is introduced to AFP machines and a spindle is mounted on the platform to hold the mandrel [8]. The collaborative AFP manufacturing workcell is expected to be able to manufacture more intricate components and improve the product rate of the manufacturing compared with the current AFP machine. To our best knowledge, there is no application using the collaborative system (constructed with one parallel robot, one serial robot and one rotary stage) for AFP. And the most of the reported collaborative
AbstractThe Automated Fiber Placement (AFP) machines have brought significant improvement on composite manufacturing. However, the current 7 DOF AFP machines normally consist of a 6 Degree-of-Freedom (DOF) serial robot and 1 DOF rotatory mandrel are designed for the manufacture of airframe components, which are usually shallow shells or tubes. They are not capable of handling some applications with more complex shapes. This paper presents the design and analysis of a 13 DOF collaborative AFP machine which consists of a 6 DOF manipulator, a 6-RSS (Revolute Spherical Spherical ) parallel robot and a spindle holding the mandrel (1 DOF) mounted on the platform of parallel robot. The collaborative machine modeling is carried out and the motion of the designed system is simulated in SimMechanics/ Matlab. The inverse kinematic models for both parallel and serial manipulators are established for path planning. In addition, the workspaces and singularities analysis of the collaborative AFP machine are carried out. The case study on three typical structures is presented and the simulation example for manufacturing of a hemisphere structure is provided. The simulation results show that the collaborative AFP machine could enlarg...