Methods for analyzing the surface quality of composite laminates

Abstract

Method for analyzing surface quality of composite laminates. The method for analyzing surface quality of laminate parts includes the steps of creating a planned dimensional representation of a desired build of a laminate part including a first surface having a first topography; placing fibers into locations of the desired build of the laminate part; curing a resin associated with the placed fibers to produce a finished laminate part including a second surface having a second topography corresponding to the first surface having the first topography; aligning the first surface, the second surface, and the fiber locations; determining a first height of a first point on the first surface and a second height of a second point on the second surface; and observing the aligned first surface, the second surface, and the fiber locations and the first height relative to the second height when analyzing the surface quality of the laminate part.

Description

Technical Field

[0001] The present disclosure relates to a method of analyzing the surface quality of a laminate component and, more particularly, to identifying the location of surface anomalies relative to the location of fibers within the laminate component. Background Art

[0002] There are currently very limited tools available for analyzing the surface quality of composite laminate parts, locating surface anomalies and the locations of internal fibers within the laminate that contribute to the surface anomalies. These tools include both non-destructive and destructive inspection procedures.

[0003] Non-destructive inspection procedures may include using the transmission of ultrasonic or x-ray waves to scan the laminate components internally. This non-destructive inspection involves expensive equipment. This inspection may also require a long lead time to facilitate analysis. The resolution of such non-destructive inspections is not always at a level to extract the exact defect and its location. These non-destructive inspections using the transmission of ultrasonic or x-ray waves may also introduce systematic noise into the analysis because the inspection requires these waves to be transmitted to scan the composite laminate material layers.

[0004] Destructive inspection procedures for laminated components involve the destruction of a coupon cutout of the component being inspected and require a high-resolution scan of a cross section of the laminated component. This procedure not only has the disadvantage of requiring the destruction of the component to facilitate analysis, but further has the disadvantage that the user receives a two-dimensional ("2D") analysis of a single slice of the laminated component at a time. Thus, analyzing a single slice at a time can make it difficult to understand anomalies that require a three-dimensional ("3D") analysis.

[0005] Therefore, there is a need to provide non-destructive inspection analysis that does not require excessive costs and time associated with equipment, inspection and analysis. There is also a need to provide high resolution inspection to accurately locate defects or anomalies in the surface and fiber locations near the anomalies within a laminate component, as the presence of surface defects or anomalies can be a result of fiber locations located below the surface of the laminate component and near the anomaly. There is also a need to avoid the introduction of system noise that can be introduced through wave transmissions that can be used to scan the interior of the laminate component. Summary of the invention

[0006] One example includes a method for analyzing the surface quality of a laminated component, the method comprising the steps of creating a planned dimensional representation of a laminated component of a desired build including a first surface having a first topography, and placing fibers at the locations of the laminated component of the desired build. The method also includes the steps of curing a resin associated with the placed fibers, thereby manufacturing a finished laminated component from the planned dimensional representation of the laminated component of the desired build, which includes a second surface having a second topography corresponding to the first surface having the first topography. Further including the steps of aligning the first surface, the second surface, and the fiber location; determining a first height of a first point on the first surface and a second height of a second point on the second surface; and observing the aligned first surface, the second surface, and the fiber location and the first height relative to the second height when analyzing the surface quality of the laminated component.

[0007] One example includes a computer-implemented method for analyzing surface quality of a laminated part, the method comprising the steps of receiving, by a processor, a data file containing a planned dimensional representation of a laminated part of a desired build including a first surface, having first topographical data for the first surface, and receiving, by the processor, a data file containing fiber locations for the laminated part of the desired build. The method further includes the steps of receiving, by the processor, a data file from a scan performed on a second surface of a finished laminated part manufactured from the planned dimensional representation of the laminated part of the desired build having second topographical data, wherein the finished laminated part is manufactured with fibers having fiber locations based on the data file containing fiber locations for the laminated part of the desired build, and the second surface corresponds to the first surface. The method further includes the steps of aligning, by a processor, a first surface, a second surface, and a fiber position of a desired laminated component, the first surface including first topographic data of the first surface from a data file containing a planned dimensional representation of the desired laminated component, the second surface including second topographic data of the second surface from a data file containing data from a scan performed on the second surface of the finished laminated component, and the fiber position of the desired laminated component from the data file containing fiber positions within the desired laminated component. Further including the steps of determining, by a processor, a first height of a first point on the first surface and a second height of a second point on the second surface, wherein the first point is from a data file containing a planned dimensional representation of the desired laminated component including the first surface having the first topographic data, and the second point is from a data file from a scan performed on the second surface having the second topographic data of the second surface of the finished laminated component. The method further includes the steps of causing a visual representation of the aligned first surface, the second surface, and the fiber position and an indication of the first height relative to the second height to be presented to a user via a display when analyzing the surface quality of the laminated component.

[0008] The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a schematic perspective view of a common horizontal reference plane showing a laminate component to be constructed as it is desired to be constructed above the common horizontal plane and a completed laminate component below the common horizontal reference plane;

[0010] Figure 2 yes Figure 1 An exploded view of a portion of a finished laminate component with the fiber locations within the individual plies of the laminate component;

[0011] Figure 3 is a flow chart of a method for analyzing the surface quality of a composite laminate;

[0012] Figure 4 Yes Scan Figure 1 a schematic perspective view of a second surface of a finished laminate component having a second topography;

[0013] Figure 5 is a schematic block diagram of a composite laminate surface quality analysis system on which the method described herein may be operated;

[0014] Figure 6 is a plan view of the fiber positions of the desired laminated part, which represents Figure 2 The location of the fibers within the finished laminate part; and

[0015] Figure 7 yes Figure 6 A plan view schematic diagram of a laminate component to be constructed, wherein the fiber positions of a laminate component to be constructed, a first surface having a first topography represented by the planned dimensions of the laminate component to be constructed, and a second surface having a second topography of the completed laminate component are all aligned. DETAILED DESCRIPTION

[0016] Laminated components may be made from one of a number of shapes and profiles to accommodate assemblies that may include the laminated components. In certain configurations of laminated components, a designer may need to alter the position of fiber locations within a layup of a laminated component to be constructed relative to a standard configuration of generally parallel spacing of fibers within the layup. Such altering of fiber locations relative to the standard configuration may include increasing the spacing between adjacent fibers within the layup of the laminated component to be constructed in terms of position, and / or including incorporating overlaps in the positions of adjacent fibers within the layup of the laminated component to be constructed. As a result of altering fiber locations in a laminated component to be constructed relative to a standard configuration, the finished laminated component manufactured may result in having surface anomalies.

[0017] When designing a planned dimensional representation of a laminated part that is desired to be constructed, as described above, the designer may need to change the fiber position within the ply, which deviates from the standard configuration of the fibers (including fibers that are spaced apart and extend approximately parallel to each other within the ply). In some cases where the fiber position is changed, one ply may have an overlap of adjacent fibers within the ply, which in turn is aligned with the overlap of adjacent fibers within another ply. This alignment configuration that overlaps the fibers may result in an abnormality in a protrusion located on the surface of the finished or cured laminated part. The protrusion will be a deviation from the surface of the planned dimensional representation of the laminated part that is desired to be constructed. The height difference of the protrusion in the surface of the finished laminated part relative to the surface height of the planned dimensional representation of the laminated part that is desired to be constructed may or may not be within a tolerance range acceptable for the intended use of the finished laminated part. The tolerance range may take into account the need to provide a suitable bonding surface or fit of the finished laminated part relative to another part within the assembly containing the finished part.

[0018] Similarly, plies superimposed on one another within a laminate part to be constructed may have adjacent fiber positions within the ply that are positioned at increased spacing relative to a standard configuration of adjacent fibers, and aligned with the increased spacing of adjacent fibers in another ply relative to the standard configuration. These increased spacing alignment configurations of adjacent fibers in different plies may result in anomalies in the presence of depressions located on the surface of a manufactured finished or cured laminate part. The height difference of the depressions in the surface of the cured finished laminate part relative to the surface height represented by the planned dimensions of the laminate part to be constructed may or may not be within a tolerance range acceptable for the intended use of the finished laminate part. The tolerance range may take into account the need to provide a suitable bonding surface or fit of the finished laminate part relative to another part in an assembly containing the finished part.

[0019] As a result of the abnormalities represented by the planned dimensions of the laminated parts that deviate from the desired construction appearing in the surface of the finished laminated parts, cheap and reliable analysis tools will help analyze the fiber configuration positions within the laminated parts and the surface abnormalities associated with the specific fiber configurations. The analysis tools described herein can provide developers or manufacturers with a cheap and reliable method that does not introduce system noise to identify abnormalities and identify the fiber positions that affect the abnormalities. If necessary, the analysis tools can provide developers or manufacturers with the ability to change the fiber positions within the laminated parts to be constructed to best bring the abnormalities that may be out of tolerance back into tolerance so that the production of the laminated parts can function as expected.

[0020] Reference Figure 1 , using a dashed line format to show the planned dimensions of the laminated component 10P (10-prime) to be constructed. Figure 110P as shown in the solid line format of the corresponding finished laminate part 10 shown in the figure. As used herein, the reference numeral 10 identifies a finished laminate part, while the reference numeral 10P identifies a laminate part that is desired to be "built". In this example, the planned dimensional representation of the laminate part 10P to be constructed is placed within a computer-aided design (CAD) file. The planned dimensional representation of the laminate part 10P to be constructed sets forth the planned dimensions of the laminate part 10P to be constructed, and provides data regarding, for example, a first topography of a first surface 12P and topographic information regarding other surfaces of the laminate part 10P to be constructed. In addition, the number and thickness of plies 14P are also included in this example planned dimensional representation of the laminate part 10P. The planned dimensional representation of the laminate part 10P to be constructed provides Figure 1 10P. The planned dimensional representation of the laminate part 10P to be constructed does not include any fibers, and therefore fiber locations do not exist within the planned dimensional representation of the laminate part 10P to be constructed. As a result, the planned dimensional representation of the laminate part 10P to be constructed does not have any anomalies on any surface, such as the first surface 12P, but instead, anomalies may appear on the second surface 12 of the finished laminate part 10 as a result of specific fiber locations within the plies 14 of the finished laminate part 10, as discussed above.

[0021] Reference Figure 1 , the finished laminate part 10 is constructed from a design of a planned dimensional representation of the desired laminate part 10P to be constructed, along with placing fibers within the locations of the desired laminate part 10P to be constructed. As described above, the planned representation of the desired laminate part 10P to be constructed does not include fibers. In this example, the fiber locations resulting in the finished laminate part 10 are provided to a numerical control device (not shown) that directs the operation of an automated fiber placement machine (not shown) used to construct the finished laminate part 10. Utilizing Figure 1 The planned dimensions of the desired laminate component 10P as seen in , combined with the placement of fibers into position for the desired laminate component 10P to be constructed, the assembly is cured and the finished laminate component 10 is produced.

[0022] Reference Figure 2 , shows a completed laminate component 10 having three plies 14A, 14B and 14C in an exploded perspective view. An exemplary standard configuration 16 of fibers 18 is shown extending along ply 14C a distance D. Other fibers 18 that deviate from the standard configuration 16 will be discussed in more detail below.

[0023] Reference Figure 3 , a flow chart of a method 20 for analyzing the surface quality of a laminated component is shown. Figure 5A schematic block diagram of a laminate component surface quality analysis system 46 is discussed together with a computer-implemented embodiment of the method for analyzing the surface quality of a laminate component 20. Analyzing the surface quality of a laminate component includes identifying and quantifying profile deviations within the surface of a manufactured laminate component compared to a corresponding surface of an ideal design of the laminate component. The analysis includes identifying and ascertaining whether surface deviations (e.g., depressions or protrusions) on a manufactured laminate component are within acceptable tolerances of a surface that is acceptable, such as to optimally bond the surface to the surface of another component. At the same time, the analysis provides identification of fiber positions within the manufactured laminate component and near the surface deviations to provide an opportunity to ascertain adjustments to the fiber positions for subsequent manufacture of the component in order to mitigate the surface deviations and provide a surface within acceptable tolerances for subsequently manufactured laminate components.

[0024] Reference Figure 3 , a method 20 for analyzing the surface quality of a laminated component comprises a step 22 of creating a planned dimensioned representation of a desired built laminated component 10P including a first surface 12P having a first topography, such as Figure 1 As shown. As mentioned earlier, the planned dimensional representation of the desired constructed laminated component 10P including the first surface 12P having the first topography is placed into the CAD file in this example. Method 20 also includes step 24: placing fibers into the position of the desired constructed laminated component 10P. As also mentioned earlier, the planned dimensional representation of the desired constructed laminated component 10P does not include fibers, which have an ideal size and contour configuration for the final manufactured finished laminated component 10. Step 24 also includes: placing the fiber position in a numerical control device (not shown) for controlling an automatic fiber placement machine (not shown) to manufacture the finished laminated component 10. Therefore, in this example, a digital representation of the fiber position can be provided to the numerical control device of the automatic fiber placement machine for constructing the finished laminated component 10, as well as a digital representation of the planned dimensional representation of the desired constructed laminated component 10P including the first surface 12P and the first topography of the first surface 12P provided to the CAD file.

[0025] The step 24 of placing the fibers in the desired laminate part 10P to be constructed also includes, in this example, placing at least two adjacent fibers within at least one ply of the desired laminate part 10P to be constructed such that the at least two adjacent fibers deviate from a standard configuration in which the fibers are spaced apart and extend generally parallel to each other within the ply. An example of a deviation from the standard configuration 16 can be seen in the finished laminate part 10. Figure 2 The step 24 of placing the fibers in the desired locations of the laminated part 10P to be constructed also includes in this example the spacing 26 between at least two adjacent fibers 18 of at least one ply 14A relative to the spacing of the finished laminated part 10. Figure 2The step 24 of placing the fibers into the desired position of the laminated part 10P to be constructed also includes the steps of: Figure 2 As seen in FIG. 1 , at least two adjacent fibers 18 of at least one ply 14B overlap.

[0026] Continue to refer to Figure 3 The method 20 further includes a step 30 of curing the resin associated with the placed fibers 18, thereby manufacturing a laminate part 10P from the planned dimensional representation of the desired construction. Figure 1 10P having a second surface 12 having a second topography (corresponding to a first surface 12P having a first topography). As discussed earlier, for a finished laminate component 10 cured with fibers within the finished laminate component 10, anomalies or deviations may occur on the second surface 12 that deviates from the ideal first surface 12P represented by the planned dimensions of the laminate component 10P to be constructed. The curing step 30 also includes: Figure 4 The second surface 12 is shown scanned to obtain a second topography of the second surface 12. The scanning is typically performed using a laser scanner 32 in this example, which provides digital data of the second topography of the second surface 12 (discussed below).

[0027] Figure 3 The method 20 for analyzing the surface quality of a laminated component also includes a step 34 of aligning the first surface 12P, the second surface 12, and the fiber positions. This step 34 will be discussed in more detail below in the discussion of the computer-implemented method for analyzing the surface quality of a laminated component. As described above, digital data can be used for the first surface 12P and the topography of the first surface 12P (for example, provided to CAD), and digital data representations of the fiber positions in various plies can be provided to a numerical control device of an automatic fiber placement machine used to construct the finished laminated component 10. In addition, digital data of the second surface 12 having the second topography of the second surface 12 is provided by scanning by a laser scanner 32. The digital data will be used to align the first surface 12P, the second surface 12, and the fiber positions (to be discussed in more detail below). The step 34 of aligning the first surface 12P having the first topography, the second surface 12 having the second topography, and the fiber positions from the planned dimensional representation of the laminated component 10P to be constructed includes: the first surface 12P, the second surface 12, and the fiber positions all have a common horizontal reference plane H (for example, as seen, located at Figure 1 between the laminated component 10P to be constructed and the completed laminated component 10) and a common vertical reference plane V ( Figure 1In the case where each of the first surface 12P, the second surface 12 and the fiber position has a common horizontal reference plane H and a common vertical reference plane V, they are aligned so that comparisons between heights on the first surface 12P and the second surface 12 and determination of the fiber position relative to the height comparisons between the first surface 12P and the second surface 12 can be readily made. This will be discussed further herein and in the computer-implemented method.

[0028] The method 20 further comprises step 36 of determining a first height of a first point 38 on the first surface 12P and a second height of a second point 40 on the second surface 12P, such as Figure 1 Schematically identified in FIG, wherein a first point 38 and a second point 40 have a common reference point 42 in a common horizontal reference plane H. In the case where the first surface 12P and the second surface 12 are aligned in the common horizontal reference plane H and have the same common reference point 42, the first point 38 and the second point 40 are at the same position relative to the first surface 12P and the second surface 12, respectively. Determining a first height of the first point 38 on the first surface 12P and a second height of the second point 40 on the second surface 12 in one example includes positioning both the planned representation of the desired constructed laminated component 10P and the completed laminated component 10 aligned in the same position at the same common height in a common vertical reference plane V. In the case where both are aligned at the same common height position relative to the vertical reference plane V, a first height can be measured from the common reference height on the vertical reference plane V to the first point 38 and a second height can be measured from the common reference height on the vertical reference plane V to the second point 40 and a second height can be provided. Subtracting the first and second heights will provide a height difference between the first point 38 and the second point 40. As long as, for example, the height difference between the first point 38 and the second point 40 is within a predetermined acceptable tolerance range, the second point 40 on the second surface 12 of the finished laminate component 10 can be used to optimally bond to the surface of another component when manufacturing an assembly including the finished component 10. If the height difference falls outside the predetermined acceptable tolerance range, the finished laminate component will not be used to manufacture the assembly. Repositioning of the fiber position can be performed to mitigate the height difference so that the surface of the laminate component is within acceptable tolerances for use in manufacturing subsequent laminate components.

[0029] Thus, if the measurements from the same common reference height to the first point 38 and the second point 40 are the same, there will be no difference in measurement between the first and second heights, thereby indicating that there is no anomaly at the second point 40 on the second surface 12 of the finished laminate component 10 at the first point 38 relative to the first surface 12P. On the other hand, if the measurement from the same common reference height to the first point 38 establishing the first height is greater than the measurement from the same common reference height to the second point 40 establishing the second height, this will indicate a concave anomaly at the second point 40 on the second surface 12 of the finished laminate component 10, where the same common reference height of the vertical reference plane V is located below both the first point 38 and the second point 40. If the measurement from the same common reference height to the first point 38 establishing the first height is less than the measurement from the same common reference height to the second point 40 establishing the second height of the second point 40, this will indicate a protrusion anomaly at the second point 40 on the second surface 12 of the finished laminate component 10 relative to the first point 38 on the first surface 12P, when the same common reference height of the vertical reference plane V is located below both the first point 38 and the second point 40.

[0030] The method 20 also includes a step 44 of observing the aligned first surface 12P, second surface 12 and fiber position and the first height of the first point 38 relative to the second height of the second point 40. This will be further discussed in the computer-implemented method to be discussed below, wherein the alignment of the first surface 12P, second surface 12 and fiber position can be digitally represented using the above-mentioned digital data related to the first surface 12P, second surface 12 and fiber position to align on the output display device 64. In addition, as will be discussed, the first height of the first point 38 relative to the second height of the second point 40 is also visually represented. This observation will provide information on the location of the anomaly in the finished laminate part 12 and the relative height or depth difference of the anomaly or deviation relative to the first surface 12P at that location, and additionally provide a fiber position representing the fiber position in the finished laminate part 10. The observation step 44 also includes the step of: in response to any height difference observed between the first height and the second height being outside the tolerance range, changing the position of at least one fiber of the laminate part 10P desired to be constructed. The tolerance range is predetermined by the designer or manufacturer to provide an appropriate bonding surface or fit of the second surface 12 relative to other components of an assembly that will include the finished laminate component 10 and the second surface 12. Modifying the position of the fibers 18 can mitigate concave or convex deviations that may be located on the finished laminate component and provide an optimal bonding or fit of the surface of the subsequently manufactured finished laminate component within acceptable tolerances and relative to the assembly that may include it.

[0031] A computer-implemented method for analyzing the surface quality of a laminated component would utilize, for example, Figure 5The laminated component surface quality analysis system 46 shown in the figure is operated. The system 46 includes a computing device 48. The computing device 48 includes a memory 50 and a processor 52. The computing device 48 can take any one of several configurations, in which the computing device 48 includes a memory 50, which includes storing non-temporary computer-readable instructions in a tangible medium and a temporary memory, and the processor 52 executes the computer-readable instructions. In this computing device 48, one or more microprocessors may be included. Also in this computing device 48, the I / O circuit 58 is shown as a box, but it should be understood that the I / O circuit 58 may include several different types of I / O circuits. The memory 50, the processor 52 and the I / O circuit 58 are all interconnected via an address / data bus 60. An input device 62 and an output display device 64 are also included in the computing device 48. In this example, the input device 62 may include one or more keyboards, mice and / or touch screens and other common input devices, and the output display device 64 may include one or more known visual display devices. Both an input device 62 and an output display device 64 are connected to the I / O circuitry 58 in this example.

[0032] In this example, the laminate component surface quality analysis system 46 also includes a numerical control device 66, which in this example will receive a data file of the fiber positions of the desired laminate component 10P to be built from the memory 50, wherein the numerical control device 66 will then be connected to an automatic fiber placement machine (not shown), which will place the fibers of the layup 14 according to the data file received by the numerical control device 66 to manufacture the finished laminate component 10. In this example, the system 46 also includes a scanner 32 (in this example, as previously mentioned, a laser scanner), which is used to scan Figure 4 1 and provides topographical data of a surface (eg, second surface 12) to a processor 52. This is one of many variations of a system 46 that may be employed to run a computer-implemented method for analyzing the surface quality of a laminated part.

[0033] The computer-implemented method for analyzing the surface quality of a laminated component can be operated on the laminated component surface quality analysis system 46 as described above, wherein the computer-implemented method includes the steps of receiving a data file containing a planned size representation of a laminated component 10P to be constructed by a processor 52, wherein the laminated component 10P to be constructed includes a first surface 12P having first topographic data of a first surface 12P. The data file does not include fiber position data. In this example, by inputting data from an input device 62 to the processor 52 when preparing a CAD file stored in the memory 50, a user can design a planned size representation of the laminated component 10P to be constructed. Also included is the step of receiving a data file containing a fiber position of the laminated component 10P to be constructed by the processor 52. In this example, the data of the data file can be derived from the input device 62, wherein the user designs the fiber positions in each ply for manufacturing the finished laminated component 10. This data may be stored in the memory 50 , for example, and may be used to send to the numerical control device 66 , which instructs an automated fiber placement machine (not shown) to appropriately place fibers for each ply of the desired laminate part 10P to be built for manufacturing the finished laminate part 10 .

[0034] The computer-implemented method includes the steps of receiving, by the processor 52, a data file containing fiber locations within a desired build of a laminated component 10P, and also includes identifying the locations of any deviations from a standard configuration between adjacent fibers in the various plies of the desired build of the laminated component 10P used to manufacture the finished laminated component 10 as mentioned earlier. The data file also includes identifying locations where the spacing 26 between two adjacent fibers 18 in at least one ply is increased relative to the standard configuration 16 (e.g., at Figure 2 The data file also includes identifying locations where two adjacent fibers 18 overlap 28 within at least one ply (e.g., at Figure 2 ply 14B as seen in FIG.

[0035] The computer-implemented method further includes the step of receiving, by the processor 52, a data file from a scan performed by the scanner 32, the scan performed on a second surface 12 having second topographic data of a finished laminate component 10 manufactured from a planned dimensional representation of a desired laminate component 10P to be built. The finished laminate component 10 is manufactured based on the data file containing fiber positions of the desired laminate component 10P to include fibers having fiber positions, and the second surface 12 corresponds to the first surface 12P.

[0036] The computer-implemented method further includes the step of aligning, by the processor 52, the first surface 12P including first topographic data of the first surface 12P from a data file containing a representation of the planned dimensions of the laminated component 10P to be constructed, the second surface 12 including second topographic data of the second surface 12 from a data file containing data from a scan performed on the second surface 12 of the completed laminated component 10, and the fiber locations from the data file containing fiber locations within the laminated component 10P to be constructed. The scanning performed as discussed earlier includes in this example utilizing a method such as Figure 4 The laser scanner 32 shown performs the scan and provides data to the processor 52 which can be stored in the memory 50. The alignment step also includes relative to a common horizontal reference plane H (e.g., Figure 1 ) and a common vertical reference plane V (not shown) align the first surface 12P, the second surface 12 and the fiber position within the desired laminate part 10P to be constructed. As discussed earlier, Figure 1 , wherein the first point 38 and the second point 40 have a common reference point 42 in the common horizontal reference plane H. Therefore, the first point 38 and the second point 40 are at the same position relative to the planned dimension representation of the desired laminate part 10P and the completed laminate part 10, respectively. A common vertical reference plane V (not shown) is oriented perpendicular to the horizontal reference plane H. The common vertical reference plane V is at Figure 6 and Figure 7 1 and 2. The direction of the arrow designated V is designated in the figure, which extends perpendicularly to a common horizontal reference plane H designated by two arrows H. The planned representation of the laminate part 10P to be built and the finished laminate part 10 are aligned in the common vertical reference plane V at the same common height.

[0037] The computer-implemented method further includes the step of determining, by the processor 52, a first height of a first point 38 on the first surface 12P and a second height of a second point 40 on the second surface 12P, such as Figure 1 . The first point 38 is from a data file containing a planned dimensional representation of a laminated part 10P to be built, the laminated part 10P to be built including a first surface 12P having first topographic data. The second point 40 is from a data file from a scan performed on a second surface 12 having second topographic data of the second surface 12 of the finished laminated part 10. The determining step includes: relative to the planned dimensional representation of the laminated part 10P to be built and the finished laminated part 10, respectively, the first point 38 and the second point 40 have a common reference point 42 in a common horizontal reference plane H, which reflects that the first point 38 and the second point 40 are in the same position relative to the horizontal reference plane H.

[0038] As described earlier, determining the first height of the first point 38 on the first surface 12P and the second height of the second point 40 on the second surface 12 in one example includes positioning both the representation of the desired laminated component 10P to be constructed and the finished laminated component 10 in a common vertical reference plane V to align at the same common height. In the case where both are aligned at the same common height position relative to the vertical reference plane V, the first height can be measured from the common reference height on the vertical reference plane V to the first point 38 and provided, and the second height can be measured from the common reference height on the vertical reference plane V to the second point 40 and provided. Subtracting the first and second heights will provide the height difference between the first point 38 and the second point 40. All of this can be calculated by the processor 52.

[0039] Thus, in one example, processor 52 may calculate measurements from the same common reference height of common vertical reference plane V, and if those measurements are the same for first point 38 and second point 40, there will be no measurement difference between the first and second heights, thereby indicating that there is no deviation or anomaly at second point 40 on second surface 12 of finished laminate component 10 at first point 38 relative to first surface 12P. On the other hand, if the measurement calculated from the same common reference height to first point 38 establishing the first height is greater than the measurement from the same common reference height to second point 40 establishing the second height, this would indicate a concave anomaly at second point 40 on second surface 12 of finished laminate component 10 at first point 38 relative to first surface 12P, if the same common reference height of vertical reference plane V is below both first point 38 and second point 40. If the measurement from the same common reference height to the first point 38 establishing the first height is less than the measurement from the same common reference height to the second point 40 establishing the second height of the second point 40, this will indicate a protrusion anomaly at the second point 40 on the second surface 12 of the finished laminate component 10 relative to the first point 38 on the first surface 12P, when the same common reference height of the vertical reference plane V is located below both the first point 38 and the second point 40.

[0040] The computer-implemented method further includes the step of causing a visual representation of the aligned first surface 12P, second surface 12 and fiber position, and an indication of the first height relative to the second height to be presented to a user via the display 64. Figure 664. The fiber positions are seen in the output display device 64 in FIG. A horizontal reference plane H is shown by two arrows designated H extending perpendicularly to each other, and a vertical reference plane V is designated by V indicating an arrow extending perpendicularly relative to the horizontal plane H. In this illustration, a digital representation of the fiber positions of a laminate part 10P of a desired construction as manufactured as the finished laminate part 10 is shown as being located in the various plies 14. This data will be the data used to manufacture the finished laminate part 10 using a numerical control device 66 for operating an automatic fiber placement machine to manufacture the finished laminate part 10. The blank triangles 68 schematically represent the positions of adjacent fibers 18 positioned at increasing spacing 26 (as shown in FIG. 1 ). Figure 2 ), shaded triangles 70 schematically represent the positions of adjacent fibers 18 in the overlap 28 position (also as shown in FIG. Figure 2 The illustration in display device 64 provides a representative illustration of the fiber locations within the finished laminate component 10.

[0041] Reference Figure 7 , such as Figure 6 18. However, in this illustration, the dotted triangle 68P schematically represents the position of adjacent fibers 18 positioned at increasing spacing 26 (eg, Figure 2 ), the solid triangle 70P schematically represents the position of adjacent fibers 18 in the overlap 28 position. Figure 7 The positions of the first surface 12P having the topography data of the first surface 12P, the second surface 12 having the topography data of the second surface 12, and the fiber 18 aligned in the display 64 have a common horizontal reference plane H and a common vertical reference plane V. The display 64 also shows an indication of the first height relative to the second height, in which the difference range of the first and second heights in this example will be indicated by different shading or color coding, wherein different colors specify a predetermined height difference range between the first and second heights.

[0042] This can be done using a number of corresponding points on the first topography of the first surface 12P and the second topography of the second surface 12, as determined by measuring or calculating the first height and the second height for the first point 38 and the second point 40, respectively. This will provide an indication of the difference between the first topography of the first surface 12P and the second topography of the second surface 12. A predetermined range of height differences between, for example, the first height and the second height can be indicated on the display 64 by color coding or using different colors, so that a particular color will specify a predetermined range of height differences between the first height and the second height. In this example, instead of different colors, different shade levels are provided, indicating, for example, different predetermined ranges of height differences between the first height and the second height for corresponding points such as the first point 38 and the second point 40. In the case where areas of the first surface 12P and the second surface 12 have height differences between corresponding points in the first surface 12P and the second surface 12 that fall within a predetermined range, the colors or shades will be the same.

[0043] For example, the shaded area 72 (or color) indicates a slight variation or small range of height differences between the first surface 12P of the planned dimension representation of the desired laminate part 10P and the corresponding points (e.g., the first point 38 and the second point 40) on the second surface 12 of the finished laminate part 10. In this example, the user will be indicated by the shading or coloring that there are no anomalies in the second surface 12 within this range of height differences between the first surface 12P of the desired laminate part 10P to be built and the second surface 12 of the finished laminate part 10, so that for the purpose of combining and / or mating with other components in the assembly that will include the finished laminate part, no changes in the fiber position are required and the shaded area 72 relative to the second surface 12 is acceptable. The color coding or shading difference also provides the user with an indication of the height difference relative to the second surface 12 as to whether the area is in a recessed position or a raised position relative to the first surface 12P.

[0044] Similarly, a different shade 74 (or different color) having a shade 74 that is slightly darker than the shade 72 (or having a different color) indicates a greater change in the first height of the first point 38 of the first surface 12P and the second height of the second point 40 of the second surface 12 and the difference between these corresponding points between the first surface 12P and the second surface 12. This shade 74 also indicates that there is no anomaly or deviation that needs to be resolved relative to the second surface 12 in this area, so no fiber position change is required in this area. However, if a change in fiber position is made, the area of ​​the different shade 74 (or coloring) will be further checked to check whether the tolerance is exceeded. As a result, the surface of the finished laminated component 10 in this area is acceptable for combination and / or matching with other components in the assembly that will include the finished laminated component 10.

[0045] The darker shade 76 (or a different color), which is a darker shade than the shade 74, indicates a greater change in the difference between the first height of the first point 38 of the first surface 12P and the second height of the second point 40 of the second surface 12, so that the corresponding points in this area and their first and second heights are outside the predetermined acceptable tolerance range. As a result, there is a surface anomaly or deviation associated with the finished laminated component 10 in this area of ​​the second surface 12. The user will need to look at the fiber position and see what changes in the fiber position can be made to alleviate the anomaly or deviation on the second surface 12 in order to construct the subsequent finished laminated component. In the case of changes in the fiber position, the user can go through the process of manufacturing the subsequent finished laminated component 10 and subject the subsequent finished laminated component 10 to the above-mentioned analysis and check to see if the anomaly or deviation has been alleviated and is now within the acceptable tolerance so that the finished laminated component 10 is ready for production.

[0046] In addition, this disclosure includes examples according to the following clauses:

[0047] Item 1. A method for analyzing the surface quality of a laminated component, the method comprising the following steps: creating a planned dimensional representation of a laminated component of a desired construction including a first surface having a first morphology; placing fibers into positions of the laminated component of the desired construction; curing (30) a resin associated with the placed fibers, thereby manufacturing a finished laminated component from the planned dimensional representation of the laminated component of the desired construction, the finished laminated component including a second surface having a second morphology corresponding to the first surface having the first morphology; aligning the first surface, the second surface, and the fiber positions; determining a first height of a first point on the first surface and a second height of a second point on the second surface; and observing the aligned first surface, the second surface, and the fiber positions and the first height relative to the second height when analyzing the surface quality of the laminated component.

[0048] Clause 2. The method of clause 1, wherein the step of placing the fibers into locations of a desired laminate component build comprises placing the locations of the fibers within a numerical control of an automated fiber placement machine used to manufacture the finished laminate component.

[0049] Item 3. A method according to Item 1, wherein the step of placing fibers in a position of a desired laminate component to be constructed comprises: placing at least two adjacent fibers within at least one ply of the desired laminate component to be constructed such that the at least two adjacent fibers within the at least one ply deviate from a standard configuration.

[0050] Clause 4. The method of clause 3, wherein the step of placing the fibers in a desired location for the laminate component to be constructed includes increasing the spacing between the at least two adjacent fibers within the at least one ply relative to a standard configuration.

[0051] Clause 5. The method of Clause 3, wherein the step of placing the fibers in a desired location of the laminate component to be constructed includes overlapping the at least two adjacent fibers within the at least one ply.

[0052] Clause 6. The method of clause 1, wherein the step of creating a planned dimensional representation of a desired built laminated component including a first surface having a first topography comprises placing the planned dimensional representation of the desired built laminated component into a CAD file.

[0053] Clause 7. The method of Clause 1, wherein the step of creating a planned dimensional representation of the laminate component desired to be built includes: the planned dimensional representation of the laminate component desired to be built excludes fibers.

[0054] Item 8. A method according to Item 1, wherein: the curing step also includes scanning the second surface to obtain a second topography of the second surface; the step of aligning a first surface having a first topography, a second surface having a second topography, and a fiber position containing a planned dimensional representation of a laminated part to be constructed includes the first surface, the second surface, and the fiber positions having a common horizontal reference plane and a common vertical reference plane; and in the step of determining a first height of a first point and a second height of a second point, the first point and the second point have the same reference point in the common horizontal reference plane and the planned dimensional representation of the laminated part to be constructed and the finished part are aligned at the same common height in the common vertical reference plane.

[0055] Clause 9. The method of clause 8, wherein the determining step further comprises determining any height difference between the first height and the second height.

[0056] Clause 10. The method of clause 9, wherein the observing step further comprises the step of altering a position of at least one fiber of the laminate component desired to be constructed in response to a height difference between the first height and the second height exceeding a tolerance range.

[0057] Item 11. A computer-implemented method for analyzing the surface quality of a laminated component, the method comprising the following steps: receiving, by a processor, a data file containing a planned dimensional representation of a laminated component to be constructed including a first surface, having first topographic data of the first surface; receiving, by the processor, a data file containing fiber positions of the laminated component to be constructed; receiving, by the processor, a data file from a scan performed on a second surface having second topographic data of a finished laminated component manufactured from the planned dimensional representation of the laminated component to be constructed, wherein the finished laminated component is manufactured with fibers having fiber positions based on the data file containing the fiber positions of the laminated component to be constructed, and the second surface corresponds to the first surface; and aligning, by the processor, the first surface including the first surface from the data file containing the planned dimensional representation of the laminated component to be constructed, the second surface, and the fiber positions of the laminated component to be constructed. a first topographical data for a surface, the second surface including second topographical data for a second surface from a data file containing data from a scan, the scan being performed on the second surface of a finished laminate part, and the fiber positions of the desired constructed laminate part being from a data file containing fiber positions within the desired constructed laminate part; determining by a processor a first height of a first point on the first surface and a second height of a second point on the second surface, wherein the first point is from a data file containing a planned dimensional representation of a desired constructed laminate part including the first surface having the first topographical data, and the second point is from a data file from a scan performed on the second surface having the second topographical data for the second surface of the finished laminate part; and causing a visual representation of the aligned first surface, the second surface, and the fiber positions, and an indication of the first height relative to the second height to be presented to a user via a display when analyzing the surface quality of the laminate part.

[0058] Clause 12. The method of clause 11, wherein the step of receiving, by a processor, a data file containing fiber positions of a desired laminate component further comprises: placing the data file into a numerical control device data file for instructing an automatic fiber placement machine to place fibers within the desired laminate component.

[0059] Clause 13. The method of clause 11, wherein the step of receiving, by a processor, a data file containing fiber locations within a desired laminate component to be constructed further identifies the location of any deviations from a standard configuration between two adjacent fibers in each ply of the desired laminate component to be constructed.

[0060] Clause 14. The method of clause 13, wherein the step of receiving, by a processor, a data file containing fiber locations within a desired laminate component construction further comprises: identifying locations within at least one ply where a spacing between at least two adjacent fibers is increased relative to a standard configuration.

[0061] Clause 15. The method of clause 13, wherein the step of receiving, by a processor, a data file containing fiber locations within a laminate component desired to be constructed further comprises: identifying a location within at least one ply where two adjacent fibers overlap.

[0062] Clause 16. The method of clause 11, wherein the step of receiving, by a processor, a data file containing a representation of planned dimensions of a laminate component desired to be constructed further comprises: the data file is a CAD file.

[0063] Clause 17. The method of clause 11, wherein the step of receiving, by the processor, a data file containing a representation of planned dimensions of a laminate component desired to be constructed further comprises: receiving a data file that does not contain fiber position data.

[0064] Clause 18. The method of clause 11, wherein the step of receiving, by the processor, a data file from a scan performed on the second surface further comprises: performing the scan using a laser scanner.

[0065] Clause 19. A method according to clause 11, wherein: the aligning step includes aligning the first surface, the second surface and the fiber position relative to a common horizontal reference plane and a common vertical reference plane within the laminate component to be constructed; and the determining step includes the first and second points having a common reference point in the common horizontal reference plane and the planned dimensional representation of the laminate component to be constructed and the finished laminate component are aligned at the same common height in the common vertical reference plane.

[0066] Clause 20. The method of clause 11, wherein causing the step of presenting to the user via the display further comprises: displaying the height difference relative to the first height and the second height using color coding such that the color will specify a predetermined height difference range between the first height and the second height.

[0067] Although various embodiments are described above, the present disclosure is not intended to be limited thereto. Changes may be made to the disclosed embodiments and these changes are still within the scope of the appended claims.

Claims

1. A method (20) for analyzing the surface quality of a laminated component, the method comprising the following steps: creating (22) a planned dimensional representation of a desired built laminate part (10P) including a first surface (12P) having a first topography; placing (24) the fibers (18) into positions of the desired laminated component (10P); curing (30) the resin associated with the placed fibers (18) to thereby produce a finished laminate component (10) from a planned dimensional representation of a desired constructed laminate component (10P), the finished laminate component (10) including a second surface (12) having a second topography corresponding to the first surface (12P) having the first topography; aligning (34) the positions of the first surface (12P), the second surface (12), and the fiber (18); determining (36) a first height of a first point (38) on the first surface (12P) and a second height of a second point (40) on the second surface (12); as well as observing (44) the aligned positions of the first surface (12P), the second surface (12) and the fibers (18) and the first height relative to the second height when analyzing the surface quality of the finished laminated component (10), wherein the determining (36) step further comprises determining any height difference between the first height and the second height; and The observing (44) step further comprises the step of: in response to a height difference between the first height and the second height exceeding a tolerance range, changing a position of at least one fiber (18) of the desired laminated component (10P).

2. The method (20) according to claim 1, wherein: The step of placing (24) fibers (18) into positions of a desired laminate component (10P) build includes placing the positions of the fibers (18) within a numerical control of an automated fiber placement machine used to manufacture the finished laminate component (10).

3. The method (20) of claim 1, wherein: The step of placing (24) fibers (18) in positions of a desired laminate component (10P) includes placing at least two adjacent fibers (18) within at least one ply (14A) of the desired laminate component (10P) such that the at least two adjacent fibers (18) within the at least one ply (14A) deviate from a standard configuration (16).

4. The method (20) according to claim 3, wherein: The at least one ply (14A) deviates from the standard configuration (16) comprising fibers that are spaced apart and extend parallel to each other within the ply.

5. The method (20) according to claim 3, wherein: The step of placing (24) the fibers (18) in positions of a desired laminate component (10P) to be constructed includes increasing the spacing (26) between at least two adjacent fibers (18) within at least one of the plies (14A) relative to the standard configuration (16).

6. The method (20) according to claim 3, wherein: The step of placing (24) the fibers (18) in the desired location of the laminate component (10P) to be constructed includes overlapping (28) of the at least two adjacent fibers (18) within the at least one ply (14B).

7. The method (20) according to claim 6, wherein: The overlap (28) of the at least two adjacent fibers (18) is within the at least one ply (14B).

8. The method (20) of claim 1, wherein: The step of creating (22) a planned dimensional representation of a desired built laminated component (10P) including a first surface (12P) having a first topography includes placing the planned dimensional representation of the desired built laminated component (10P) into a CAD file.

9. The method (20) of claim 1, wherein: The step of creating (22) a planned dimensional representation of a desired laminate component (10P) to be constructed includes: said planned dimensional representation of said desired laminate component (10P) to be constructed excludes fibers (18).

10. The method (20) of claim 1, wherein: The curing (30) step further comprises scanning the second surface (12) to obtain the second topography of the second surface (12); The step of aligning (34) the positions of the first surface (12P) having the first topography, the second surface (12) having the second topography, and the fibers (18) of the planned dimensioned representation of the desired constructed laminated component (10P) includes the positions of the first surface (12P), the second surface (12), and the fibers (18) having a common horizontal reference plane (H) and a common vertical reference plane (V); and In the step of determining (36) the first height of the first point (38) and the second height of the second point (40), the first point (38) and the second point (40) have the same reference point (42) in the common horizontal reference plane (H), and the planned dimensional representation of the desired laminated part (10P) and the finished laminated part (10) are aligned at the same common height in the common vertical reference plane (V).

11. A computer-implemented method for analyzing the surface quality of a laminated component, the method comprising the steps of: receiving, by a processor, a data file containing a planned dimensional representation of a desired constructed laminate component including a first surface, the data file having first topographical data of the first surface; receiving, by a processor, a data file containing fiber locations for the desired laminate component construction; receiving, by a processor, a data file from a scan performed on a second surface having second topographical data of a finished laminate component manufactured from a planned dimensional representation of the desired laminate component to be built, wherein the finished laminate component is manufactured with fibers having fiber positions based on a data file containing fiber positions of the desired laminate component to be built, and the second surface corresponds to the first surface; and aligning, by a processor, the first surface including first topographic data for a first surface from a data file containing a representation of planned dimensions of the laminated component to be constructed, the second surface including second topographic data for a second surface from a data file containing data from a scan performed on the second surface of the completed laminated component, and the fiber locations of the laminated component to be constructed from a data file containing fiber locations within the laminated component to be constructed; determining, by a processor, a first height of a first point on the first surface and a second height of a second point on the second surface, wherein the first point is from a data file containing a planned dimensional representation of the desired built laminate component including the first surface having the first topographic data, and the second point is from a data file from a scan performed on the second surface having second topographic data of the second surface of the finished laminate component; and causing a visual representation of the aligned first surface, the second surface and the fiber position and an indication of the first height relative to the second height to be presented to a user via a display when analyzing the surface quality of the laminate part, The step of causing the display to be presented to the user further comprises: displaying the height difference relative to the first height and the second height using color coding, such that the color will specify a predetermined height difference range between the first height and the second height.

12. The method according to claim 11, wherein: The step of receiving, by a processor, a data file containing fiber locations for the desired laminate component build further includes placing the data file into a numerical control device data file for instructing an automated fiber placement machine to place fibers within the desired laminate component build.

13. The method according to claim 11, wherein: The step of receiving, by a processor, a data file containing fiber locations within the desired laminate component build also identifies the locations of any deviations from a standard configuration between two adjacent fibers in each ply of the desired laminate component build.

14. The method according to claim 13, wherein: The step of receiving, by a processor, a data file containing fiber locations within the desired constructed laminate component further includes identifying locations within at least one ply where a spacing between at least two adjacent fibers is increased relative to the standard configuration.

15. The method according to claim 13, wherein: The step of receiving, by a processor, a data file containing fiber locations within the desired laminate component build further includes identifying locations within at least one ply where two adjacent fibers overlap.

16. The method according to claim 11, wherein: The step of receiving, by a processor, a data file containing a representation of the planned dimensions of the desired laminate component to be constructed further comprises: the data file being a CAD file.

17. The method according to claim 11, wherein: The step of receiving, by the processor, a data file containing a representation of the planned dimensions of the desired laminate component to be constructed further comprises receiving a data file that does not contain fiber position data.

18. The method according to claim 11, wherein: The step of receiving, by the processor, a data file from a scan performed on the second surface further includes performing the scan using a laser scanner.

19. The method of claim 11, wherein: The step of aligning includes aligning said first surface, said second surface, and said fiber positions relative to a common horizontal reference plane and a common vertical reference plane within said desired constructed laminate component; and The determining step includes the first point and the second point having a common reference point in the common horizontal reference plane and the planned dimensioned representation of the desired laminate component to be constructed and the finished laminate component being aligned at the same common height in a common vertical reference plane.

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