I. Core Breakthroughs

Breakthrough 1 : Compact structure overcomes space constraints V Cavity collision bottleneck, achieving 96 ° Automated placement with an extremely small nip angle

Traditional standard AFP The head is difficult to fit. 100 ° The following V The inner surface of the mold is highly prone to interference with the mold sidewalls. This particular lay‑up head features a significantly reduced overall footprint and, when paired with a dual‑rotation obstacle‑avoidance trajectory algorithm, has been shown in testing to stably form angles of… 96 °, Rounded corners only 7.5mm Bending structure that fills the gap in automated composite lay-up equipment for small‑angle components, replacing manual layering.

Breakthrough 2 : Integrated multifunctional design, reducing the footprint while retaining the full suite of standard features. AFP Process unit

Small, rudimentary lay‑up stations on the market typically lack refrigeration, automatic film‑peeling, precise compaction, and automated cutting modules, forcing operators to simplify the process. In contrast, this equipment integrates, within a lightweight frame, full‑featured capabilities including low‑temperature refrigeration for prepregs, active take‑up of release films, flexible sponge‑based compaction, pneumatic cutting, and servo‑controlled tension regulation. This ensures controllable lay‑up temperatures for thermosetting materials, effectively preventing premature resin curing.

Breakthrough 3 : Innovative Attempt V A mathematical model for a two-node rotating obstacle-avoidance path, accurately mitigating interference risks.

Targeting V A geometric model is used to formulate a system of geometric constraint equations, from which a two‑stage rotational positioning formula is derived. This enables precise calculation of the robot’s rotational avoidance positions before and after the corner, ensuring that the compaction roller remains perpendicular to the mold at all times while preventing collisions between the head and the body. Offline simulation can predict potential interferences, significantly reducing the time required for on‑site teach‑in and debugging.

Breakthrough 4 : A plug-and-play standardized electrical drive system, compatible with mainstream six-axis robots.

Design an integrated drive control cabinet, compatible with FANUC Native PLC Communication, including integrated modules for temperature control, servo drives, and pneumatic relays, DB A series of standardized interfaces enables rapid integration with robot bodies, eliminating the need for extensive modifications to the robotic arm’s electrical control system. This allows both university laboratories and small- and medium-sized enterprises to upgrade their existing robotic production lines at low cost.

II. Technological Innovation

Innovation 1  Lightweight, compact mechanical body design

• Size Optimization: The overall machine footprint has been reduced to that of a conventional placement head. 20% , the overall machine weight is kept at FANUC M-20iA 20kg Within the rated load range;
• Refrigeration and Material-Feeding System: Peltier Cooling Module +  Coordinated cooling fan operation and low-temperature control throughout the prepreg filament process prevent resin from becoming sticky and curing prematurely at room temperature.
• Automatic release film recovery: dual-servo torque‑adjustment mechanism; simultaneous constant‑tension control during raw material unwinding and blue‑film rewinding; automatic stripping and collection of the protective film during the laying process.
• Flexible Compaction Unit: Pneumatic Piston +  Sponge segmented compaction roller, adaptively conforming to surface undulations to ensure tight contact and prevent lifting in corner areas.
• Pneumatic cutting mechanism: Automatically trims the fiber tow at the end of the lay-up stroke, enabling continuous multi‑layer, uninterrupted laying.

Innovation 2 V Geometry-Based Obstacle-Avoidance Path Planning Algorithm for a Specific Type

• Geometric Constraint Modeling: Defining the collision‑prone zones of the lay‑up head (left and right supports, take‑up rollers), and deriving… V Form factor angle, fillet radius, and the formula for the robot’s minimum clearance distance;
• Two-stage rotation strategy: At the first rotation point before the corner, adjust the attitude to avoid the left side of the fuselage; after passing the arc, perform a second rotation to restore the roller’s orientation perpendicular to the part surface.
• RoboDK Simulation and Adaptation: Import the 3D digital model of the layup head, perform batch simulations under various ply‑angle and fillet conditions, and determine in advance whether interference will occur.
• Output standard robotic motion programs, supporting automatic offset of multi-layer staggered‑ply paths.

Innovation 3  Modular Integrated Electrical Control System

• Integrated Drive Unit: 12V/5V Multi-channel regulated power supply, stepper drive, Arduino The main controller and high-power relay are integrated into a single unit;
• Hierarchical Communication: Upper-Level Robot PLC ↔ Drive Box ↔ Refrigeration /  Servo /  Three-level communication for pneumatic actuators;
• Status Visualization: LED The fault indicator light displays the operating status of refrigeration, wire feeding, winding, compaction, and cutting in real time.
• Standardized multi-interface: DB9/DB25/DB15 Industrial connector, with quick‑release assembly and replacement of the laying head, enabling rapid switching between multiple tooling configurations.

Innovation 4  Thermosetting materials are compatible with the full suite of process control logic.

• Low-temperature constant-temperature feeding, with strict control to keep the laying area temperature below 70 ℃, to prevent resin crosslinking reactions;
• Closed-loop servo tension control prevents slippage of high-tension tow and wrinkling under low tension.
• Compaction pressure is adjustable in stages, with distinct pressure settings for the straight sections and corner areas, ensuring both optimal conformability and fiber integrity.

III. Application Scenarios

Small aviation V Stiffener-type and corner-box composite components (core application scenario)

Stringers for the aircraft fuselage, interior connection corner fittings, and small fairing‑bending structures—no manual material layup required in tight internal cavities; fully automated. AFP Enhance ply‑to‑ply consistency, reduce wrinkling and gap defects, and minimize rework during quality inspection.

  UAV irregular load-bearing bracket, bent composite shell

For complex bent components of small and medium-sized aircraft, the limited mold space precludes the use of large lay-up equipment. This compact end-effector is compatible with small- and medium-sized six-axis robots, enabling automated forming for small-batch prototyping.

  Composite Material Processing Test Platform of Research Institutes

Universities and R&D laboratories establish low-cost AFP Test bench, currently available FANUC Directly mounted on universal robots, used for V Exploration of molding and small‑scale curved‑surface layup processes, significantly reducing equipment procurement costs.

  Rail transit and lightweight bending auxiliary components for new energy applications

Battery pack V Molded protective brackets and small composite reinforcement corners for vehicle bodies, as well as medium- and small‑batch non‑standard bent components, replace manual layup processes to enhance production efficiency and product uniformity.

  Small-scale composite bending structure for ships

Shipborne lightweight equipment support structures, automated forming of small‑size, complex‑shaped preforms, and enhanced fatigue resistance of the components.

IV. Summary of the Article

(1) Core Research Findings

• R&D of a lightweight, integrated, compact thermoset. AFP Head placement, with a footprint only half that of conventional models. 20% , compatible with FANUC M-20iA Six-axis robot with fully integrated process modules for cooling, film stripping, compaction, and cutting.
• Supporting facilities V Mathematical model and offline simulation method for double-rotation obstacle avoidance of shaped surfaces, capable of stably forming the minimum… 96 ° Angle, 7.5mm Internal‑corner bend components address the challenge of automated ply placement interference in tight internal cavities.
• Standardized plug-and-play electrical drive unit, enabling rapid deployment of compact systems without modifying the robot’s onboard electrical control. AFP Workstation;
• The low-temperature temperature-control system prevents premature curing of thermoset prepregs, while tension and compaction are jointly regulated to eliminate slippage and delamination defects in corner regions.

(II) Engineering Application Value

Traditional large-scale AFP The equipment can only process large-curvature, open-shell structures; small-sized… V Bent components of this type have long relied on manual lay-up, resulting in inconsistent quality and high labor costs. This compact lay-up head hardware… +  A comprehensive path-planning solution enables standard industrial robots to perform automated composite‑layup in tight, complex cavities. Small and medium-sized enterprises and research laboratories can retrofit their existing equipment at low cost, achieving automated quality improvement and efficiency gains for small, irregularly shaped composite parts, thereby expanding… AFP Equipment-applicable structural boundaries.

(3) Current Research Limitations

Only compatible with thermosets. 1/4 Inch‑prepreg filament, undeveloped thermoplastic laser‑heating version; intended solely for V Flat‑type press brake die; the saddle and multi‑corner complex three‑dimensional cavities have not been validated; the on‑line visual gap‑inspection module has not yet been integrated.

(IV) Future Expansion Directions

• A new laser heating module has been added, and a compact, thermoplastic‑specific version has been developed. AFP end;
• Optimize the structure to further reduce the minimum forming angle to 90 Within °;
• An integrated visual real-time correction system enables online compensation for layup gaps.
• Compatible with multi-robot collaboration platforms, enabling the development of comprehensive process workflows for large-scale, complex, multi‑bend components.

(5) Industry Insights

Current AFP Equipment is trending toward miniaturization and flexibility. For narrow, bent composite parts such as stiffeners and corner boxes, lightweight, compact layup heads represent a key technological approach, relying on small‑scale end effectors. +  The segmented‑rotation obstacle‑avoidance trajectory algorithm can overcome spatial interference constraints in mold design, eliminate reliance on manual ply placement, and significantly expand the industrial application scope of automated fiber placement technology for small and medium-sized complex‑shaped components.

Image and Text Guide

Figure 1 – Fanuc M20iA Robot

Figure 2  – Common AFP Head (b) The head designed by the research team (a) Differences in geometric structure and dimensions

Figure 3 – Peltier elements, fans, and feeding systems

Figure 4  – Electrical Controller Schematic

Figure 5 – Top view and 3D view of the drive housing

Figure 6  – Simplified schematic diagram of the component

Figure 7 – Based on the actual design AFP Simplified Diagram

Figure 8  – Schematic diagram of the potential collision point and the initial rotation point

Figure 9 – Schematic diagram of potential collisions and the second point of rotation

Figure 10  – Rotational position

Figure 11  – Simulated environment ( RoboDK ) in the AFP and its components

Figure 12  – Hard Disk Drive Architecture

Figure 13  – 96  Test apparatus for testing components

Table 1  – Experimental Test Procedure

Table 2 – The final result after modifying all parameters