Tooling apparatus and method for applying material to a pre-formed insert
A tooling apparatus for applying a tape material to a pre-formed insert is provided. The tooling apparatus comprises at least one guiding element coupled to an apparatus frame. An attachment shaft defines a rotational axis and extends through the guiding element. The attachment shaft includes an attachment element for securing the pre-formed insert thereto. An activation element is operatively engaged with the attachment shaft to rotate the pre-formed insert about the rotational axis at a predetermined rotation rate. A tape control assembly is spaced from the attachment shaft for axial translation along a tape control axis at a predetermined translation rate. Rotation of the pre-formed insert about the rotational axis and translation of the tape control element at the predetermined translation rate causes the material to be drawn under tension from the tape control assembly and applied to the pre-formed insert in a plurality of layers.
1 . A tooling apparatus for applying a material to a pre-formed insert, the tooling apparatus comprising:
an apparatus frame having a guiding element and an attachment shaft defining a rotational axis, wherein the attachment shaft is operatively coupled to the apparatus frame at the guiding element and is adapted to receive the pre-formed insert thereon such that the pre-formed insert is configured for rotation about the rotational axis;
an activation element operatively engaged with the attachment shaft to facilitate rotation of the attachment shaft and the pre-formed insert about the rotational axis at a predetermined rotation rate;
a tape control assembly spaced apart from the attachment shaft and capable of axial translation along a tape control axis at a predetermined translation rate, wherein the tape control axis is spaced apart from and substantially parallel with the rotational axis, and wherein the tape control assembly comprises:
a floor;
a pair of opposing walls;
a tape carrier configured to convey a tape material to the tensioning system, the tape carrier being releasably mounted between the pair of opposing walls;
a tensioning system disposed between the pair of opposing walls, the tensioning system comprising:
a plurality of pinch rollers extending between the pair of opposing walls, wherein the plurality of pinch rollers is rotatable about a roller axis that is disposed between the rotational axis and the tape control axis relative to the floor of the tape control assembly and radially spaced from and extends substantially parallel to the rotational axis; and
a plurality of rollers extending between the pair of opposing walls and disposed between the tape carrier and the plurality of pinch rollers; and
wherein actuation of the activation element and thereby rotation of the pre-formed insert about the rotational axis at the predetermined rotation rate, and translation of the tape control assembly at the predetermined translation rate, causes the tape material to be drawn under tension and applied from the tape control assembly to the pre-formed insert in a plurality of overlapping layers, wherein the plurality of overlapping layers defines a predetermined arrangement.
2 . The apparatus of claim 1 wherein the plurality of overlapping layers of material applied to the pre-formed insert comprises a plurality of layers of a first material and at least one layer of a second material, and wherein the plurality of layers of the first material and the at least one layer of the second material each have a predetermined thickness.
3 . The apparatus of claim 2 wherein the predetermined thickness of the plurality of layers of the first material and the at least one layer of the second material collectively comprise a collective implement thickness.
4 . The apparatus of claim 3 wherein the at least one layer of the second material further comprises a plurality of ring tabs adapted for integrating the implement with a portion of a boat hull.
5 . The apparatus of claim 4 wherein the first material and the second material each comprise a tape material.
6 . The apparatus of claim 5 wherein the tape material of the first material or second material comprises a fiberglass tape material.
7 . The apparatus of claim 6 wherein the first material comprises a first fiberglass tape material and the second material comprises a second fiberglass tape material, and wherein the first fiberglass tape material is different than the second fiberglass tape material.
8 . The apparatus of claim 1 further comprising a rack and pinion assembly operatively coupled to the tape control assembly and configured to facilitate axial translation of the tape control assembly along the tape control axis at the predetermined translation rate.
9 . The apparatus of claim 1 wherein the activation element comprises a mechanical crank mechanism integrated with the attachment shaft and adapted to be manually actuated by an operator.
10 . The apparatus of claim 1 wherein the activation element comprises a motor and gearbox assembly operatively engaged with the attachment shaft, such that a rotation of the motor is transitioned into a rotation of the attachment shaft about the rotational axis via the gearbox assembly to thereby facilitate rotation of the pre-formed insert disposed on the attachment shaft.
11 . The apparatus of claim 10 wherein the motor and gearbox assembly is controlled by a computerized control strategy written on the tangible, non-transitory memory of a controller and transmitted over a communications network.
12 . The apparatus of claim 11 wherein the activation element is actuated by a foot pedal assembly operatively engaged therewith.