JP7610205B2 - TAPE APPLICATION DEVICE, TAPE APPLICATION METHOD, AND METHOD FOR CONTROLLING TAPE APPLICATION DEVICE - Google Patents

Description

The present invention relates to a tape application device, a tape application method, and a method for controlling a tape application device, and more specifically, to a tape application device used in manufacturing fiber-reinforced plastic (FRP) molded products and the like by applying tape to a surface to be applied, a tape application method using the device, and a method for controlling a tape application device.

A method is known for manufacturing fiber reinforced plastic (FRP) molded products of a desired shape by attaching a tape-like product (also called a prepreg tape or UD tape) made of fiber bundles such as carbon fibers that have been pre-impregnated with resin to a target surface.

These manufacturing methods are called various names such as ATL (Auto Tape Layup), ATW (Auto Tape Welding), and AFP (Auto Fiber Placement), but they are not strictly distinct. In this specification, the manufacturing method in which the tape is applied to the surface while being pressed is collectively called ATL, and the equipment used for this (tape application equipment) is called the ATL equipment.

An example of such an ATL device is disclosed in Japanese Patent Application Laid-Open No. 2003-233996.
The ATL device described in Patent Document 1 includes an articulated robot and an ATL head attached to the tip of an arm of the articulated robot. The ATL head is equipped with a pressure roller that clamps the tape between the tape-receiving surface of a workpiece and the ATL head, and presses the tape against the tape-receiving surface.

The workpiece to be affixed is, for example, an injection molded product of a thermoplastic resin, and the tape impregnated with the same thermoplastic resin is affixed to the surface of the workpiece to reinforce the workpiece. When the workpiece is a molded product having a three-dimensional shape, such as an injection molded product of a thermoplastic resin, it often has a shape error with respect to the designed shape and dimensions.
When the workpiece has shape errors like this, the ATL device described in Patent Document 1 has the problem that there may be areas where the pressure roller of the ATL head presses insufficiently against the surface to be affixed, resulting in variations in the pressure state, making it difficult to maintain a constant pressure state of the pressure roller against the surface to be affixed.

The applicant has therefore previously proposed a tape application device that can maintain a constant pressure state of the pressure roller against the tape application surface of the workpiece even when the workpiece has shape errors, thereby improving the performance of applying tape to the tape application surface (Patent Document 2).

The tape application device described in Patent Document 2 includes an application head that applies tape to a surface of a workpiece, and the application head includes a pressing section that presses the tape against the surface, and a parallel link mechanism that operates to change the pressing position and/or pressing posture of the pressing section to match the shape of the surface.

In the tape application device described in Patent Document 2, the application head is equipped with the parallel link mechanism, which makes it possible to operate the pressing position and/or pressing posture of the pressing part so as to follow the shape of the surface to be applied. Even if the work has a shape error, it is possible to keep the pressing state of the pressing part against the surface to be applied constant, thereby improving the application performance of the tape.

[Problem to be solved by the invention]
However, in a tape application device having a mechanism for applying a load to the application head, such as the parallel link mechanism, a problem such as that shown in FIG. 6 may occur.
Fig. 6 is a schematic diagram showing the application head portion to explain problems that occur in a conventional tape application device. Fig. 6(a) shows the state when application of tape (not shown) to the workpiece 2 has been completed, Fig. 6(b) shows the state after the workpiece 2 has been moved from under the application head 200, and Fig. 6(c) shows the state when a new workpiece 2 has been brought under the application head 200.

As shown in Figures 6(a) and (b), in a conventional tape application device, when the application of tape to the workpiece 2 is completed and the workpiece 2 is moved from under the application head 200, when the pressing part 300 is separated from the application surface 2a of the workpiece 2, there is no object to be pressed by the pressing mechanism 400. As a result, each link part 430 constituting the pressing mechanism 400 is fully extended downward, and the position of the pressing part 300 is also lowered accordingly (as shown in Figure 6(b)).

In this state, as shown in FIG. 6(c), if the next workpiece 2 to be applied is brought under the application head 200 or the application head 200 is moved horizontally, the workpiece 2 and the pressing part 300 may collide at an unintended location, causing a problem when the tape application operation to the workpiece 2 is repeated.

JP 2018-149730 A International Publication No. 2020/184237

Means for solving the problem and their effects

The present invention has been made in consideration of the above problems, and aims to provide a tape application device, a tape application method, and a method for controlling a tape application device that can smoothly transition to the application operation and can continuously and stably apply tape to the surface, even when the tape application operation to the surface is performed repeatedly.

In order to achieve the above object, the tape application device (1) according to the present invention comprises:
A tape application device comprising an application head for applying a tape to a surface to be applied and a moving means for moving the application head in a three-dimensional space,
The application head is
a pressing portion for pressing the tape against the receiving surface;
an adjustment unit provided between the moving means and the pressing unit, the adjustment unit controlling the position and/or posture of the pressing unit and the pressing force of the pressing unit against the attachment surface;
at least in a separated state in which the pressing unit is separated from the applied surface, the pressing unit is controlled by the adjustment unit using a position control method in which the pressing unit is controlled to an arbitrary position and/or posture within the application head,
In a pressing state in which the pressing portion is in contact with the surface to be affixed directly or via the tape, the adjustment portion is controlled by a pressure control method capable of applying a predetermined pressing force to the surface to be affixed, regardless of its position and/or posture.

According to the above-mentioned tape application device (1), in the separated state, the adjustment unit controls the pressing portion by a position control method in which the pressing portion is controlled to any position and/or posture within the application head, and in the pressed state, the adjustment unit controls the pressing portion by a pressure control method capable of applying a predetermined pressing force to the applied surface regardless of its position and/or posture.
Therefore, even when the tape application operation to the application surface is repeatedly performed while switching between the separated state and the pressed state, it is possible to prevent the pressing portion and the application surface from coming into contact or colliding with each other at unintended locations. Therefore, the pressing portion can be smoothly shifted from the arbitrary position and/or posture to a posture in which a predetermined pressing force is applied to the application surface directly or via the tape, and the tape application operation to the application surface can be performed stably and continuously.

Further, a tape application device (2) according to the present invention is the above-mentioned tape application device (1), further comprising:
The parallel link mechanism comprises:
A base portion;
An end portion to which the pressing portion is attached;
a plurality of link portions provided in parallel between the base portion and the end portion;
Each of these links is
With universal joints on both ends,
and an actuator provided between the universal joints,
In the separated state, the length of each of the plurality of link portions is controlled by the actuator, and thereby the pressing portion is controlled to the arbitrary position and/or posture within the joining head by the position control method,
In the pressed state, the length of each of the multiple link portions is controlled by the actuator, and the pressing portion is controlled to apply a predetermined pressing force to the attached surface by the pressure control method, regardless of its position and/or posture.

According to the tape application device (2), the adjustment unit is configured to include the parallel link mechanism, and in the separated state, the length of each of the plurality of link parts is controlled by the actuator, and the pressing part is controlled to the arbitrary position and/or posture by the position control method within the application head so that the plurality of link parts are not fully extended downward. This makes it possible to prevent the pressing part and the applied surface from coming into contact or colliding with each other at unintended locations in the separated state.
In addition, in the pressing state, the length of each of the plurality of link parts is controlled by the actuator, and the pressing parts are controlled by the pressure control method to apply a predetermined pressing force to the adherend surface regardless of their position and/or posture. This makes it possible to operate the pressing parts by the parallel link mechanism so that the pressing posture (load posture) of the pressing parts follows the shape of the adherend surface having a shape error, even if the shape of the adherend surface has a shape error with respect to a design shape.
Furthermore, when the tape application operation to the receiving surface is repeatedly performed while switching between the separated state and the pressed state, the length of the multiple link sections that make up the parallel link mechanism can be controlled to smoothly transition from the arbitrary position and/or posture to a posture that applies a predetermined pressing force to the receiving surface, thereby continuously controlling the stable application operation of the tape to the receiving surface.

The tape application device (3) according to the present invention is the above-mentioned tape application device (2),
The pressing portion is
A pressure roller that presses the tape;
a roller support portion attached to the end portion in a state in which the pressure roller is supported,
The application head is
The tape conveying device further includes at least one of a conveying means for conveying the tape and a heating means for heating the tape and/or the application surface,
The roller support portion has
At least one of the transport means and the heating means is integrally attached.

According to the above-mentioned tape application device (3), the pressure roller is attached to the end portion of the parallel link mechanism via the roller support portion, and at least one of the conveying means and the heating means is integrally attached to the roller support portion.
In this way, even if the pressure roller is integrated with at least one of the conveying means and the heating means, and the weight of the application head increases, the pressure part is controlled to the arbitrary position and/or posture by the position control method within the application head so that the plurality of link parts do not become fully extended downward in the separated state. This makes it possible to prevent the pressure part and the applied surface from coming into contact or colliding with each other at unintended locations in the separated state.
Furthermore, even if the weight of the application head increases, in the pressing state, the length of each of the plurality of link parts is controlled by the actuator. This allows the pressing part to be accurately adjusted from the arbitrary position and/or posture to a posture that applies a predetermined pressing force to the application surface directly or via the tape, and allows the conveying means to convey the tape and the heating means to heat the tape and/or the application surface in a constant state. Therefore, even if the shape of the application surface has a shape error with respect to the design shape, it is possible to integrally operate at least one of the conveying means and the heating means together with the pressing part by the parallel link mechanism so that the pressing posture of the pressing part follows the shape of the application surface that has a shape error.

The tape application device (4) according to the present invention is characterized in that the actuator in the tape application device (2) or (3) is an air cylinder.

According to the tape application device (4), the actuator is an air cylinder, and therefore compared to other cylinder types (e.g., hydraulic cylinders, electric cylinders, etc.), the force when the pressing part is pressed against the application surface is easily absorbed or alleviated, i.e., the so-called compliance characteristics (passive smoothness, soft pressing action) are achieved. Therefore, even if the shape of the application surface has a shape error with respect to the design shape, the effect of absorbing the shape error by the pressing action can be enhanced, and the pressing part can be operated more smoothly by the air cylinder so that the pressing posture of the pressing part follows the shape of the application surface having a shape error.

The tape application device (5) according to the present invention is characterized in that in the tape application device (1), the adjustment unit includes at least one air cylinder.

According to the tape application device (5), the adjustment unit includes at least one air cylinder, and therefore, compared to other cylinder types (e.g., hydraulic cylinders, electric cylinders, etc.), the force when the pressing unit is pressed against the application surface is easily absorbed or alleviated, i.e., the configuration exhibits so-called compliance characteristics (passive smoothness, soft pressing action). Therefore, even if the shape of the application surface has a shape error with respect to the design shape, the effect of absorbing the shape error by the pressing action can be enhanced, and the pressing unit can be operated more smoothly by the air cylinder so that the pressing posture of the pressing unit follows the shape error of the application surface.

The tape application device (6) according to the present invention is the tape application device (4) or (5),
The air cylinder is
A cylinder portion to which air is supplied;
A rod portion that advances and retreats in response to the pressure in the cylinder portion;
a pressure detection unit that detects a pressure inside the cylinder unit;
A displacement detection unit that detects a displacement of the rod portion,
In the separated state, the pressure in the cylinder portion detected by the pressure detection portion and/or the displacement of the rod portion detected by the displacement detection portion are controlled so that the pressing portion is controlled to the arbitrary position and/or posture within the joining head,
In the pressed state, the pressure inside the cylinder portion detected by the pressure detection unit and/or the displacement of the rod portion detected by the displacement detection unit are controlled so that the pressing portion applies a predetermined pressing force to the attachment surface regardless of its position and/or posture.

According to the above-mentioned tape application device (6), by controlling the displacement of the rod portion of the air cylinder, it is possible to improve the responsiveness of the operation of switching between the arbitrary position and/or posture in the separated state and the posture in which the specified pressing force is applied to the application surface in the pressed state.
In addition, in the pressed state, it is possible to improve the responsiveness when controlling the displacement of the rod portion of the air cylinder, and it is possible to operate the pressing portion with good responsiveness using the air cylinder so that the pressing posture of the pressing portion follows the shape of the attachment surface, which has shape errors.

The tape application device (7) according to the present invention is characterized in that, in any one of the tape application devices (2) to (4), the arbitrary position and/or posture is a posture in which the pressing part is positioned so that the load direction relative to the application surface is the normal direction.

According to the tape application device (7), when moving from the arbitrary position and/or posture to a posture in which the predetermined pressure force is applied to the surface to be applied, the tape can be applied while pressing the pressing part against the surface to be applied in a direction in which the load direction relative to the surface to be applied is the normal direction. Therefore, the tape can be stably applied to the surface to be applied.

The tape application device (8) according to the present invention is any one of the tape application devices (1) to (7),
The height from the upper end of the adjustment portion to the lower end of the pressing portion in the arbitrary position and/or posture is adjusted to be the height from the upper end of the adjustment portion to the lower end of the pressing portion when in the pressed state at a height position based on the shape design data of the surface to be attached.

According to the tape application device (8), when the application head, which is in the arbitrary position and/or posture, is moved by the moving means to the application start position on the surface to be applied, if the shape of the surface to be applied conforms to the shape design data (in other words, there is no shape error), the lower end of the pressing part (in other words, the part in contact with the surface to be applied) will be positioned on the surface to be applied, and the head can smoothly transition to a posture in which a load is applied to the surface to be applied.

The tape application device (9) according to the present invention is any one of the tape application devices (1) to (8) described above, characterized in that the moving means moves the application head based on the shape design data of the surface to be applied.

According to the tape application device (9), the moving means moves the application head itself based on the shape design data of the application surface, and the adjustment unit controls the pressing unit to the arbitrary position and/or posture within the application head in the separated state, and controls the pressing unit to a posture that applies a predetermined pressing force to the application surface regardless of the position and/or posture in the pressed state.
Therefore, even if the shape of the applied surface has a shape error with respect to the design shape, the adjustment unit can operate the pressing unit so that the pressing posture of the pressing unit follows the shape of the applied surface having the shape error. Therefore, the tape can be stably applied to the applied surface continuously.

The tape application device (10) according to the present invention is characterized in that in the tape application device (9), the moving means is a gantry structure.

According to the above-mentioned tape application device (10), the application head is attached to the gantry structure, so that the gantry structure can stably control the linear motion of the application head (e.g., control of motion in the X, Y and Z axis directions).
By combining stable control of this linear motion with control of the adjustment unit, when the tape application operation to the receiving surface is repeatedly performed while switching between the separated state and the pressed state, it is possible to more smoothly transition from maintaining the arbitrary position and/or posture to a posture in which a predetermined pressing force is applied to the receiving surface directly or via the tape, thereby enhancing the effect of being able to continuously perform a stable tape application operation to the receiving surface.

The tape application device (11) according to the present invention is the above-mentioned tape application device (10),
The gantry structure includes:
an X-axis linear motion mechanism for moving the workpiece having the attachment surface in the X-axis direction;
a Y-axis linear motion mechanism disposed above the X-axis linear motion mechanism in the Y-axis direction;
a Z-axis linear motion mechanism supported by the Y-axis linear motion mechanism and including an application head attachment part movable in the Z-axis direction;
An Xθz-axis stage that supports the workpiece rotatably in a yaw (θz) direction is mounted on the X-axis linear motion mechanism,
The application head is attached to the application head attachment portion,
The adjustment unit,
The pressing portion is configured to be rotatable in at least one of the roll (θy) direction and the pitch (θx) direction.

According to the above-mentioned tape application device (11), the gantry structure is provided with linear motion mechanisms in the X, Y and Z axis directions, the Xθz axis stage that rotates in the yaw (θz) direction is mounted on the X axis linear motion mechanism, and the adjustment unit is configured to be able to rotate the pressing unit in at least one of the roll (θy) direction and the pitch (θx) direction, so that the configuration of the adjustment unit can be simplified.

The tape application device (12) according to the present invention is characterized in that in the tape application device (9), the moving means is an articulated robot.

According to the above-mentioned tape application device (12), since the moving means is composed of an articulated robot, the positioning accuracy of the articulated robot can be complemented by the adjustment unit of the application head, and the performance of applying the tape to the application surface when using the articulated robot can be improved.

A tape application method according to the present invention is a method for applying the tape to the surface by using any one of the tape application devices (1) to (12), comprising the steps of:
In the separated state, the adjustment unit is controlled by the position control method so that the pressing unit is brought into the arbitrary position and/or posture within the joining head.
In the pressing state, the adjustment unit is controlled by the pressure control method so as to apply a predetermined pressing force to the attachment surface, regardless of the position and/or posture of the pressing unit.

According to the above-mentioned tape application method, in the separated state, the adjustment unit adjusts the pressing portion within the application head by the position control method so that it is at the desired position and/or posture, and in the pressed state, the adjustment unit adjusts the pressing portion by the pressure control method to a posture that applies a predetermined pressing force to the applied surface, regardless of its position and/or posture.
Therefore, even when the tape application operation to the application surface is repeatedly performed while switching between the separated state and the pressed state, it is possible to prevent the pressing portion and the application surface from coming into contact or colliding with each other at unintended locations. Therefore, it is possible to smoothly transition from holding the arbitrary position and/or posture to a posture in which a predetermined pressing force is applied to the application surface directly or via the tape, and it is possible to continuously perform a stable application operation of the tape to the application surface.

A method for controlling a tape application device according to the present invention includes: an application head including a pressing unit that presses a tape against a surface to be applied with the tape; and an adjustment unit that controls a position and/or posture of the pressing unit and a pressing force of the pressing unit against the surface to be applied with the tape;
a moving means for moving the application head in a three-dimensional space,
The adjustment unit,
performing position control in which the pressing portion is controlled to an arbitrary position and/or attitude within the application head at least in a separated state in which the pressing portion is separated from the application surface;
In a pressing state in which the pressing portion is in contact with the adhered surface directly or via the tape, pressure control is performed so that a predetermined pressing force can be applied to the adhered surface regardless of the position and/or posture of the pressing portion,
The control of the operation of the adjustment unit is switched depending on whether the contact is in the separated state or the pressed state.

According to the above-mentioned control method for the tape application device, the adjustment unit is capable of appropriately switching between operational control according to the separated state and the pressed state, thereby preventing contact or collision between the pressing unit and the surface to be applied at unintended locations.
Therefore, when the adjustment unit repeatedly performs the operation of applying tape to the receiving surface while switching between the separated state and the pressed state, it can smoothly transition from maintaining the arbitrary position and/or posture to a posture in which a predetermined pressing force is applied to the receiving surface directly or via the tape, and stable control of the operation of applying the tape to the receiving surface can be continuously performed.

1 is a schematic diagram showing a configuration example of an ATL head in an ATL device according to an embodiment of the present invention; 1 is an overall perspective view showing a specific configuration example of an ATL device according to an embodiment; 2 is an enlarged perspective view of the periphery of an ATL head of the ATL device according to the embodiment; 10 is a flowchart showing an example of a joining process operation performed by a robot control unit and an ATL head control unit of the ATL apparatus according to the embodiment. 5A and 5B are schematic diagrams illustrating an example of the operation of an ATL head in the ATL device according to the embodiment. 1 is a schematic diagram showing an application head portion for explaining a problem that occurs in a conventional tape application device. FIG.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of a tape application device, a tape application method, and a method for controlling a tape application device according to the present invention will be described with reference to the accompanying drawings.
1 is a schematic diagram showing an example of the configuration of an ATL head in an ATL device according to an embodiment of the present invention. The ATL device is an example of a tape application device according to the present invention, and the ATL head is an example of an application head.

The ATL device 10 is a device for manufacturing a molded product reinforced with tape 1 by attaching tape 1 to a workpiece 2, and is equipped with an ATL head 20 for attaching tape 1 to the attachment surfaces 2a, 2ab of the workpiece 2 while pressing the tape 1.

The ATL head 20 is attached to a handling robot 70. The handling robot 70 may be a general-purpose industrial robot for moving the ATL head 20 in three-dimensional space, for example, a gantry structure (also called a Cartesian coordinate mechanism), or may be a multi-joint robot (also called a serial multi-joint mechanism). The handling robot 70 is preferably equipped with a mechanism (three degrees of freedom) that allows the ATL head 20 to move in translation at least in the XYZ axis directions. The operation control of the handling robot 70 is performed by a robot control unit 70a. The robot control unit 70a stores three-dimensional coordinate data (design shape data) of the attachment surface 2a of the work 2, programs for controlling the operation of each part based on the three-dimensional coordinate data, etc., which are used to control the movement of the ATL head 20. The robot control unit 70a may be configured using a general-purpose computer device.

The workpiece 2 is, for example, a molded product having a three-dimensional shape, and may be a molded product made of resin such as thermoplastic resin or thermosetting resin, or may be a molded product made of metal, etc.

For example, the tape 1 is formed by pre-impregnating at least a portion of a fiber bundle with resin, and may be impregnated with a thermoplastic resin (also called UD tape) or with a thermosetting resin (also called prepreg tape). The tape 1 may also contain carbon fiber, or may be a resin tape with many short fibers mixed in. The type of tape 1 may be appropriately selected depending on the material of the workpiece 2. The tape 1 may also be in the form of multiple tapes arranged in parallel.

The ATL head 20 includes a pressing unit 30 that presses the tape 1 against the application surfaces 2a, 2ab of the workpiece 2, and a parallel link mechanism 40 that is provided between the handling robot 70 and the pressing unit 30 and controls the position and/or posture of the pressing unit 30, as well as the pressing force of the pressing unit 30 on the application surfaces 2a, 2ab. The parallel link mechanism 40 is an example of an adjustment unit. In the following description, for convenience, "position and/or posture" will be referred to as "position and posture."

The pressing unit 30 includes a pressing roller 31 that presses the tape 1, and a roller support unit 32 that is attached to the end unit 42 of the parallel link mechanism 40 while rotatably supporting the pressing roller 31. The pressing roller 31 may be configured as a resin roller, an elastic roller, a metallic roller, or the like, depending on the characteristics of the tape 1 or the material of the workpiece 2. The size (diameter, width) of the pressing roller 31 may be appropriately selected depending on the type and size of the tape 1 used and the type and shape of the workpiece 2. In another configuration example, a pressing member such as a pressing shoe may be used instead of the pressing roller 31.

The parallel link mechanism 40 includes a base portion 41 that is attached to the handling robot 70, an end portion 42 to which the pressing portion 30 is attached, and a plurality of link portions 43 that are arranged in parallel between the base portion 41 and the end portion 42.

Each of these link parts 43 has universal joints 44, 45, such as universal joints or spherical joints, at both ends, and an air cylinder 46 as an actuator provided between these universal joints 44, 45. The parallel link mechanism 40 is capable of changing the position (translation) and attitude (rotation) of the end part 42 by controlling the length of each of the multiple link parts 43 with the air cylinder 46.

The parallel link mechanism 40 is generally composed of three to six link parts 43, although the number of link parts 43 is not particularly limited as long as the position and posture of the pressure roller 31 can be adjusted so that the pressure roller 31 applies a load to the application surfaces 2a, 2ab via the tape 1. In the following description, the term "load" may be read as "pressing force." In addition, in the present invention, the term "pressing force" is used as a concept that includes absolute load and direction. Reducing the number of link parts 43 simplifies the configuration of the parallel link mechanism 40. On the other hand, increasing the number of link parts 43 increases the support force of the parts attached to the end parts 42, and the parallel link mechanism 40 can be configured to be less susceptible to the effects of moments associated with the operation of the parallel link mechanism 40.

The degrees of freedom of the parallel link mechanism 40 may be set taking into consideration the operational function (degrees of freedom) of the handling robot 70. In this case, it is preferable to adopt a parallel link mechanism 40 that allows the pressure roller 31 to rotate at least in the roll direction and pitch direction. Regardless of the operational function of the handling robot 70, a six-degrees-of-freedom mechanism, that is, a mechanism that moves in six directions (three translational directions and three rotational directions), may be applied to the parallel link mechanism 40.

The air cylinder 46 includes a cylinder portion 46a to which air is supplied, a rod portion 46b that moves forward and backward according to the pressure inside the cylinder portion 46a, a pressure sensor (pressure detection portion) 46c that detects the pressure inside the cylinder portion 46a, and a displacement sensor (displacement detection portion) 46d that detects the displacement of the rod portion 46b. The air cylinder 46 is preferably configured as a double-acting cylinder, but is not limited to this.

The cylinder section 46a is connected to a servo valve 46e via a pressure sensor 46c. The servo valve 46e adjusts the amount of air flowing into and out of the cylinder section 46a, and controls the pressure difference between the two chambers of the cylinder section 46a. The servo valve 46e is connected to an air pressure supply section 46f that outputs compressed air from a compressor or the like.

The displacement sensor 46d may be any device capable of measuring the amount of displacement of the rod portion 46b, and may be, for example, a magnetic linear encoder that detects the amount of displacement of the rod portion 46b from the amount of magnetic displacement, an optical linear encoder, or a potentiometer.

The pressure signal detected by the pressure sensor 46c and the displacement signal detected by the displacement sensor 46d are each output to the ATL head control unit 46g. The ATL head control unit 46g stores three-dimensional coordinate data indicating the design shape of the workpiece 2, as well as programs that control the operation of each part of the ATL head 20 based on the three-dimensional coordinate data, pressure signal, displacement signal, etc.

The ATL head control unit 46g uses, for example, detection signals acquired from the pressure sensor 46c and displacement sensor 46d of each air cylinder 46 as control parameters to control the operation of the servo valve 46e of each air cylinder 46, and performs processing to control the pressure within the cylinder portion 46a of each air cylinder 46 and/or the displacement of the rod portion 46b.
For example, in a separated state where at least the pressure roller 31 is separated from the application surface 2a, the ATL head control unit 46g controls the operation of each unit of the parallel link mechanism 40 by a position control method that controls the pressing unit 30 to an arbitrary position and/or posture within the ATL head 20. In other words, in the separated state, the ATL head control unit 46g controls the operation of the parallel link mechanism 40 so that at least the pressure roller 31 is held in a predetermined reference position and posture within the ATL head 20. The predetermined reference position and posture is an example of an arbitrary position and/or posture. In addition, the arbitrary position and/or posture may change over time (with time).

The predetermined reference position and posture is, for example, a posture in which the displacement of the rod portion 46b of each air cylinder 46 constituting the parallel link mechanism 40 is adjusted to a predetermined value near the middle position of the maximum stroke length. The predetermined value can be set to an arbitrary value depending on the size of each part of the ATL device 10 and the shape and size of the workpiece 2 to be attached. The height from the base portion 41 of the parallel link mechanism 40 to the lower end point of the pressure roller 31 in this posture is adjusted to, for example, a predetermined height Zh. This predetermined height Zh is set as the head reference height of the ATL head 20.
This head reference height corresponds to the head height when the pressure roller 31 of the ATL head 20 is placed on the application surface 2a, assuming that there is no shape error in the workpiece 2. In other words, the head reference height is the head height when the head is in a pressed state at a height position based on the three-dimensional shape data of the application surface 2a (design height position of the workpiece 2).

The specified reference position and posture is preferably a posture in which the pressure roller 31 is positioned so that the load direction relative to the attachment surface 2a of the work 2 is the normal direction. For example, the pressure roller 31 is positioned so that the load direction relative to the design shape of the attachment surface 2a of the work 2, which is the starting position for attaching the tape 1, is the normal direction (direction A shown in FIG. 1). The load direction may also be interpreted as the pressing direction. In addition, it is preferable to adjust the height from the base portion 41 of the parallel link mechanism 40 to the lower end point of the pressure roller 31 in this posture to a specified height Zh.

In addition, the ATL head control unit 46g controls the operation of each part of the parallel link mechanism 40 by a pressure control method that allows the pressing unit 30 to apply a predetermined pressing force to the attached surfaces 2a, 2ab regardless of its position and/or posture in a pressing state in which the pressing roller 31 is in contact with the attached surfaces 2a, 2ab directly or via the tape 1. In other words, the ATL head control unit 46g controls the operation of the parallel link mechanism 40 in the pressing state so that the pressing roller 31 applies a predetermined load to the attached surfaces 2a, 2ab directly or via the tape 1 from maintaining a predetermined reference position and posture. The ATL head control unit 46g has a function of switching the operation control of the parallel link mechanism 40 depending on the separated state and pressed state of the pressing roller 31.

For example, the ATL head control unit 46g calculates the angle of each air cylinder 46 and the stroke length of each rod portion 46b based on the detection signal captured from the pressure sensor 46c and displacement sensor 46d of each air cylinder 46 in the pressing state of the pressure roller 31. The ATL head control unit 46g also calculates an index (for example, an excess or deficiency of pressure or an excess or deficiency of displacement taking into account the shape error of the work 2) for the pressure roller 31 to apply a predetermined load to the application surface 2a directly or via the tape 1, and controls the operation (pressurization operation or depressurization operation) of the servo valve 46e of each air cylinder 46 based on these calculated indexes. By this control, the position and posture of the end portion 42 are adjusted so that the load direction of the pressure roller 31 relative to the application surface 2a, 2ab is normal, and the pressure roller 31 presses the application surface 2a, 2ab directly or via the tape 1 while maintaining a predetermined load.

For example, as shown in FIG. 1, if the work 2 has a shape error (-Δh) from the design shape on the attachment surface 2ab, the displacement (length) of each link 43 of the parallel link mechanism 40 is adjusted so that the head height (height from the base portion 41 to the lower end point of the pressure roller 31) when the tape 1 is being attached to the attachment surface 2ab is (head reference height Zh + Δh). Note that the load direction of the pressure roller 31 with respect to the attachment surface 2ab may not necessarily be the normal direction, and the configuration allows the load direction of the pressure roller 31 to be flexibly adjusted depending on the shape error of the attachment surface 2ab, etc.

The ATL head control unit 46g controls the parallel link mechanism 40 when the pressure roller 31 is in the pressed state, so that no gap is formed between the pressure roller 31 and the tape 1, and the pressure roller 31 presses the attached surfaces 2a, 2ab of the work 2 via the tape 1 from a direction perpendicular to the attached surfaces 2a, 2ab (normal direction). The ATL head control unit 46g may be configured using a general-purpose computer. The robot control unit 70a and the ATL head control unit 46g may also be configured as a single control unit.

In this configuration example, the actuator of the parallel link mechanism 40 is configured as an air cylinder 46 that is driven by air pressure, but the actuator that can be applied to the present invention is not limited to the air cylinder 46. For example, it can also be configured as a linear actuator such as a hydraulic cylinder or an electric cylinder.

The ATL head 20 further includes a feeder (conveying means) 50 for conveying the tape 1, and a heating means 60 for heating at least one of the tape 1 and the applied surface 2a sent from the feeder 50 to the pressure roller 31. The feeder 50 and the heating means 60 are attached to an attachment guide 61 fixed to the roller support portion 32. Note that the heating means 60 is not an essential element, and if heat treatment of the tape 1 is not required, the ATL head 20 may be configured without the heating means 60. Also, a detachable portion (not shown) for the heating means 60 may be provided on the attachment guide 61, so that the heating means 60 can be attached and detached to the attachment guide 61. The operation of the feeder 50 and the heating means 60 is controlled by the ATL head control portion 46g.

The heating means 60 is preferably capable of heating the tape 1 and the application surfaces 2a, 2ab without contact, and may be, for example, a radiation light source such as an infrared lamp, laser, or IR lamp, or a hot air source such as a hot air nozzle, or a combination of these.

The feeder 50 has, for example, a pair of conveyor belts 51, and is configured to convey the tape 1 by rotating the pair of conveyor belts 51 using the power of a motor (not shown). Note that a heater may be provided within the feeder 50, and the pair of conveyor belts 51 may be preheated to a predetermined temperature. This makes it possible to preheat the tape 1 before it reaches the application point (point B shown in FIG. 1).

The feeder 50 may be equipped with a winding mechanism (not shown) that winds the tape 1 from a bobbin, or may supply the tape 1 that has been cut to a predetermined length. Alternatively, the tape 1 may be wound from a winding mechanism (not shown) that is installed separately from the ATL head 20, and the tape 1 may be supplied to the feeder 50 along the transport path.
The ATL device 10 is also provided with an operation unit (not shown) for performing operation input and setting input for each part of the device, and signals input via the operation unit are output to the robot control unit 70a and the ATL head control unit 46g.

Figure 2 is an overall perspective view showing a specific configuration example of an ATL device according to an embodiment. Also, Figure 3 is an enlarged perspective view of the ATL head and its surroundings in the ATL device shown in Figure 2. Note that components having the same functions as the components of the ATL device 10 shown in Figure 1 are given the same reference numerals, and their explanations will be omitted.

In the ATL device 10 shown in FIGS. 2 and 3, a handling robot 70 to which the ATL head 20 is attached is composed of a gantry structure (cartesian coordinate mechanism) 71.
The basic configuration of the ATL head 20 shown in Figures 2 and 3 is substantially the same as that of the ATL head 20 shown in Figure 1, but in the ATL head 20 shown in Figures 2 and 3, the parallel link mechanism 40 is composed of four link parts 43. In the following explanation, the direction in which the workpiece 2 is moved is defined as the X-axis direction, the direction perpendicular to this in the horizontal plane is defined as the Y-axis direction, and the direction perpendicular to both the X-axis and Y-axis directions is defined as the Z-axis direction.

The gantry structure 71 is equipped with an X-axis linear motion mechanism 72 equipped with an Xθz-axis stage 73 that supports the workpiece 2 so that it can move in the X-axis direction and rotate in the yaw (θz) direction (around the Z axis), a Y-axis linear motion mechanism 74 that is suspended in the Y-axis direction above the X-axis linear motion mechanism 72, and a Z-axis linear motion mechanism 75 that is supported by the Y-axis linear motion mechanism 74 and can move in the Z-axis direction.

The X-axis linear motion mechanism 72 includes an X-axis guide section 72a, an X-axis slide table 72b slidably attached to the X-axis guide section 72a, and an Xθz-axis stage 73 rotatably mounted in the yaw (θz) direction on the X-axis slide table 72b. The workpiece 2 is placed on the Xθz-axis stage 73.

The Y-axis linear motion mechanism 74 includes a gate-shaped Y-axis guide portion 74a and a Y-axis slider 74b slidably attached to the Y-axis guide portion 74a.
The Z-axis linear motion mechanism 75 includes a Z-axis guide portion 75a attached to the Y-axis slider 74b, a Z-axis slider 75b slidably attached to the Z-axis guide portion 75a, and a Z-axis bracket 75c attached to the Z-axis slider 75b. An ATL head attachment portion 76 is attached to the lower end of the Z-axis bracket 75c, and the ATL head 20 is attached to the ATL head attachment portion 76.

Next, the operation of the ATL device 10 for applying the tape 1 to the workpiece 2 will be described.
With regard to the application operation of the tape 1 using the ATL device 10, the X-axis linear motion mechanism 72 realizes the X-axis translational motion of the work 2, and the Xθz-axis stage 73 realizes the Z-axis (yaw (θz) direction) rotational motion of the work 2. Furthermore, the Y-axis linear motion mechanism 74 realizes the Y-axis translational motion of the ATL head 20, and the Z-axis linear motion mechanism 75 realizes the Z-axis translational motion of the ATL head 20.

The parallel link mechanism 40 of the ATL head 20 realizes, for example, an operation of holding the pressure roller 31 in a predetermined reference position and posture within the ATL head 20 when the pressure roller 31 is in a separated state. In addition, the parallel link mechanism 40 realizes, for example, at least the Y-axis (roll (θy) direction) rotational movement of the pressure roller 31 and the X-axis (pitch (θx) direction) rotational movement of the pressure roller 31 when the pressure roller 31 is in a pressed state, and an operation of applying a predetermined load to the applied surface 2a directly or via the tape 1 by the pressure roller 31. The operation of applying a predetermined load may be an operation of pressing so as to follow the actual shape of the applied surface 2a, and is preferably an operation of pressing from the normal direction to the applied surface 2a.

Figure 4 is a flow chart showing an example of the processing operation performed by the robot control unit 70a and the ATL head control unit 46g in the ATL device 10 according to the embodiment. Also, Figure 5 is a schematic diagram of the main parts for explaining an example of the operation of the ATL head 20 in the ATL device 10 according to the embodiment. Note that in this processing operation example, a case is explained in which the operation of the ATL head 20 is controlled so that the tape 1 is sequentially attached to the attachment surfaces 2a, 2ab of the workpiece 2 in a line.

First, in step S1, the robot control unit 70a determines whether or not there has been an operation input to return the ATL head 20 to a predetermined origin position, and if it determines that such an operation input has been received, the process proceeds to step S2.

In step S2, the robot control unit 70a controls the operation of the Y-axis linear motion mechanism 74 and the Z-axis linear motion mechanism 75 of the gantry structure 71 to move the ATL head 20 to the origin position, and then proceeds to step S3. The origin position is, for example, a position above the application start position of the tape 1.

In step S3, the robot control unit 70a and the ATL head control unit 46g determine whether or not there has been an operation input to start applying the tape 1 to the workpiece 2, and if it is determined that such an operation input has been received, the process proceeds to step S4. Note that steps S1 and S3 may be combined to determine whether or not there has been an operation input, and the process may proceed to steps S2 and S4.

In step S4, the ATL head control unit 46g starts position control by the parallel link mechanism 40 so that the pressure roller 31 is held in a predetermined reference position and posture (the state of the ATL head 20 in FIG. 5A), and the process proceeds to step S5.
The specified reference position and posture is, for example, a posture in which the displacement of the rod portion 46b of each air cylinder 46 constituting the parallel link mechanism 40 is adjusted to a specified value near the middle position of the maximum stroke length, and the height from the base portion 41 of the parallel link mechanism 40 to the lower end point of the pressing roller 31 is adjusted to, for example, a specified height (=head reference height) Zh.

In step S5, the robot control unit 70a controls the operation of the X-axis linear motion mechanism 72 of the gantry structure 71 to move the Xθz-axis stage 73 in the X-axis direction, and controls the movement of the workpiece 2 so that the start position of tape 1 application to the workpiece 2 placed on the Xθz-axis stage 73 is positioned directly under the ATL head 20 (state of the workpiece 2 in FIG. 5(a)), and then proceeds to step S6.

In step S6, the robot control unit 70a controls the operation of the Z-axis linear motion mechanism 75 of the gantry structure 71 based on the three-dimensional shape data (design shape data) of the workpiece 2, and controls the ATL head 20 to lower so that the pressure roller 31 is positioned on the attachment surface 2a of the workpiece 2 (see Figures 5 (b) and (c)), and then proceeds to step S7. Note that even during the operation control of steps S5 and S6, the parallel link mechanism 40 controls the position of the pressure roller 31 to be held at a predetermined reference position and posture (head reference height Zh).

In step S7, the ATL head control unit 46g switches from control for holding the pressure roller 31 in a predetermined reference position and posture (position control) to control for putting the pressure roller 31 in a posture for applying a predetermined load to the tape-attached surface 2a (load control) in order to proceed to the tape-attaching operation of the tape 1 (see FIG. 5(c)), and then proceeds to step S8. Note that the term "load control" may be read as "pressure control".
In the position control, even if any disturbance acts on the ATL device 10, the position of the pressing portion 30 in the ATL head 20 is maintained at a predetermined position.
In addition, in the load control, even if there is an error in the shape of the surface to be affixed of the workpiece 2, the pressure roller 31 of the pressing section 30 is controlled to apply a predetermined load (i.e., pressing force) to the surfaces to be affixed 2a, 2ab directly or via the tape 1.

In step S8, the robot control unit 70a and the ATL head control unit 46g cooperate to start controlling the operation of applying the tape 1 to the application surface 2a of the workpiece 2 (see FIGS. 5(c), (d), and (e)). That is, the robot control unit 70a controls the operation of the Y-axis linear motion mechanism 74 and the Z-axis linear motion mechanism 75 based on the three-dimensional shape data of the workpiece 2, and starts controlling the movement of the ATL head 20 in the Y-axis and Z-axis directions.

This movement control is a control that moves the ATL head 20 itself in the Y-axis and X-axis directions based on the three-dimensional shape data of the workpiece 2 while maintaining the height of the base part 41 of the parallel link mechanism 40 attached to the Z-axis bracket 75c from the attachment surface 2a at the head height (reference head height) Zh when the head is in a predetermined reference position and posture,

Then, in parallel with the control of the robot control unit 70a to move the ATL head 20, the ATL head control unit 46g operates each unit of the ATL head 20 to perform processing to start controlling the application of the tape 1. That is, the ATL head control unit 46g operates the feeder 50 to start control to transport the tape 1 between the pressure roller 31 and the application surfaces 2a, 2ab.

The ATL head control unit 46g also operates the parallel link mechanism 40 to start load control in which the pressure roller 31 applies a predetermined load to the application surfaces 2a, 2ab directly or via the tape 1, for example, control in which the pressure roller 31 presses the tape 1 with a predetermined load from the normal direction to the application surfaces 2a, 2ab (the direction of arrow A in Figures 5(c) and (d)). Note that the pressing direction of the pressure roller 31 is not limited to the normal direction of the application surfaces 2a, 2ab. Furthermore, the ATL head control unit 46g starts a heating process by the heating means 60, and starts heating the tape 1 and/or the application surfaces 2a, 2ab.

As shown in FIG. 5(d), if the workpiece 2 has a shape error (-Δh) from the design shape on the attachment surface 2ab, the displacement (length) of the rod portion 46b of each air cylinder 46 of the parallel link mechanism 40 is adjusted so that the head height (height from the base portion 41 to the lower end point of the pressure roller 31) when the tape 1 is pressed against the attachment surface 2ab becomes the head reference height Zh+Δh.

Then, the robot control unit 70a and the ATL head control unit 46g control the application of the tape 1 to the application surfaces 2a, 2ab along the application path of the tape 1 on the workpiece 2, and then the process proceeds to step S9.

In the next step S9, the robot control unit 70a determines whether the ATL head 20 has reached the application end position of the tape 1 through the operation of the Y-axis linear motion mechanism 74. If it determines that the application end position has not been reached, it continues the application process that began in step S8, whereas if it determines that the application end position (see FIG. 5(e)) has been reached, it proceeds to step S10.

In step S10, the ATL head control unit 46g performs processing to end the application of the tape 1. That is, the ATL head control unit 46g controls the cutting of the tape 1 by the cutting unit provided in the feeder 50 and controls the stopping of the heating operation by the heating means 60, completes the application of one piece (one line) of tape 1, and then proceeds to step S11.

In step S11, the ATL head control unit 46g switches from the control of placing the pressure roller 31 in a position that applies a predetermined load to the attachment surface 2a (load control), which has been continuously performed during the processing in steps S7 to S10, to control of holding the pressure roller 31 in a predetermined reference position and posture (position control), and then proceeds to step S12.

In step S12, the ATL head control unit 46g starts position control by the parallel link mechanism 40 so that the pressure roller 31 is held in a predetermined reference position and posture within the ATL head 20, and then proceeds to step S13.

In the next step S13, the robot control unit 70a determines whether or not all application of the tape 1 to the application surface 2a of the workpiece 2 has been completed based on the operation history of the gantry structure 71, and if it determines that all application has not been completed, the process proceeds to step S14.

In step S14, the robot control unit 70a controls the operation of the Y-axis linear motion mechanism 74 and the Z-axis linear motion mechanism 75 of the gantry structure 71 to move the ATL head 20 above the next tape 1 application start position (see FIG. 5(f)). The robot control unit 70a also controls the operation of the X-axis linear motion mechanism 72 to move the Xθz-axis stage 73 in the X-axis direction, and controls the movement of the work 2 so that the next tape 1 application start position for the work 2 placed on the Xθz-axis stage 73 is located directly below the ATL head 20. Note that even during the operation control of steps S13 and S14, the parallel link mechanism 40 performs position control to hold the pressure roller 31 at a predetermined reference position and posture (head reference height Zh) within the ATL head 20.

Then, the process returns to step S6, and the tape 1 is sequentially lined up and attached to the attachment surface 2a of the workpiece 2. On the other hand, if it is determined in step S14 that all of the tape 1 has been attached, the process proceeds to step S15.

In step S15, the robot control unit 70a controls the operation of the Y-axis linear motion mechanism 74 and the Z-axis linear motion mechanism 75 of the gantry structure 71 to move the ATL head 20 to a predetermined origin position, and controls the operation of the X-axis linear motion mechanism 72 to move the Xθz-axis stage 73 to a predetermined origin position, and then ends the process.

In the above operation example, the operation of the ATL head 20 is controlled so that the tape 1 is applied sequentially to the application surfaces 2a, 2ab of the workpiece 2 in a line, but the manner in which the tape 1 is applied to the application surfaces 2a, 2ab is not limited to this. For example, in other operation examples, depending on the quality standards of the molded product, the tape 1 may be applied in a state in which adjacent pieces of tape 1 overlap, or adjacent pieces of tape 1 may be applied in a state in which they do not overlap (a state in which a predetermined gap is provided).

As described above, the state of application of the tapes, such as the overlap or gap between them, may be regulated in terms of the quality of the molded product. For example, if the pressure roller is unable to press in the normal direction of the surfaces 2a, 2ab to be applied, causing the application trajectory of the pressure roller to shift, the overlap or gap between the tapes 1 may become unstable, which may impair the quality of the molded product.

However, with the ATL device 10 according to this embodiment, the parallel link mechanism 40 of the ATL head 20 adjusts the direction of the load applied according to the shape error of the surface 2a during the application operation, so that the pressure roller 31 can be reliably pressed against the surface 2a directly or via the tape 1. Therefore, even when adjacent tapes 1 are applied in a partially overlapping state, or when adjacent tapes 1 are applied so that they do not overlap, i.e., so that a certain gap is provided, it is possible to perform stable application with a certain degree of overlap and gap between the tapes 1, and it is possible to improve the quality of the molded product to which the tape 1 is applied.

In addition, because tape 1 is an aggregate of fibers such as carbon fibers, if the cross-sectional shape of tape 1 is distorted, it may adversely affect the quality of the molded product. For example, if the pressure roller cannot be pressed in the normal direction, a force is generated in the axial direction of the pressure roller, which may displace the fibers near the contact surface of tape 1 with the pressure roller, causing the cross-sectional shape of tape 1 to be distorted.

However, with the ATL device 10, the parallel link mechanism 40 of the ATL head 20 makes it possible to accurately press the pressure roller 31 in the normal direction of the application surface 2a, so there is no risk of the cross-sectional shape of the tape 1 being distorted by the pressure roller 31, and it is possible to improve the quality of the molded product.

According to the ATL device 10 of the above embodiment, the ATL head control unit 46g can appropriately switch the operation control of the parallel link mechanism 40 depending on whether the pressure roller 31 is in the separated state or the pressed state.
When the pressure roller 31 is in the separated state, the length of each of the multiple link parts 43 is controlled by the air cylinder 46, and the parallel link mechanism 40 holds the pressure part 30 in a predetermined reference position and posture within the ATL head 20 so that the rod part 46b of the air cylinder 46 does not reach a fully extended downward state. This makes it possible to prevent the pressure part 30 and the workpiece 2 from contacting or colliding with each other at unintended locations when the pressure roller 31 is in the separated state.

In addition, when the pressure roller 31 is in the pressing state, the length of each of the multiple link portions 43 is controlled by the air cylinder 46, and the pressure roller 31 of the pressing portion 30 is accurately adjusted from maintaining a predetermined reference position and posture to a posture in which a load is applied to the applied surface 2a directly or via the tape 1.
As a result, even if the workpiece 2 has a shape error, the pressing roller 31 can be operated by the parallel link mechanism 40 so that the pressing posture (load posture) of the pressing roller 31 follows the affixed surface 2ab of the workpiece 2, which has a shape error.

Therefore, even when the tape 1 is repeatedly applied to the application surfaces 2a, 2ab of the workpiece 2 having a three-dimensional shape while switching between the pressure roller 31's separated state and pressed state, it is possible to prevent the pressure roller 31 and the workpiece 2 from contacting or colliding at unintended locations. Furthermore, when the pressure roller 31 is in the pressed state, the parallel link mechanism 40 can be controlled to smoothly transition from holding a predetermined reference position and posture to a posture in which a load is applied to the application surfaces 2a, 2ab directly or via the tape 1, and the stable application operation of the tape 1 to the application surfaces 2a, 2ab of the workpiece 2 can be continuously controlled.

In addition, according to the ATL device 10, the pressure roller 31 is attached to the end portion 42 of the parallel link mechanism 40 via the roller support portion 32, and at least one of the feeder 50 and the heating means 60 is integrally attached to the roller support portion 32.
In this way, even if the pressure roller 31 is integrated with at least one of the feeder 50 and the heating means 60 and the ATL head 20 becomes heavy, at least the pressure roller 31 is appropriately held in a predetermined reference position and posture within the ATL head 20 so that the multiple link parts 43 do not become fully extended downward when the pressure roller 31 is in the separated state. Furthermore, even if the weight of the ATL head 20 increases, when the pressure roller 31 is in the pressed state, the pressure roller 31 is accurately adjusted from the predetermined reference position and posture to a posture in which a load is applied to the application surfaces 2a, 2ab directly or via the tape 1, and the feeder 50 can transport the tape 1 and the heating means 60 can heat the tape 1 and/or the application surfaces 2a, 2ab in a constant state.
Therefore, even if the shape of the applied surface 2a has a shape error with respect to the design shape, it is possible to operate at least one of the feeder 50 and the heating means 60 together with the pressing section 30 by the parallel link mechanism 40 so that the pressing posture of the pressing roller 31 imitates the shape of the applied surface 2ab which has a shape error.

In addition, according to the ATL device 10, an air cylinder 46 is used as an actuator of the parallel link mechanism 40. Therefore, compared to other cylinder types (e.g., hydraulic cylinders, electric cylinders, etc.), the force when the pressing part 30 is pressed against the application surface 2a, 2ab is easily absorbed or alleviated, that is, the so-called compliance characteristic (passive smoothness, soft pressing operation) is achieved. Furthermore, even if the shape of the work 2 has a shape error with respect to the design shape, the effect of absorbing the shape error by the pressing operation can be enhanced, and the pressing part 30 can be operated more smoothly by the air cylinder 46 so that the pressing posture of the pressing roller 31 follows the shape of the application surface 2ab having a shape error. In addition, since the air cylinder 46 is used as an actuator for adjusting the length, the parallel link mechanism 40 can be made space-saving, and an ATL head 20 with high degree of freedom without being bulky can be realized.

Furthermore, according to the ATL device 10, by controlling the displacement of the rod portion 46b of the air cylinder 46, it is possible to improve the responsiveness of the operation of switching between a predetermined reference position and posture in the separated state and a posture in which the rod portion 46b is pressed with a predetermined load in the pressed state.
In addition, in the pressed state, it is possible to improve the responsiveness when controlling the displacement of the rod portion 46b of the air cylinder 46, and it is possible to operate the pressing portion 30 with good responsiveness using the air cylinder 46 so that the pressing posture of the pressing roller 31 follows the shape of the applied surface 2a, which has shape errors.

In addition, with the ATL device 10, when transitioning from holding a predetermined reference position and posture to a posture in which a load is applied to the surfaces 2a, 2ab to be stuck directly or via the tape 1, the pressure roller 31 can be pressed against the surfaces 2a, 2ab to be stuck, with the load direction relative to the surfaces 2a, 2ab being the normal direction, to stick the tape 1. This allows for a stable sticking operation of the tape 1 to the surfaces 2a, 2ab to be performed.

In addition, according to the ATL device 10, the height from the base part 41 of the parallel link mechanism 40 to the lower end of the pressure roller 31 in a predetermined reference position and posture is adjusted to a predetermined head reference height Zh. Therefore, when the ATL head 20 held in a predetermined reference position and posture is moved by the gantry structure 71 to the application start position of the application surface 2a of the workpiece 2, if the shape of the application surface 2a is as per the shape design data (in other words, if there is no shape error), the lower end of the pressure roller 31 (in other words, the contact part with the application surface 2a) will be located on the application surface 2a. Therefore, it is possible to move extremely smoothly to a posture in which a load is applied to the application surface 2a in that state.

Furthermore, according to the ATL device 10, the ATL head 20 is moved by the gantry structure 71 based on the shape design data of the application surface 2a. Then, by the parallel link mechanism 40, in the separated state, at least the pressing part 30 is adjusted so as to be held in a predetermined reference position and posture within the ATL head 20, and in the pressed state, the pressing roller 31 of the pressing part 30 is adjusted to a posture that applies a predetermined load to the application surfaces 2a, 2ab.
Therefore, even if the shape of the applied surface 2a of the work 2 has a shape error with respect to the design shape, the pressure roller 31 can be operated by the parallel link mechanism 40 so that the pressing posture of the pressure roller 31 follows the shape of the applied surface 2ab having a shape error. Therefore, the tape 1 can be stably applied continuously to the applied surfaces 2a, 2ab.

Furthermore, according to the ATL device 10, the ATL head 20 is attached to the Z-axis linear motion mechanism 75 which is attached to the Y-axis linear motion mechanism 74 of the gantry structure 71, so that the linear motion of the ATL head 20 (in this case, motion control in the Y and Z axis directions) can be stably controlled by the Y-axis linear motion mechanism 74 and the Z-axis linear motion mechanism 75.
By combining this stable control of linear motion with control of the parallel link mechanism 40, when the operation of applying tape 1 to the receiving surfaces 2a, 2ab is repeatedly performed while switching the pressure roller 31 between a separated state and a pressed state, it is possible to smoothly transition from maintaining a predetermined reference position and posture to a posture in which a load is applied to the receiving surfaces 2a, 2ab directly or via the tape 1, and a stable operation of applying tape 1 to the receiving surfaces 2a, 2ab can be continuously performed.

In addition, according to the ATL device 10, the gantry structure 71 includes linear motion mechanisms in the X, Y, and Z directions and an Xθz axis stage 73 that rotates in the yaw (θz) direction, and the parallel link mechanism 40 is configured to be able to rotate the pressure roller 31 in the roll (θy) direction and the pitch (θx) direction. This configuration allows the parallel link mechanism 40 to be configured with four link parts 43, simplifying the configuration of the parallel link mechanism 40.

In addition, according to the ATL device 10, the ATL head control unit 46g can increase the responsiveness of the length control of each of the air cylinders 46 that make up the multiple link units 43, thereby increasing the responsiveness of the operation of making the pressing position and/or pressing posture of the pressing roller 31 conform to the shape of the application surfaces 2a, 2ab.

In addition, according to the ATL device 10, the pressure roller 31 is attached to the end portion 42 of the parallel link mechanism 40 via the roller support portion 32, and the feeder 50 and the heating means 60 are attached to the roller support portion 32 via the mounting guide 61. With this configuration, the pressure roller 31, the feeder 50, and the heating means 60 can be moved in an integrated state to follow the shape of the application surfaces 2a, 2ab, and the pressure roller 31 can perform the pressing operation, the feeder 50 can transport the tape 1, and the heating means 60 can heat the tape 1 and/or the application surfaces 2a, 2ab in a constant state.

In addition, according to the ATL device 10, the base portion 41 of the parallel link mechanism 40 is attached to the gantry structure 71, so that the gantry structure 71 can stably control the motion of the ATL head 20 in the X, Y and Z axis directions. By combining the stable control of this linear motion with the control of the parallel link mechanism 40, it is possible to easily realize an operation that accurately controls the pressing position and/or pressing posture of the pressing roller 31 of the ATL head 20 so that it follows the shape of the application surfaces 2a, 2ab. Furthermore, by combining with the gantry structure 71, the workspace of the ATL head 20 can be expanded.

In addition, when the ATL head 20 is attached to the gantry structure 71, the following advantages are obtained compared to when it is attached to an articulated robot. That is, the rigidity of the ATL head 20 can be increased, the pressing force of the ATL head 20 can be increased, and further, the footprint of the ATL device 10 (in other words, the volume occupied by the device, including the operating range of the entire device) can be reduced.

In addition, according to the ATL device 10, the gantry structure 71 includes linear motion mechanisms in the X, Y, and Z directions and an Xθz axis stage 73 that rotates in the yaw (θz) direction, and the parallel link mechanism 40 is composed of four link sections 43, so the configuration of the parallel link mechanism 40 can be simplified.

Although the embodiment of the present invention has been described in detail above, the above description is merely an example of the present invention in every respect. It goes without saying that various improvements, modifications, and combinations of configurations are possible without departing from the scope of the present invention.

For example, in the above embodiment, the ATL head 20 is attached to the Z-axis linear motion mechanism 75 of the gantry structure 71, but in another embodiment, the ATL head 20 may be attached to the tip of the arm of a multi-joint robot.
In a multi-joint robot, motion errors are likely to accumulate at each joint, but in the parallel link mechanism 40, motion errors at each joint are less likely to accumulate, so the positioning accuracy of the multi-joint robot can be complemented, and the performance of applying the tape 1 to the application surface 2a can be improved using the multi-joint robot. Furthermore, by combining with a multi-joint robot, the workspace of the ATL head 20 can be expanded.

In addition, in the above embodiment, a parallel link mechanism 40 is used as an adjustment unit that is provided between the handling robot 70 and the pressing unit 30 and can adjust the position and posture of the pressing unit 30. However, in another embodiment, a mechanism having one air cylinder may be used as the adjustment unit. For example, it is also possible to have a configuration that combines a gantry structure or a multi-joint robot as a moving means with an ATL head whose adjustment unit is configured as a mechanism having one air cylinder.

In the above embodiment, a linear (telescopic) actuator such as an air cylinder 46 is used as the link section 43 of the parallel link mechanism 40. However, in another embodiment, it is also possible to configure a parallel link mechanism in which a rotary actuator is used as the link section 43.

The present invention can be applied to any field where it is required to improve the adhesion performance of the tape to the surface to which it is to be applied, such as when manufacturing a molded product having a three-dimensional shape by applying the tape to the surface to which it is to be applied.

1 Tape 2 Work 2a, 2ab Tape-applied surface 10 ATL device (tape-applying device)
20 ATL head (applying head)
30 Pressing portion 31 Pressing roller 32 Roller support portion 40 Parallel link mechanism 41 Base portion 42 End portion 43 Link portions 44, 45 Universal joint 46 Air cylinder (actuator)
46a: Cylinder portion 46b: Rod portion 46c: Pressure sensor (pressure detection portion)
46d Displacement sensor (displacement detection unit)
46e Servo valve 46f Air supply unit 46g ATL head control unit 50 Feeder (transport means)
60 Heating means 61 Mounting guide 70 Handling robot 70a Robot control unit 71 Gantry structure 72 X-axis linear motion mechanism 72a X-axis guide unit 72b X-axis slide table 73 Xθz-axis stage 74 Y-axis linear motion mechanism 74a Y-axis guide unit 74b Y-axis slider 75 Z-axis linear motion mechanism 75a Z-axis guide unit 75b Z-axis slider 75c Z-axis bracket 76 ATL head mounting unit (applying head mounting unit)
A Normal direction B Attachment point

200 Application head 300 Pressing unit 400 Pressing mechanism 430 Link unit

Claims (14)

A tape application device comprising an application head for applying a tape to a surface to be applied and a moving means for moving the application head in a three-dimensional space,
The application head is
a pressing portion for pressing the tape against the receiving surface;
an adjustment unit provided between the moving means and the pressing unit, the adjustment unit controlling the position and/or posture of the pressing unit and the pressing force of the pressing unit against the attachment surface;
at least in a separated state in which the pressing unit is separated from the applied surface, the pressing unit is controlled by the adjustment unit using a position control method in which the pressing unit is controlled to an arbitrary position and/or posture within the application head,
A tape application device characterized in that, in a pressing state in which the pressing portion is in contact with the surface to be applied directly or via the tape, the adjustment portion controls the pressing portion using a pressure control method that can apply a predetermined pressing force to the surface to be applied, regardless of its position and/or posture. The adjustment unit is configured to include a parallel link mechanism,
The parallel link mechanism comprises:
A base portion;
An end portion to which the pressing portion is attached;
a plurality of link portions provided in parallel between the base portion and the end portion;
Each of these links is
With universal joints on both ends,
and an actuator provided between the universal joints,
In the separated state, the length of each of the plurality of link portions is controlled by the actuator, and thereby the pressing portion is controlled to the arbitrary position and/or posture within the joining head by the position control method,
The tape application device of claim 1, characterized in that in the pressing state, the length of each of the multiple link portions is controlled by the actuator, and the pressing portion is controlled to apply a predetermined pressing force to the application surface by the pressure control method regardless of its position and/or posture. The pressing portion is
A pressure roller that presses the tape;
a roller support portion attached to the end portion in a state in which the pressure roller is supported,
The application head is
The tape conveying device further includes at least one of a conveying means for conveying the tape and a heating means for heating the tape and/or the application surface,
The roller support portion has
3. The tape application device according to claim 2, wherein at least one of said transport means and said heating means is integrally attached. The tape application device according to claim 2 or 3, characterized in that the actuator is an air cylinder. The adjustment unit,
2. The tape application device according to claim 1, further comprising at least one air cylinder. The air cylinder is
A cylinder portion to which air is supplied;
A rod portion that advances and retreats in response to the pressure in the cylinder portion;
a pressure detection unit that detects a pressure inside the cylinder unit;
a displacement detection unit that detects a displacement of the rod portion,
In the separated state, the pressure in the cylinder portion detected by the pressure detection portion and/or the displacement of the rod portion detected by the displacement detection portion are controlled so that the pressing portion is controlled to the arbitrary position and/or posture within the joining head,
The tape application device of claim 4 or claim 5, characterized in that in the pressing state, the pressure within the cylinder portion detected by the pressure detection unit and/or the displacement of the rod portion detected by the displacement detection unit are controlled so that the pressing portion applies a predetermined pressing force to the application surface regardless of its position and/or posture. The tape application device according to any one of claims 2 to 4, characterized in that the arbitrary position and/or posture is a posture in which the pressing part is positioned in a direction in which the load direction relative to the tape application surface is the normal direction. The height from the upper end of the adjustment part to the lower end of the pressing part in the arbitrary position and/or posture is
A tape application device as described in any one of claims 1 to 7, characterized in that the height from the upper end of the adjustment portion to the lower end of the pressing portion when in the pressed state is adjusted to a height position based on the shape design data of the tape application surface. The tape application device according to any one of claims 1 to 8, characterized in that the moving means moves the application head based on design data of the shape of the surface to be applied. The tape application device according to claim 9, characterized in that the moving means is a gantry structure. The gantry structure includes:
an X-axis linear motion mechanism for moving the workpiece having the attachment surface in the X-axis direction;
a Y-axis linear motion mechanism disposed above the X-axis linear motion mechanism in the Y-axis direction;
a Z-axis linear motion mechanism supported by the Y-axis linear motion mechanism and including an application head attachment part movable in the Z-axis direction;
An Xθz-axis stage that supports the workpiece rotatably in a yaw (θz) direction is mounted on the X-axis linear motion mechanism,
The application head is attached to the application head attachment portion,
The adjustment unit,
11. The tape application device according to claim 10, wherein the pressing portion is configured to be rotatable in at least one of a roll (θy) direction and a pitch (θx) direction. The tape application device according to claim 9, characterized in that the moving means is an articulated robot. A tape application method for applying the tape to the surface using the tape application device according to any one of claims 1 to 12, comprising the steps of:
In the separated state, the adjustment unit is controlled by the position control method so that the pressing unit is brought into the arbitrary position and/or posture within the joining head.
A tape application method characterized in that, in the pressed state, the adjustment unit is controlled by the pressure control method so as to apply a predetermined pressing force to the applied surface regardless of the position and/or posture of the pressing unit. an application head including a pressing unit that presses the tape against a surface to be applied and an adjustment unit that controls the position and/or posture of the pressing unit and the pressing force of the pressing unit against the surface to be applied;
a moving means for moving the application head in a three-dimensional space,
The adjustment unit,
performing position control in which the pressing portion is controlled to an arbitrary position and/or attitude within the application head at least in a separated state in which the pressing portion is separated from the application surface;
In a pressing state in which the pressing portion is in contact with the adhered surface directly or via the tape, pressure control is performed so that a predetermined pressing force can be applied to the adhered surface regardless of the position and/or posture of the pressing portion,
A method for controlling a tape application device, comprising: switching operation control of said adjustment unit depending on said spaced state and said pressed state.

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