Composite Structure Warping Control System

Abstract

The present invention relates to a warpage control system for a composite structure, and discloses a method, apparatus, and system for managing a composite part (104). Warpage (116) at an acceptable level (114) of the composite part (104) is identified. The warpage (116) of the composite part (104) is a variation in the manufactured composite part (104) that deviates from the design specifications (119) of the composite part (104). An orientation (118) in a stacking sequence (120) is selected for the plies (122) in the composite part (104), which results in the composite part (104) having warpage (116) at an acceptable level (114) and a desired strength (124) to form a selected orientation (126). The composite part (104) is manufactured using the selected orientation (126).

Description

Technical Field

[0001] The present disclosure generally relates to manufacturing and, more particularly, to manufacturing composite parts. More specifically, the present disclosure relates to a method, apparatus, and system for controlling warping in manufacturing composite parts. Background Art

[0002] Warping typically occurs in the manufacturing of composite parts. For an aircraft, composite parts can include, for example, skin panels, wings, stabilizer panels, and other components. For example, these types of composite panels can be reinforced with stiffening structures to reduce or avoid structural bending or buckling when loads are applied to these types of structures. Stiffening structures such as stringers can be formed on composite panels or other composite structures. Forming reinforced composite parts using these components typically results in warping, where the dimensions of the manufactured part deviate from the design specifications of the part. Warping of composite parts has been regarded as an acceptable manufacturing problem.

[0003] Due to warping, composite parts cannot fit with other composite parts when assembling parts for an aircraft. As a result, there are gaps when placing the parts together for assembly.

[0004] Spacers can be used in these cases. A spacer is a structure for aligning parts. A spacer can be, for example, a washer, a wedge, a strip of material, or some other structure that fills the gap between two parts, where the gap is created due to warping of one or more parts.

[0005] However, the use of spacers is time-consuming and increases the manufacturing cost. For example, the gaps between parts need to be identified and measured. In some cases, warping can result in gaps that are too small such that the gaps can be closed when the parts are connected to each other. In these cases, no spacers are needed.

[0006] When the gaps are too large, spacers will be manufactured to fit into the gaps. In some cases, the gaps can have complex shapes, requiring more time and effort to create spacers to fit into the gaps. Then the operator installs the spacers into the gaps.

[0007] This process is time-consuming and expensive, especially when installing a large number of spacers (such as hundreds or thousands of spacers) during the manufacturing process of aircraft parts. Additionally, the use of spacers can also increase the weight of the aircraft.

[0008] Accordingly, there is a desire for a method and apparatus that take into account at least some of the problems discussed above and other possible problems. For example, there is a desire for a method and apparatus that can overcome the technical problem of the dimensions of these parts deviating from the composite part specifications when manufacturing composite parts. Summary of the Invention

[0009] Embodiments of the present disclosure provide a method for managing composite parts. Identify an acceptable level of warpage of the composite part. Warpage of the composite part is a variation in the manufactured composite part that deviates from the design specifications of the composite part. Select an orientation for the plies in the composite part in a stacking sequence to form a selected orientation such that manufacturing the composite part using the selected orientation results in the composite part having an acceptable level of warpage and desired strength.

[0010] Another embodiment of the present disclosure provides a composite part system that includes a computer system and a composite part designer in the computer system. The composite part designer is configured to identify an acceptable level of warpage of the composite part. Warpage is a variation in the manufactured composite part that deviates from the design specifications of the composite part. The composite part designer selects an orientation for the plies in the composite part in a stacking sequence to form a selected orientation in the stacking sequence such that manufacturing the composite part using the selected orientation in the stacking sequence results in the composite part having an acceptable level of warpage and desired strength.

[0011] Yet another embodiment of the present disclosure provides a product management system that includes manufacturing equipment and a controller communicatively coupled to the manufacturing equipment. The controller is configured to control the manufacturing equipment to manufacture a composite part using a part design in which the plies in the composite part have a selected orientation in a stacking sequence to form a selected orientation in the stacking sequence such that manufacturing the composite part using the selected orientation in the stacking sequence results in the composite part having an acceptable level of warpage and desired strength, where warpage is a variation in the composite part that deviates from the design specifications of the composite part during manufacturing.

[0012] These features and functions may be implemented independently in various embodiments of the present disclosure or may be combined in other embodiments. More details can be seen by referring to the following description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The features believed to be novel characteristics of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments, and further preferred usage modes of the illustrative embodiments and their further purposes and features, will be best understood when read in conjunction with the following detailed description of the illustrative embodiments of the present disclosure, where:

[0014] Figure 1 is an illustration of a composite part environment according to an illustrative embodiment;

[0015] Figure 2 is an illustration of a block diagram of a user interface system for designing a composite part according to an illustrative embodiment;

[0016] Figure 3 is an illustration of a result displayed in a graphical user interface according to an illustrative embodiment;

[0017] Figure 4 is a diagram of the result displayed in a graphical user interface according to an illustrative embodiment;

[0018] Figure 5 is a diagram of the result displayed in a graphical user interface according to an illustrative embodiment;

[0019] Figure 6 is a diagram of the result displayed in a graphical user interface according to an illustrative embodiment;

[0020] Figure 7 is a diagram of a flowchart of a process for managing composite parts according to an illustrative embodiment;

[0021] Figure 8 is a diagram of a flowchart of a process for selecting the orientation of plies in a composite part according to an illustrative embodiment;

[0022] Figure 9 is a diagram of a flowchart of a process for selecting the orientation of plies in a composite part according to an illustrative embodiment;

[0023] Figure 10 is a diagram of a flowchart of a process for displaying the result from analyzing the orientation of plies according to an illustrative embodiment;

[0024] Figure 11 is a diagram of a flowchart of a process for manufacturing a composite part according to an illustrative embodiment;

[0025] Figure 12 is a diagram of a block diagram of a data processing system according to an illustrative embodiment;

[0026] Figure 13 is a diagram of an aircraft manufacturing and maintenance method according to an illustrative embodiment;

[0027] Figure 14 is a diagram of a block diagram of an aircraft in which an illustrative embodiment can be implemented; and

[0028] Figure 15 is a diagram of a block diagram of a product management system described according to an illustrative embodiment. DETAILED DESCRIPTION

[0029] The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that currently, the warping of a panel with a balanced and symmetric ply layup is considered an inherent behavior of the composite material and is independent of the in-plane properties of the laminate. The illustrative embodiments recognize and take into account that currently warping is not considered a defect that can be predicted.

[0030] The illustrative embodiments recognize and account for the fact that current design processes do not use the level of warping as a variable. The illustrative embodiments recognize and account for the fact that current design processes would prefer to focus on providing desired properties of composite structures such as lower wing panels without considering the warping that may occur. For example, the illustrative embodiments recognize and account for the fact that a desired property may be the absence of splits in a composite part of a skin panel on the underside of, for example, an aircraft wing.

[0031] Accordingly, the illustrative examples provide a method, apparatus, and system for designing and manufacturing a composite part that achieves a desired level of warping and maintains the desired properties of the composite part. For example, the illustrative examples manage a composite part. Identify an acceptable level of warping of the composite part. Warping of the composite part is a variation from the design specifications of the manufactured composite part. Select an orientation in a stacking sequence for plies in the composite part to form a selected orientation such that manufacturing the composite part using the selected orientation results in the composite part having an acceptable level of warping and desired strength.

[0032] Referring to the drawings and particularly to Figure 1 , a diagram of a composite part environment is shown in accordance with an illustrative embodiment. The composite part environment 100 is an environment in which a composite part 102 is designed for use in a product 104 such as an aircraft 106. The composite part 102 takes a variety of different forms. For example, the composite part 102 can be one of a skin panel, a fairing, an engine case, a stringer, a door, a wing, a panel, and certain other suitable types of parts that can be used in the product 104 and particularly in the aircraft 106.

[0033] In this illustrative example, a design 108 for the composite part 102 is created by a composite part designer 110 in a part manager 111 in a computer system 112. As shown, the composite part designer 110 can be implemented in software, hardware, firmware, or a combination thereof. When software is used, the operations performed by the composite part designer 110 can be implemented as program code configured to run on hardware such as a processor unit. When firmware is used, the operations performed by the composite part designer 110 can be implemented as program code and data and can be stored in a persistent memory to run on the processor unit. When hardware is employed, the hardware can include circuitry that operates to perform the operations in the composite part designer 110.

[0034] In an illustrative example, the hardware can take the form of at least one selected from circuit systems, integrated circuits, application specific integrated circuits (ASICs), programmable logic devices, or some other suitable type of hardware configured to perform a number of operations. For a programmable logic device, the device can be configured to perform a number of operations. The device can be reconfigured at a later time or can be permanently configured to perform a number of operations. Programmable logic devices include, for example, programmable logic arrays, programmable array logic, field programmable logic arrays, field programmable gate arrays, and other suitable hardware devices. Additionally, the process can be implemented in an organic component integrated with an inorganic component and can consist entirely of organic components other than humans. For example, the process can be implemented as a circuit in an organic semiconductor.

[0035] Computer system 112 is a physical hardware system and includes one or more data processing systems. When there is more than one data processing system in computer system 112, these data processing systems communicate with each other using a communication medium. The communication medium can be a network. The data processing systems can be selected from at least one of a computer, a server computer, a tablet computer, or some other suitable data processing system.

[0036] As used herein, the phrase "at least one" when used with a list of items means that different combinations of one or more of the listed items can be used and that only one of each item in the list may be required. In other words, "at least one" means that any combination of items and the number of items can be used from the list, but not all items in the list are required. The item can be a particular object, thing, or category.

[0037] For example but not limited to, "at least one of item A, item B, or item C" can include item A, item A and item B, or item B. This example can also include item A, item B, item C, or item B and item C. Of course, any combination of these items can exist. In some illustrative examples, "at least one" can be, for example but not limited to: two item As, one item B, and ten item Cs, four item Bs and seven item Cs, or other suitable combinations.

[0038] As shown, composite part designer 110 operates to manage composite part 102. Managing composite part 102 by composite part designer 110 includes identifying warpage 116 of composite part 102 at an acceptable level 114. Warpage 116 of composite part 102 is a variation of the manufactured composite part 102 from the design specifications 119 of composite part 102. In an illustrative example, design specifications 119 specify parameters of composite part 102 (including at least one of dimensions, strength, tolerances, or other parameters relative to composite part 102).

[0039] In this illustrative example, the composite part designer 110 selects an orientation 118 in the stack order 120 for the ply 122 in the composite part 102 to form a selected orientation 126 in the stack order 120. Manufacturing the composite part 102 using the selected orientation 126 in the stack order 120 results in the composite part 102 having an acceptable level 114 of warpage 116 and a desired strength 124 to form the selected orientation 126.

[0040] The composite part designer 110 treats warpage 116 as a variable when selecting the orientation 118. The selection of the orientation 118 is made such that the composite part 102 has both an acceptable level 114 of warpage 116 and a desired strength 124. In this illustrative example, the desired strength 124 can be based on a design specification 119. The specification can specify a safety margin desired for the composite part 102.

[0041] In the illustrative example, the composite part designer 110 can select an orientation 118 for the ply 122 in the composite part 102, which results in the composite part 102 having an acceptable level 114 of warpage 116 and a desired strength 124, thereby forming the selected orientation 126 in a number of different ways. For example, the composite part designer 110 can select a candidate orientation 128 in the stack order 120 for the ply 122. The composite part designer 110 can perform a stress analysis 130 on the composite part 102 using the candidate orientation 128 of the ply 122 in the stack order 120. As shown, the stress analysis 130 includes a simulation of one or more types of forces that can be applied to the composite part 102. For example, the simulation can be a set of loads applied to the composite part 102. Other forces can include frictional forces, tensile forces, or other suitable types of forces.

[0042] In the illustrative example, the stress analysis 130 can take the form of a laminate analysis 131. The laminate analysis 131 can be implemented using currently used analysis algorithms that can be used to analyze the composite part 102. These algorithms can implement classical laminate theory. In this theory, the engineering and physical properties of the ply are developed based on the angle of the fibers relative to the primary load direction. The properties are summed in a particular direction relative to the ply thickness and divided by the total thickness. The laminate analysis 131 can be run on the composite part design 150 to determine parameters such as strength, damage tolerance, or other parameters of the composite part 102 manufactured using the composite part design 150. The laminate analysis 131 can be used to calculate properties of the laminate of the composite part 102 such as having a ply 122 with an orientation 118 in the stack order 120.

[0043] In this illustrative example, one of the characteristics of composite part 102 is the amount or level of warpage 116. The amount of warpage 116 can be determined by laminate analysis 131 using stack sequence 120, which includes the orientation 118 of plies 122 in addition to other information such as dimensions, material type, or other information required for analysis design 108. In the illustrative example, as Figure 4 shown and as described below in Figure 4 , laminate analysis 131 calculates warpage data (such as α Y and α X , and normalized warpage (α Y / α X ).

[0044] When the results of stress analysis 130 indicate that composite part 102 has an acceptable level 114 of warpage 116 and the desired strength 124 of composite part 102, composite part designer 110 uses the candidate orientation 128 in stack sequence 120 as the selected orientation 126.

[0045] When stress analysis 130 is performed on composite part 102 with candidate orientation 128, composite part designer 110 can select a new orientation 132 in stack sequence 120 to indicate that composite part 102 does not have the desired strength 124. By changing the orientation in stack sequence 120, the position of plies 122 can be changed to another position in stack sequence 120.

[0046] Composite part designer 110 uses the new orientation 132 of plies 122 in stack sequence 120 as candidate orientation 128 to perform stress analysis 130 on composite part 102. Composite part designer 110 repeats selecting the new orientation 132 as candidate orientation 128 and performing stress analysis 130 on composite part 102 using candidate orientation 128 of plies 122 in stack sequence 120 until the desired strength 124 exists in composite part 102.

[0047] The selected orientation 126 can include at least one of a 90-degree ply, a +45-degree ply, a -45-degree ply, or a 0-degree ply. For example, the selected orientation 126 can include a 90-degree ply, a +45-degree ply, a -45-degree ply, and a 0-degree ply. In another illustrative example, the selected orientation 126 can include at least ten percent of the plies with a 90-degree orientation. In another illustrative example, the selected orientation 126 can include at least 12.5% to 20% of the plies with a 90-degree orientation. In yet another illustrative example, the selected orientation 126 can include 40% to 50% of the plies with a 45-degree orientation. In this example, the 45-degree orientation can be a +45-degree orientation, a -45-degree orientation, or some combination thereof.

[0048] In an illustrative example, the degrees of different orientations can be based on a reference axis. For example, these degrees can be relative to the part axis of the composite part 102. In another example, the degrees of the plies 122 can be relative to a tool head in a machine such as an automated tape laying machine or other automated tool.

[0049] Illustrative examples of diagrams of many plies of these orientations are provided only as illustrative examples and are not intended to limit the ways in which many plies of different orientations can be selected. These and other orientations can be used for the selected orientation 126 such that there is an acceptable level 114 of warp 116 and a desired strength 124 in the composite part 102. Additionally, the positions of the different orientations forming the stack sequence 120 can be a third variable in addition to the acceptable level 114 of warp 116 and the desired strength 124.

[0050] In an illustrative example, at least one of the candidate orientations 128 or the new orientation 132 can be selected by the composite part designer 110 in a number of different ways. The selection can be made using the input 134 received from at least one of the operator 136 or the artificial intelligence system 138.

[0051] In the depicted example, the operator 136 is the person who designs the composite part 102 in the aircraft 106. The artificial intelligence system 138 is a system with intelligent behavior and can be based on the functions of the human brain.

[0052] As shown, the artificial intelligence system 138 includes at least one of an artificial neural network, a cognitive system, a Bayesian network, fuzzy logic, an expert system, a natural language system, or some other suitable system. Machine learning is used to train the artificial intelligence system. Machine learning involves inputting data into a process and allowing the process to adjust and improve the function of the artificial intelligence system.

[0053] A cognitive system is a computing system that mimics the functions of the human brain. A cognitive system can be, for example, IBM Watson available from International Business Machines Corporation.

[0054] In this illustrative example, the part manager 111 can also include a controller 140 in the computer system 112. As shown, the controller 140 is configured to control the manufacture of the composite part 102 in the product management system 142 using the selected orientation 126. In other words, the composite part 102 can be manufactured in the product management system 142 using the selected orientation 126.

[0055] By having a selected orientation 126 in the stacking sequence 120, the composite part designer 110 can generate a composite part design 150. The composite part design 150 is a design that can be used by the controller 140 to fabricate a composite part 102 such that the composite part 102 has an acceptable level 114 of warp 116 and a desired strength 114. The design can be, for example, a computer-aided design model, a computer-aided manufacturing model, a computer numerical control (CNC) program, or some other type of model.

[0056] In an illustrative example, the composite part design 150 is contrary to the design 108. The design 108 includes design specifications 119. The design specifications 119 can include the layup of plies 122 having an initial stacking sequence, and the orientations of the plies 122 having the initial stacking sequence. These orientations can be changed to form a selected orientation 126 in the stacking sequence 120, which results in the composite part 102 fabricated using the selected orientation 126 in the stacking sequence 120 having an acceptable level 114 of warp 116 and a desired strength 124.

[0057] For example, the controller 140 can use the composite part design 150 that includes the selected orientation 126 of the plies 122 in the composite part 102 in the stacking sequence 120 to fabricate the composite part 102. The controller 140 can use the selected orientation 126 in the composite part design 150 to control the operation of the ply layup system 144 to lay up the plies 122 of the composite part 102 to form a composite layup 146. In this illustrative example, the ply layup system 144 can be, for example, at least one of an automated fiber placement machine, a tape laying machine, or other suitable hardware equipment that can operate to lay up the plies 122 in the selected orientation 126 to form a composite layup 146.

[0058] In an illustrative example, a program can be used to form the control of one or more machines in the ply layup system 144. For example, when using an automated fiber placement machine, the machine can be a computer numerical control (CNC) automated fiber placement machine. The CNC program can be generated from the design of the part, such as a computer-aided design drawing. The program can be run by the controller 140 to control the operation of the automated fiber placement machine. In some illustrative examples, the controller 140 can be part of the automated fiber placement machine.

[0059] In addition, the controller 140 can control the curing system 148 to cure the composite layup 146 to form the composite part 102. As shown, the curing system 148 can be at least one of a curing oven, an autoclave, a curing lamp system, or other suitable hardware equipment that can cure the composite layup 146 to form the composite part 102.

[0060] In this illustrative example, the part manager 111 is part of the composite part system 115. At least one of the laminate layup system 144 or the curing system 148 can also be part of the composite part system 115.

[0061] Next, with reference to Figure 2 , a diagram of a block diagram of a user interface system for designing composite parts is depicted according to an illustrative embodiment. In the illustrative example, the same reference numerals can be used in more than one figure. This reuse of reference numerals in different figures represents the same element in different figures.

[0062] In this illustrative example, the user interface system 200 provides an interface for an operator 136 to interact with at least one of the composite part designer 110 or the controller 140 in the computer system 112 in Figure 1 .

[0063] As shown, the user interface system 200 includes a display system 202 and an input system 204. These components can be connected to the computer system 112 or be considered part of the computer system 112.

[0064] In this illustrative example, the display system 202 is a physical hardware system and includes one or more display devices on which a graphical user interface 206 can be displayed. The display device can include at least one of a light-emitting diode (LED) display, a liquid crystal display (LCD), an organic light-emitting diode (OLED) display, a computer monitor, a projector, a flat panel display, a head-up display (HUD), or some other suitable device that can output information to visually present information.

[0065] As shown, the display system 202 is configured to display the graphical user interface 206. The operator 136 is a person who can interact with the graphical user interface 206 through user input 208 generated for the computer system 112 by the input system 204. The input system 204 is a physical hardware system and can be selected from at least one of a mouse, a keyboard, a trackball, a touch screen, a stylus, a motion-sensing input device, a cyber glove, or some other suitable type of input device.

[0066] For example, the operator 136 can use the graphical user interface 206 to select or create a composite part design 150 for the composite part 102. In this illustrative example, the operator 136 can generate user input 208 to select an acceptable level 114 of warp 116 and a desired strength 124 for the composite part 102, the latter three as shown in the block diagram in Figure 1 .

[0067] A user input 208 can be generated to identify an orientation 126 of a selection of plies 122 in a stack order 120 to form a composite part design 150. The composite part design 150 is a design used by a controller 140 to fabricate a composite part 102.

[0068] As shown, the composite part design 150 includes a stack order 120 of plies 122 that form the composite part 102. In this illustrative example, the stack order 120 can be obtained from Figure 1 a design 108 of the composite part 102.

[0069] In this illustrative example, an operator 136 can select a set of candidate orientations 128. As shown, the user input 208 can also select which plies in the stack order 120 have a particular orientation. In other words, the operator 136 can maintain the same percentage of candidate orientations 128, but change which layers in the stack order 120 have a particular orientation.

[0070] As shown, a set of candidate orientations 128 can be displayed on a graphical user interface 206 as a ply percentage envelope 220. In this illustrative example, a set of candidate orientations 128 is a ply percentage. For example, a set of candidate orientations can be 35 / 50 / 15, where 35 is the percentage of plies 122 with a 0-degree orientation; 50 is the percentage of plies 122 with a + / -45-degree orientation; and 15 is the percentage of plies 122 with a 90-degree orientation in the stack order 120.

[0071] These ply percentage envelopes can be percentages of plies in different orientations. These percentages can be specific values or ranges of plies (such as 0-degree plies, + / -45-degree plies, and 90-degree plies). In this illustrative example, the + / -45-degree plies are equal percentages of +45-degree plies and -45-degree plies. For example, selecting 30% for the + / -45-degree plies means that 15% of the plies are +45 degrees and 15% of the plies are -45 degrees.

[0072] Selecting a ply percentage envelope in the ply percentage envelope 220 causes a set of candidate orientations 128 of the stack order 120 to be sent to the composite part designer 110 in the user input 208.

[0073] The composite part designer 110 can perform a stress analysis 130 using a set of candidate orientations 128 of the stack order 120 to generate results 210. The results 210 can include data or information for at least one of strength, safety margin, warping, laminate efficiency, or other information about the composite part 102 with the candidate orientations 128 in the stack order 120 of the composite part 102.

[0074] In this illustrative example, the stress analysis 130 is in the form of a laminate analysis 131. The laminate analysis 131 can receive a structural load 222 to analyze a set of candidate orientations 128 selected by the user input 208.

[0075] In this illustrative example, the results 210 can be displayed in the graphical user interface 206 for the operator 136 to view. The results 210 can be displayed in a variety of different ways. For example, a line graph, a bar graph, text, raw simulation data, or other suitable types of display can be used to display the results 210.

[0076] In addition, the composite part designer 110 can also display the stack sequence 120 and other suitable information with respect to the design 108 of the composite part 102. For example, a visualization of the composite part 102 with warpage 116 can be displayed, and a visualization of the composite part 102 without warpage 116 following the design 108 can be displayed.

[0077] Based on the results 210 displayed in the graphical user interface 206, the operator 136 can select a new orientation 132 to be used as a candidate orientation 128 by selecting the ply percentage envelope 220 displayed in the graphical user interface 206. The laminate analysis 131 can be performed on the updated candidate orientations. This process can be repeated until the candidate orientations 128 provide desired results for the warpage 116 at an acceptable level 114 and the desired strength 124.

[0078] In some illustrative examples, multiple sets of candidate orientations 128 can provide warpage 116 at an acceptable level 114 and the desired strength 124. In such cases, one set of candidate orientations 128 can be selected based on different factors. These other factors can include at least one of cost, manufacturing difficulty, maximum strength, minimum warpage amount, or other suitable factors.

[0079] For example, several sets of candidate orientations 128 can provide warpage 116 at an acceptable level 114 and the desired strength 124. However, even if all warpage 116 is within the acceptable level 114, some sets of candidate orientations 128 can provide a lower level of warpage 116. In other words, the acceptable level 114 of warpage 116 can be a threshold for the maximum level of acceptable warpage 116.

[0080] As another example, even if all sets of candidate orientations 128 provide the desired strength 124, some sets of candidate orientations 128 can provide a higher level of strength. In other words, the desired strength 124 can be the minimum value or threshold level of the strength of the composite part 102.

[0081] In addition, the result 210 displayed in the graphical user interface 206 may also include suggestions for the ply percentage envelope 220 that meet the warpage 116 and desired strength 124 of the acceptable level 114. These suggestions and the result 210 may be generated by at least one of the laminate analysis 131 or the artificial intelligence system 138. The operator 136 may generate a user input 208 that selects one of the suggested ply percentage envelopes 220. This selection causes the selected ply percentage envelope to be used in the composite part design 150.

[0082] The illustration of the ply percentage envelope 220 in the graphical user interface 206 is presented as one way in which the operator 136 may select a candidate orientation 128 from the analysis. This illustration is not intended to limit the ways in which the candidate orientation 128 may be selected. Still in other illustrative examples, the operator 136 may enter the candidate orientation 128 for the stacking sequence 120 in the graphical user interface 206 rather than selecting a ply percentage envelope from the ply percentage envelope 220. In yet another exemplary example, the artificial intelligence system 138 may select the candidate orientation 128 without a user input 208 generated by the operator 136.

[0083] In one illustrative example, one or more technical solutions are proposed that overcome the technical problem of manufacturing composite parts with dimensions deviating from the specifications of the composite parts. Specifically, in the illustrative example, there are one or more technical solutions that reduce the number of shims installed in an object such as an aircraft. As a result, in the illustrative example, one or more technical solutions may provide the technical effect of reducing the gap between assembled composite parts. In the illustrative example, composite parts with smaller gaps requiring shims may be utilized to reduce the number of shims manufactured and installed.

[0084] The computer system 112 may be configured to perform at least one of the steps, operations, or actions described in the different illustrative examples using software, hardware, firmware, or a combination thereof. As a result, the computer system 112 operates as a dedicated computer system, where the composite part designer 110 in the computer system 112 treats the warpage 116 as a variable and is capable of generating a composite part design that can be used to manufacture composite parts with an acceptable level 114 of warpage 116 and desired strength 124. Specifically, compared to a general-purpose computer system that currently does not have the composite part designer 110, the composite part designer 110 transforms the computer system 112 into a dedicated computer system.

[0085] In an illustrative example, a process is integrated into a practical application for managing composite parts in computer system 112 using composite part designer 110, which increases the performance of computer system 112 in controlling the manufacture of composite parts in a product management system. In other words, composite part design 150 in computer system 112 is for the practical application of a process in composite part design 150 integrated into computer system 112, and this process selects the orientation 118 of ply 122 in stack sequence 120. In this illustrative example, orientation 118 can be selected to form a selected orientation 126 in stack sequence 120. Stack sequence 120 with the selected orientation 126 can execute composite part design 150, which can be used to manufacture composite part 102. Manufacturing composite part 102 using composite part design 150 can cause composite part 102 to have desired characteristics (such as warpage 116 at an acceptable level 114 and desired strength 124).

[0086] Figure 1 The illustration of composite part environment 100 in does not intend to imply physical or architectural limitations on the manner in which an exemplary embodiment can be implemented. Other components or components in place of the shown components can be used. Some components may be unnecessary. Additionally, there are blocks to illustrate some functional components. When implemented in an illustrative embodiment, one or more of these blocks can be combined, divided, or combined and divided into different blocks.

[0087] Although the illustrative example is described with respect to aircraft 106, another illustrative example can be applied to other types of platforms. The platform can be, for example, a mobile platform, a fixed platform, a land-based structure, a water-based structure, and an air-based structure. More specifically, the platform can be a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, a building, and other suitable platforms that use composite parts.

[0088] Figures 3 to 6 is an example of one implementation of a graphical user interface 206 displayed to operator 136 in display system 202. Operator 136 can interact with graphical user interface 206 and use input system 204 to generate user input 208 to select candidate orientation 128. Additionally, these figures also depict when displayed to operator 136 Figure 2 the different forms that results 210 in can take. The display of graphical user interface 206 can be performed by composite part designer 110.

[0089] First, referring to Figure 3 , an illustration of results displayed in a graphical user interface is depicted according to an illustrative embodiment. In this figure, graphical user interface 300 is for use inFigure 2 An example of an embodiment of the graphical user interface 206 that displays the result 210.

[0090] In this example, Table 302 shows the parameters for different ply percentage envelopes. As shown, column 304 depicts different types of ply percentage envelopes.

[0091] In this illustrative example, the laminate in column 304 is a composite part that includes layers of plies having all the same orientation (such as 0 degrees). In other rows, the ply percentage envelopes show the percentages of plies having the following order of orientations: 0 degrees, + / - 45 degrees, and 90 degrees. In this illustrative example, "+ / -" degrees means that the percentage of 45-degree plies is evenly distributed between -45 degrees and +45 degrees.

[0092] As shown, column 306 contains the values of the modulus of elasticity in the x direction, and column 308 contains the values of the modulus of elasticity in the y direction. Column 310 contains the values of Poisson's ratio, where V XY represents the strain of the laminate having the XY plane in the y direction, which is caused by the load in the X direction. As shown in column 312, V YX is Poisson's ratio, where the strain in the X direction results in a load in the Y direction on the XY plane.

[0093] In Table 302, column 314 includes the value of Poisson's ratio divided by the modulus of elasticity in the x direction. The values in this column are obtained from the application of the generalized Hooke's law, the applicable law for orthotropic materials including composites, in combination with Betti's law. This information indicates that the elastic properties control the strength contribution of a given thin ply for a given orientation within the laminate, independent of the shear modulus, Gxy.

[0094] Column 316 includes the values of the ply efficiency. It can be seen that the thin ply in row 305 has the highest efficiency. The efficiency takes into account factors such as warping, ply orientation, ply percentage, and other factors.

[0095] In this illustrative example, the graphical indicator 318 identifies the recommended percentage ply envelope. In this example, the recommended ply percentage envelopes are indicated by the graphical indicator 318, which includes 37 / 45 / 18; 40 / 40 / 20; and 40 / 45 / 15.

[0096] The bar graph 320 shows the laminate efficiency of composite parts with different ply percentage envelopes compared to the thin ply. The bar graph 320 graphically depicts the values in column 316 in the graphical user interface 300.

[0097] Go to Figure 4, an illustration of the results displayed in a graphical user interface is depicted according to an illustrative embodiment. In this figure, the graphical user interface 400 is an example of an implementation of the graphical user interface 206 for displaying the results 210 in Figure 2 an

[0098] In this example, the line graph 402 shows a comparison of the effect of the ply percentage on the warping of a composite part such as a panel. As shown, the x-axis 403 depicts the ply percentage envelope, and the y-axis 401 depicts the normalized warping. The normalized warping is the warping that has been normalized with respect to one of the ply percentage envelopes so that the ply percentage envelopes can be compared to each other. In this illustrative example, the ply percentage envelope 37 / 45 / 18 is selected because it is the layup of the composite part with the lowest warping.

[0099] In this illustrative example, the line 404 is the normalized warping. The line 406 is the ratio of the 0-degree plies and 90-degree plies, and the line 408 represents the percentage of the + / -45-degree plies in different ply percentage envelopes. The line 406 describes the effect of the + / -45 plies on the warping of the composite part.

[0100] The graphical indicator 410 identifies the valid layup ranges. This range covers the following ply percentage envelopes: 35 / 50 / 15; 37 / 45 / 18; and 40 / 40 / 20. Using these ply percentage envelopes, the percentages are arranged in the following order: 0-degree plies; + / -45-degree plies; and 90-degree plies.

[0101] As shown, the graphical indicator 410 displayed on the graphical user interface 400 indicates the appropriate or recommended ply percentage envelope.

[0102] In Figure 5 an Figure 2 an

[0103] As shown, the line graph 502 shows the relationship between the laminate efficiency and the Poisson mismatch ratio. In this example, the x-axis 501 represents the ply percentage envelope, and the y-axis 503 represents the relationship between the laminate efficiency and the Poisson mismatch ratio.

[0104] In this illustrative example, line 504 in line graph 502 shows the laminate efficiency of composite parts using different ply percentage envelopes. Laminate efficiency shows the efficiency of composite parts manufactured using a specific ply percentage envelope. In this illustrative example, the maximum efficiency is considered to be the ply with a 0-degree orientation. The governing efficiency of this type of composite part is 1.0.

[0105] Line 506 in line graph 502 depicts the Poisson's ratio mismatch for different ply percentage envelopes. As can be seen from line graph 502, there is a direct correlation between laminate efficiency and Poisson's ratio mismatch. A lower Poisson's ratio mismatch results in a higher laminate efficiency. For example, it is desirable for the Poisson's ratio of each ply to be 0.34. This value is selected so that the ply does not overextend, reducing the likelihood of premature delamination or failure. A Poisson's ratio less than 0.34 can reduce or eliminate problems such as delamination or peeling. As the Poisson's ratio decreases, the mechanical residual stress in the composite part also decreases.

[0106] In this illustrative example, graphical indicator 508 identifies the recommended percentage envelopes for use in composite parts. In this illustrative example, graphical indicator 508 recommends the following ply percentage envelopes: 35 / 50 / 15; 37 / 45 / 18; and 40 / 40 / 20. Using these ply percentage envelopes, the percentages are arranged in the following order: 0-degree ply; + / -45-degree ply; and 90-degree ply.

[0107] Now refer Figure 6 , an illustration of the results displayed in a graphical user interface is depicted according to an illustrative embodiment. In this figure, graphical user interface 600 is an example of one implementation of graphical user interface 206 for displaying results 210 in Figure 2 .

[0108] As shown, line graph 602 shows the relationship between laminate strength and warpage. In this example, the x-axis 601 represents the ply percentage envelope, and the y-axis 603 represents the ratio of warpage to laminate efficiency.

[0109] In line graph 602, line 604 represents the normalized warpage. The warpage can be normalized by using the ply percentage envelope with the lowest amount of warpage.

[0110] Line 606 represents the laminate efficiency. In this example, since the load is placed along the ply, the defect of the composite part with a ply having a 0-degree orientation is 1.0. Compared to the 0-degree ply, other plies (such as + / -45 degrees and 90 degrees) have a lower level of efficiency.

[0111] As shown, the graphical indicator 608 identifies the recommended percentage envelopes for the plies. In this illustrative example, the graphical indicator 608 identifies the following percentage envelopes for the plies: 35 / 50 / 15; 37 / 45 / 18; and 40 / 40 / 20. Using these percentage envelopes for the plies, the percentages are arranged in the following order: 0-degree plies; + / -45-degree plies; and 90-degree plies.

[0112] For how it is possible to implement Figure 2 an example of the graphical user interface 206 shown in block diagram form in Figures 3 to 6 a graphical illustration of the graphical user interface in

[0113] is provided. For example, other types of graphical displays can use other types of charts. For example, in addition to or instead of the charts depicted in these figures, scatter plots, waterfall charts, area charts, or other types of graphs or charts can be used. As another example, the graphical indicator can include at least one of an animation, text, an icon, an image, or other suitable types of graphical indicators that can draw an operator's attention to a particular percentage of plies or other information displayed in the graphical user interface.

[0114] Next, turning to Figure 7 an illustration of a flowchart of a process for managing composite parts is depicted according to an illustrative embodiment. Figure 7 The process in Figure 1 can be implemented in hardware, software, or both. When implemented in software, the process can take the form of program code run by one of a plurality of processor units in one or more hardware devices located in one or more computer systems. For example, the process can be implemented in the

[0115] part manager 111 in the computer system 112 of

[0116] The process selects an orientation in a stack sequence for a ply in a composite part, the orientation resulting in the composite part having an acceptable level of warpage and a desired strength, to form a selected orientation (operation 702). The process then terminates. The composite part can be manufactured using the selected orientation.

[0117] Next, referring to Figure 8 , a diagram of a flowchart of a process for selecting an orientation of a ply in a composite part is shown according to an illustrative embodiment. Figure 8 The process in Figure 7 is an example of one way that operation 702 in

[0118] The process begins by selecting a candidate orientation in a stack sequence for the ply (operation 800). The process performs a stress analysis on the composite part using the candidate orientation in the stack sequence of the ply (operation 802). When the stress analysis indicates that the composite part has a strength that meets the desired strength of the composite part, the process uses the candidate orientation in the stack sequence as the selected orientation (operation 804). The process then terminates.

[0119] Next, referring to Figure 9 , a diagram of a flowchart of a process for selecting an orientation of a ply in a composite part is shown according to an illustrative embodiment. Figure 9 The process in Figure 7 is an example of one way that operation 702 in

[0120] The process begins by selecting a candidate orientation in a stack sequence for the ply (operation 900). Operation 900 can be performed by receiving user input that selects the candidate orientation. For example, user input to a graphical user interface can be received, the user input selecting one of multiple sets of candidate orientations displayed on the graphical user interface. The multiple sets of candidate orientations can be ply percentage envelopes. Each ply percentage envelope is a set of candidate orientations.

[0121] The process performs a stress analysis on the composite part using the candidate orientation in the stack sequence of the ply (operation 902). The process determines whether the composite part with the candidate orientation has a strength that meets the desired strength of the composite part based on the results of the stress analysis (operation 904).

[0122] If the stress analysis indicates that the strength of the composite part with the candidate orientation meets the desired strength of the composite part, the process uses the candidate orientation in the stack sequence as the selected orientation (operation 906). The process then terminates.

[0123] Referring again to operation 904, if the stress analysis indicates that the strength of the composite part with the candidate orientation does not meet the desired strength of the composite part, the process selects a new orientation for the candidate orientation in the stacking sequence (operation 908). The process returns to operation 902 to perform a stress analysis on the composite part using the candidate orientation in the stacking sequence of the plies.

[0124] Go to Figure 10 , an illustration of a flowchart of a process for displaying the results of the orientation from the analyzed plies is depicted according to an illustrative embodiment. Figure 11 The process in can be implemented using hardware, software, or both. When implemented in software, the process can take the form of program code run by one of a plurality of processor units in one or more hardware devices located in one or more computer systems.

[0125] For example, the process can be implemented in Figure 1 the part manager 111 in the computer system 112 in. More specifically, the process can be implemented in the composite part designer 110 to display the results 210 in the graphical user interface 206 on the display system 202 in Figure 2 .

[0126] The process begins by identifying a composite part design that includes candidate orientations of plies for forming the composite part in a stacking sequence (operation 1000). The process runs a stress analysis using the composite part design (operation 1002).

[0127] The process receives the results from the stress analysis (operation 1004). In this illustrative example, the results can include information selected from at least one of the following: warp level, strength, orientation ratio, orientation percentage, multiple sets of candidate orientations, or a graphical indicator identifying the best set of candidate orientations or the range of multiple sets of candidate orientations.

[0128] The process displays the results in a graphical user interface in the display system (operation 1006). The process also displays the candidate orientations in the stacking sequence (operation 1008).

[0129] Determine whether a user input to accept the candidate orientation is received (operation 1010). If a user input is received to accept the candidate orientation, the candidate orientation is used as the selected orientation in the stacking sequence in the composite part design (operation 1012). The process then terminates.

[0130] Referring again to operation 1010, if a user input to accept the candidate orientation is not received, the process receives a user input selecting a new orientation as the candidate orientation (operation 1014). The process then returns to operation 1002.

[0131] Go to Figure 11, A diagram showing a flowchart of a process for manufacturing a composite part according to an illustrative embodiment. Figure 11 The process in Figure 1 can be implemented using hardware, software, or both. When implemented in software, the process can take the form of program code run by one or more processor units in one or more hardware devices located in one or more computer systems. For example, the process can be implemented in

[0132] the part manager 111 in the computer system 112 of

[0133] The management of composite parts includes at least one of designing composite parts, manufacturing composite parts, or both designing and manufacturing composite parts.

[0134] The flowcharts and block diagrams in the depicted different embodiments illustrate the architecture, functionality, and operation of some possible implementations of the apparatus and method in the illustrative embodiments. In this regard, each block in the flowchart or block diagram can represent at least one of a module, segment, function, or operation or part of a step. For example, one or more blocks can be implemented as program code, hardware, or a combination of program code and hardware. When implemented in hardware, the hardware can, for example, take the form of an integrated circuit that is manufactured or configured to perform one or more operations in the flowchart or block diagram. When implemented as a combination of program code and hardware, the implementation can take the form of firmware. Each block in the flowchart or block diagram can be implemented using a dedicated hardware system for performing different operations or a combination of dedicated hardware and program code run by the dedicated hardware.

[0135] In some alternative implementations of the illustrative embodiments, one or more of the functions labeled in the blocks may not occur in the order labeled in the figures. For example, in some cases, depending on the functions involved, two consecutively shown blocks can be executed substantially simultaneously, or sometimes the blocks can be executed in the reverse order. Additionally, other blocks can be added in addition to the blocks shown in the flowchart or block diagram.

[0136] Now turning to Figure 12, A diagram showing a block diagram of a data processing system according to an illustrative embodiment. The data processing system 1200 can be used to implement one or more data processing systems in the computer system 112 in Figure 1 In this illustrative example, the data processing system 1200 includes a communication framework 1202 that provides communication between a processor unit 1204, a memory 1206, a persistent storage device 1208, a communication unit 1210, an input / output (I / O) unit 1212, and a display 1214. In this example, the communication framework 1202 takes the form of a bus system.

[0137] The processor unit 1204 is configured to execute instructions of software that can be loaded into the memory 1206. The processor unit 1204 includes one or more processors. For example, the processor unit 1204 can be selected from at least one of a multi-core processor, a central processing unit (CPU), a graphics processing unit (GPU), a physics processing unit (PPU), a digital signal processor (DSP), a network processor, or some other suitable type of processor.

[0138] The memory 1206 and the persistent storage device 1208 are examples of storage devices 1216. A storage device is any hardware that can store at least one of, for example but not limited to, data, program code in functional form, or other suitable information, whether temporary, permanent, or both temporary and permanent. In these illustrative examples, the storage device 1216 can also be referred to as a computer-readable storage device. In these examples, the memory 1206 can be, for example, a random access memory or any other suitable volatile or non-volatile storage device. Depending on the particular implementation, the persistent storage device 1208 can take various forms.

[0139] For example, the persistent storage device 1208 can include one or more components or devices. For example, the persistent storage device 1208 can be a hard disk drive, a solid state drive (SSD), a flash memory, a rewritable optical disc, a rewritable magnetic tape, or some combination of the above. The medium used by the persistent storage device 1208 can also be removable. For example, a removable hard disk drive can be used for the persistent storage device 1208.

[0140] In these illustrative examples, the communication unit 1210 provides communication with other data processing systems or devices. In these illustrative examples, the communication unit 1210 is a network interface card.

[0141] The input / output unit 1212 allows for the input and output of data with other devices that may be connected to the data processing system 1200. For example, the input / output unit 1212 can provide a connection for user input through at least one of a keyboard, a mouse, or other suitable input devices. Additionally, the input / output unit 1212 can send output to a printer. The display 1214 provides a mechanism for displaying information to the user.

[0142] Instructions for at least one of an operating system, an application, or a program can be located in the storage device 1216, which communicates with the processor unit 1204 through the communication framework 1202. Processes of different embodiments can be executed by the processor unit 1204 using computer-implemented instructions located in a memory such as the memory 1206.

[0143] These instructions are referred to as program code, computer-usable program code, or computer-readable program code that can be read and executed by a processor in the processor unit 1204. The program code in different embodiments can be embodied on different physical or computer-readable storage media such as the memory 1206 or the persistent storage device 1208.

[0144] The program code 1218 is in functional form on a computer-readable medium 1220 that can be selectively removable and can be loaded onto or transmitted to the data processing system 1200 for execution by the processor unit 1204. In these illustrative examples, the program code 1218 and the computer-readable medium 1220 form a computer program product 1222. In the illustrative example, the computer-readable medium 1220 is a computer-readable storage medium 1224.

[0145] In these illustrative examples, the computer-readable storage medium 1224 is a physical or tangible storage device for storing the program code 1218, rather than a medium that propagates or transmits the program code 1218.

[0146] Alternatively, the program code 1218 can be transmitted to the data processing system 1200 using a computer-readable signal medium. The computer-readable signal medium can be, for example, a propagated data signal that contains the program code 1218. For example, the computer-readable signal medium can be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals can be transmitted over a connection such as a wireless connection, a fiber optic cable, a coaxial cable, a wire, or any other suitable type of connection.

[0147] The different components shown for data processing system 1200 do not imply architectural limitations on the manner in which different embodiments may be implemented. In some illustrative examples, one or more components may be incorporated into another component or otherwise form a part of another component. For example, in some illustrative examples, memory 1206 or portions thereof may be incorporated into processor unit 1204. Different illustrative embodiments may be implemented in a data processing system that includes components in addition to, or in place of, those shown for data processing system 1200. Figure 12 The other components shown may be different from the illustrative examples shown. Different embodiments may be implemented using any hardware device or system capable of running program code 1218.

[0148] In the case of Figure 13 aircraft manufacturing and maintenance method 1300 as shown and Figure 14 aircraft 1400 as shown, illustrative embodiments of the present disclosure are described. First, turning to Figure 13 , a diagram of an aircraft manufacturing and maintenance method is described according to an illustrative embodiment. During pre-production, aircraft manufacturing and maintenance method 1300 may include Figure 14 specification and design 1302 of aircraft 1400 in

[0149] and material procurement 1304. Figure 14 During production, component and sub-component manufacturing 1306 of aircraft 1400 in Figure 14 and system integration 1308 are performed. Thereafter, Figure 14 aircraft 1400 in

[0150] may be certified and delivered 1310 for use 1312. While in use 1312 by a customer,

[0151] aircraft 1400 in Figure 14 is scheduled for routine maintenance and service 1314, which may include modification, reconfiguration, refurbishment, and other maintenance or service. Figure 13The aircraft manufacturing and maintenance method 1300 is produced, and may include a fuselage 1402 and an interior 1406 having a plurality of systems 1404. Examples of the systems 1404 include one or more of a propulsion system 1408, an electrical system 1410, a hydraulic system 1412, and an environmental system 1414. Any number of other systems may be included. Although an aviation example is shown, different illustrative embodiments may be applied to other industries such as the automotive industry.

[0152] In Figure 13 At least one stage of the aircraft manufacturing and maintenance method 1300 may employ the devices and methods embodied herein.

[0153] In one illustrative example, similar to Figure 13 The way of producing components or subassemblies when the aircraft 1400 in Figure 13 is put into use 1312 to fabricate or manufacture the components or subassemblies produced in the component and subassembly manufacturing 1306 of Figure 13 One or more device embodiments, method embodiments, or combinations thereof may be utilized in production stages such as Figure 13 the component and subassembly manufacturing 1306 and system integration 1308 in

[0154] One or more device embodiments, method embodiments, or combinations thereof may be utilized during maintenance and service 1314 in

[0155] when the aircraft 1400 is put into use 1312, or both. Using multiple different illustrative embodiments can sufficiently speed up the assembly of the aircraft 1400, reduce the cost of the aircraft 1400, or both speed up the assembly of the aircraft 1400 and reduce the cost of the aircraft 1400.

[0156] Now turning to Figure 15 , an illustration of a block diagram of a product management system is depicted according to an illustrative embodiment. The product management system 1500 is a physical hardware system. In this illustrative example, the product management system 1500 includes at least one of a manufacturing system 1502 or a maintenance system 1504.

[0157] Manufacturing system 1502 is configured to manufacture products such as Figure 14 the aircraft 1400 in. As shown, manufacturing system 1502 includes manufacturing equipment 1506. Manufacturing equipment 1506 includes at least one of manufacturing equipment 1508 or assembly equipment 1510.

[0158] Manufacturing equipment 1508 is equipment for manufacturing Figure 14 components of parts used to form the aircraft 1400 in. For example, manufacturing equipment 1508 may include machines and tools. These machines and tools may be at least one of a drill, a hydraulic press, a furnace, a mold, a composite tape laying machine, a vacuum system, a lathe, or other suitable types of equipment. Manufacturing equipment 1508 may be used to manufacture at least one of metal parts, composite parts, semiconductors, circuits, fasteners, ribs, skin panels, spars, antennas, or other suitable types of parts.

[0159] Assembly equipment 1510 is equipment for assembling parts to form Figure 14 the aircraft 1400 in. Specifically, assembly equipment 1510 is used to assemble components and parts to form Figure 14 the aircraft 1400 in. Assembly equipment 1510 may also include machines and tools. These machines and tools may be at least one of a robotic arm, a track, a quick installation system, an orbital-based drilling system, or a robot. Assembly equipment 1510 can be used to assemble parts such as seats, horizontal stabilizers, wings, engines, engine casings, landing gear systems, and Figure 14 other parts of the aircraft 1400 in.

[0160] In this illustrative example, maintenance system 1504 includes maintenance equipment 1512. Maintenance equipment 1512 may include any equipment required to perform maintenance on the Figure 14 aircraft 1400. Maintenance equipment 1512 may include tools for performing different operations on parts on the Figure 14 aircraft 1400. These operations may include at least one of disassembling parts, refurbishing parts, inspecting parts, reworking parts, manufacturing replacement parts, or other operations for performing maintenance on the Figure 14 aircraft 1400. These operations may be used for routine maintenance, inspection, upgrade, refurbishment, or other types of maintenance operations.

[0161] In the illustrative example, maintenance equipment 1512 may include ultrasonic inspection equipment, X-ray imaging systems, vision systems, drills, tracks, and other suitable equipment. In some cases, maintenance equipment 1512 may include manufacturing equipment 1508, assembly equipment 1510, or both, to produce and assemble parts required for maintenance.

[0162] The product management system 1500 also includes a control system 1514. The control system 1514 is a hardware system and may also include software or other types of components. The control system 1514 is configured to control the operation of at least one of the manufacturing system 1502 or the maintenance system 1504. Specifically, the control system 1514 may control the operation of at least one of the manufacturing equipment 1508, the assembly equipment 1510, or the maintenance equipment 1512.

[0163] In this illustrative example, the control system 1514 may include Figure 1 a controller 140 therein. In this illustrative example, the controller 140 may receive a composite part design 150 from the composite part designer 110 and control the operation of the manufacturing equipment 1508 to manufacture the composite part 102. In this illustrative example, the manufacturing equipment 1508 may include a laminate layup system 144 and a curing system 148.

[0164] The hardware in the control system 1514 may be implemented using hardware that may include computers, circuits, networks, and other types of equipment. The control may take the form of directly controlling the manufacturing equipment 1506. For example, robots, computer-controlled machines, and other equipment may be controlled by the control system 1514. In other illustrative examples, the control system 1514 may manage the operations performed by the operator 1516 during the manufacture or performance of maintenance of the aircraft 1400. For example, the control system 1514 may assign tasks, provide instructions, display models, or perform other operations to manage the operations performed by the operator 1516. As depicted in these illustrative examples, the controller 140 that may be implemented in the control system 1514 may be used to manage Figure 1 at least one of the manufacture or maintenance of the aircraft 1400 in Figure 14 therein.

[0165] In different illustrative examples, the operator 1516 may operate or interact with at least one of the manufacturing equipment 1506, the maintenance equipment 1512, or the control system 1514. Such interaction may occur to manufacture Figure 14 the aircraft 1400 in

[0166] Of course, the product management system 1500 may be configured to manage Figure 14 products other than the aircraft 1400 in

[0167] Accordingly, the illustrative embodiments provide a method, an apparatus, and a system for managing composite parts. Identify an acceptable level of warpage of the composite part. Warpage of the composite part is a variation in the manufactured composite part that deviates from the design specifications of the composite part. Select an orientation in a stacking sequence for the plies in the composite part to form a selected orientation in the stacking sequence such that manufacturing the composite part using the selected orientation in the stacking sequence results in the composite part having the acceptable level of warpage and the desired strength.

[0168] In the illustrative example, one or more technical solutions are proposed, which overcome the technical problem of manufacturing a composite part with dimensions deviating from the specifications of the composite part. Specifically, in the illustrative example, there is one or more technical solutions that reduce the number of shims installed in an object such as an aircraft. As a result, in the illustrative example, one or more technical solutions can provide the technical effect of reducing the gap between assembled composite parts. In the illustrative example, using composite parts with gaps that require fewer shims can reduce the number of shims manufactured and installed.

[0169] The descriptions of the different illustrative embodiments have been presented for purposes of illustration and description, and are not intended to be exhaustive or to limit the embodiments to the disclosed forms. The different illustrative examples describe components that perform actions or operations. In the illustrative embodiments, the components can be configured to perform the described actions or operations. For example, a component can have a configuration or design for a structure that provides the component with the ability to perform the actions or operations described in the exemplary example as being performed by the component.

[0170] In addition, the present disclosure includes embodiments according to the following clauses:

[0171] Clause 1. A method for managing a composite part (104), the method comprising:

[0172] Identifying an acceptable level (114) of warpage (116) of the composite part (104), wherein the warpage (116) of the composite part (104) is a variation in the manufactured composite part (104) that deviates from the design specifications (119) of the composite part (104); and

[0173] Selecting an orientation (118) in a stacking sequence (120) for plies (122) in the composite part (104) to form a selected orientation (126) in the stacking sequence (120) such that manufacturing the composite part (104) using the selected orientation (126) in the stacking sequence (120) results in the composite part (104) having the acceptable level (114) of warpage (116) and the desired strength (124).

[0174] Clause 2. The method according to Clause 1, wherein selecting the orientation (118) of the ply (122) in the composite part (104) in the stacking sequence (120) to form the selected orientation (126) in the stacking sequence (120) such that manufacturing the composite part (104) using the selected orientation (126) in the stacking sequence (120) results in the composite part (104) having the acceptable level (114) of warpage (116) and the desired strength (124) includes:

[0175] Selecting a candidate orientation (128) of the ply (122) in the stacking sequence (120);

[0176] Performing a stress analysis (130) on the composite part (104) using the candidate orientation (128) of the ply (122) in the stacking sequence (120); and

[0177] When the stress analysis (130) indicates that the composite part (104) has the desired strength (124) of the composite part (104), using the candidate orientation (128) in the stacking sequence (120) as the selected orientation (126).

[0178] Clause 3. The method according to Clause 2, wherein selecting the orientation (118) of the ply (122) in the composite part (104) in the stacking sequence (120) to form the selected orientation (126) in the stacking sequence (120) such that manufacturing the composite part (104) using the selected orientation (126) in the stacking sequence (120) results in the composite part (104) having the acceptable level (114) of the warpage (116) and the desired strength (124) further includes:

[0179] When the stress analysis (130) on the composite part (104) with the candidate orientation (128) indicates that the composite part (104) does not have the desired strength (124), selecting a new orientation (132) as the candidate orientation (128) in the stacking sequence (120);

[0180] Performing the stress analysis (130) on the composite part (104) using the candidate orientation (128) of the ply (122) in the stacking sequence (120); and

[0181] Repeat the selection of the new orientation (132) and perform the stress analysis (130) on the composite part (104) using the candidate orientation (128) of the ply (122) in the stacking sequence (120) until the desired strength (124) exists in the composite part (104).

[0182] Clause 4. The method according to clause 2, wherein the stress analysis (130) includes a simulation of a set of structural loads (222) applied to the composite part (104).

[0183] Clause 5. The method according to clause 2, wherein selecting the candidate orientation (128) of the ply (122) in the stacking sequence (120) includes:

[0184] Receiving user input (208) made to a graphical user interface (206) in a display system (202), wherein the user input (208) selects multiple sets of the candidate orientations (128) displayed on the graphical user interface (206).

[0185] Clause 6. The method according to any of the preceding clauses, further comprising:

[0186] Manufacturing the composite part (104) in a product management system using the selected orientation (126).

[0187] Clause 7. The method according to any of the preceding clauses, further comprising:

[0188] Controlling a ply laying system (144) to lay the ply (122) of the composite part (104) using the selected orientation (126) to form a composite layup (146); and

[0189] Curing the composite layup (146) to form the composite part (104).

[0190] Clause 8. The method according to any of the preceding clauses, wherein the selected orientation (126) includes 90-degree plies (122), +45-degree plies (122), -45-degree plies (122), and 0-degree plies (122).

[0191] Clause 9. The method according to any of the preceding clauses, wherein the selected orientation (126) includes at least 10% of the plies (122) having a 90-degree orientation.

[0192] Clause 10. The method according to any of the preceding clauses, wherein the selected orientation (126) includes at least 12.5% to 20% of the plies (122) having a 90-degree orientation.

[0193] Clause 11. The method according to any one of the preceding clauses, wherein the selected orientation (126) comprises 40% to 50% of the plies (122) having a 45-degree orientation.

[0194] Clause 12. The method according to any one of the preceding clauses, wherein the composite part (104) is a skin panel, a fairing, an engine case, a stringer, a door, a wing, and a panel.

[0195] Clause 13. A composite part system (115) comprising:

[0196] a computer system (112); and

[0197] a composite part designer (110) in the computer system (112), wherein the composite part designer (110) is configured to:

[0198] identify warpage (116) at an acceptable level (114) of the composite part (104), wherein the warpage (116) is a variation from the design specification (119) of the manufactured composite part (104); and

[0199] select an orientation (118) for the plies (122) in the composite part (104) in a stack sequence (120) to form a selected orientation (126) in the stack sequence (120) such that manufacturing the composite part (104) using the selected orientation (126) in the stack sequence (120) results in the composite part (104) having the warpage (116) at the acceptable level (114) and a desired strength (124).

[0200] Clause 14. The composite part system (115) according to Clause 13, wherein, to form the selected orientation (126) in the stack sequence (120) by selecting the orientation (118) for the plies (122) in the composite part (104) in the stack sequence (120) such that manufacturing the composite part (104) using the selected orientation (126) in the stack sequence (120) results in the composite part (104) having the warpage (116) at the acceptable level (114) and the desired strength (124), the composite part designer (110) is configured to:

[0201] select candidate orientations (128) for the plies (122) in the stack sequence (120);

[0202] Perform a stress analysis (130) on the composite part (104) using the candidate orientation (128) of the ply (122) in the stack sequence (120); and

[0203] When the stress analysis (130) indicates that the composite part (104) has the desired strength (124) of the composite part (104), use the candidate orientation (128) in the stack sequence (120) as the selected orientation (126).

[0204] Clause 15. The composite part system (115) according to Clause 14, wherein the orientation (118) in the stack sequence (120) is selected for the ply (122) in the composite part (104) to form the selected orientation (126) in the stack sequence (120), such that manufacturing the composite part (104) using the selected orientation (126) in the stack sequence (120) results in the composite part (104) having warpage (116) at the acceptable level (114) and the desired strength (124), and the composite part (104) designer is further configured to:

[0205] When the stress analysis (130) on the composite part (104) with the candidate orientation (128) indicates that the composite part (104) does not have the desired strength (124), select a new orientation (132) in the stack sequence (120);

[0206] Perform the stress analysis (130) on the composite part (104) using the new orientation (128) of the ply (122) in the stack sequence (120); and

[0207] Repeat selecting the new orientation (132) as the candidate orientation (128) and performing the stress analysis (130) on the composite part (104) using the candidate orientation (128) of the ply (122) in the stack sequence (120) until the desired strength (124) exists in the composite part (104).

[0208] Clause 16. The composite part system (115) according to Clause 14, wherein the stress analysis (130) includes a simulation of a set of structural loads (222) applied to the composite part (104).

[0209] Clause 17. The composite part system (115) according to Clause 14, wherein a candidate orientation (128) is selected for the ply (122) in the stacking sequence (120), and the composite part (104) designer receives user input (208) made to the graphical user interface (206) in the display system (202), wherein the user input (208) selects multiple sets of the candidate orientations (128) displayed on the graphical user interface (206).

[0210] Clause 18. The composite part system (115) according to any one of Clauses 13-17, further comprising:

[0211] A controller (140) in the computer system (112), wherein the controller (140) is configured to control the manufacture of the composite part (104) in the product management system using the selected orientation (126).

[0212] Clause 19. The composite part system (115) according to any one of Clauses 13-18, further comprising:

[0213] The controller (140) in the computer system (112), wherein the controller (140) is configured to control the ply laying system (144) to lay the ply (122) of the composite part (104) using the selected orientation (126) to form a composite ply (146), and control the curing system (148) to cure the composite ply (146) so as to form the composite part (104).

[0214] Clause 20. The composite part system (115) according to any one of Clauses 13-19, wherein the selected orientation (126) includes 90-degree plies (122), +45-degree plies (122), -45-degree plies (122), and 0-degree plies (122).

[0215] Clause 21. The composite part system (115) according to any one of Clauses 13-20, wherein the selection includes at least 10% of the plies (122) having a 90-degree orientation.

[0216] Clause 22. The composite part system (115) according to any one of Clauses 13-21, wherein the selected orientation (126) includes at least 12.5% to 20% of the plies (122) having a 90-degree orientation.

[0217] Clause 23. The composite part system (115) according to any one of Clauses 13-22, wherein the selected orientation (126) includes 40% to 50% of the plies (122) having a 45-degree orientation.

[0218] Clause 24. The composite part system (115) according to any one of Clauses 13 - 23, wherein the composite part (104) is a skin panel, a fairing, an engine casing, a stringer, a door, a wing, and a panel.

[0219] Clause 25. A product management system (1500), comprising:

[0220] manufacturing equipment (1508); and

[0221] a controller (140) in communication with the manufacturing equipment (1508), wherein the controller (140) is configured to control the manufacturing equipment (1508) to manufacture the composite part (104) using the plies (122) in the composite part (104) having a selected orientation (126) in a stacking sequence (120), resulting in the composite part (104) having a warp (116) with an acceptable level (114) of warp (116) and a desired strength (124), wherein the warp (116) is a variation in the composite part (104) that deviates from the design specifications (119) of the composite part (104) during manufacturing.

[0222] Clause 26. The product management system according to Clause 25, further comprising:

[0223] a composite part designer (110), wherein the composite part designer (110) is configured to identify the acceptable level (114) of warp (116) of the composite part (104); and select an orientation (118) in the stacking sequence (120) to form the selected orientation (126) of the plies (122) in the composite part (104), such that manufacturing the composite part (104) using the selected orientation (126) in the stacking sequence (120) results in the composite part (104) having the acceptable level (114) of warp (116) and the desired strength (124).

[0224] Clause 27. The product management system according to any one of Clauses 25 - 26, wherein the manufacturing equipment (1508) comprises:

[0225] a ply laying system (144) that lays the plies (122) of the composite part (104) using the selected orientation (126) under the control of the controller (140) to form a composite layup (146); and

[0226] a curing system (148) that cures the composite layup (146) under the control of the controller (140) to form the composite part (104).

[0227] Numerous modifications and variations will be apparent to those of ordinary skill in the art. Additionally, different illustrative embodiments may provide different features compared to other desired embodiments. The selected one or more embodiments are chosen and described in order to best explain the principles of the embodiments, practical applications, and to enable others of ordinary skill in the art to understand the disclosure of the various embodiments with various modifications that are suitable for the particular uses contemplated.

Claims

1. A method for managing a composite part (104), the method comprising: Identifying warpage (116) at an acceptable level (114) of the composite part (104), wherein the warpage (116) of the composite part (104) is a variation in the manufactured composite part (104) that deviates from the design specifications (119) of the composite part (104); and Selecting an orientation (118) of plies (122) in a stacking sequence (120) for the composite part (104) to form a selected orientation (126) in the stacking sequence (120), such that manufacturing the composite part (104) using the selected orientation (126) in the stacking sequence (120) results in the composite part (104) having the warpage (116) at the acceptable level (114) and a desired strength (124), which includes: Selecting candidate orientations (128) in the stacking sequence (120) for the plies (122); Performing a stress analysis (130) on the composite part (104) using the candidate orientations (128) of the plies (122) in the stacking sequence (120); When the stress analysis (130) indicates that the composite part (104) has the desired strength (124) of the composite part (104), using the candidate orientation (128) in the stacking sequence (120) as the selected orientation (126); When the stress analysis (130) on the composite part (104) with the candidate orientation (128) indicates that the composite part (104) does not have the desired strength (124), selecting a new orientation (132) for the candidate orientation (128) in the stacking sequence (120); Performing the stress analysis (130) on the composite part (104) using the candidate orientations (128) of the plies (122) in the stacking sequence (120); and Repeating the selection of the new orientation (132) and performing the stress analysis (130) on the composite part (104) using the candidate orientations (128) of the plies (122) in the stacking sequence (120) until the desired strength (124) is present in the composite part (104).

2. The method according to claim 1, wherein the stress analysis (130) includes a simulation of a set of structural loads (222) applied to the composite part (104).

3. The method according to claim 1, wherein selecting the candidate orientations (128) in the stacking sequence (120) for the plies (122) includes: Receiving a user input (208) made to a graphical user interface (206) in a display system (202), wherein the user input (208) selects multiple sets of the candidate orientations (128) displayed on the graphical user interface (206).

4. The method according to any one of the preceding claims, further comprising: Manufacture the composite part (104) in a product management system using the selected orientation (126).

5. The method according to any one of claims 1 - 3, further comprising: Controlling a ply laying system (144) to lay the plies (122) of the composite part (104) using the selected orientation (126) to form a composite ply (146); and Curing the composite ply (146) to form the composite part (104).

6. The method according to any one of claims 1 - 3, wherein the selected orientation (126) includes 90 - degree plies (122), +45 - degree plies (122), - 45 - degree plies (122), and 0 - degree plies (122).

7. The method according to any one of claims 1 - 3, wherein the selected orientation (126) includes at least 10% of the plies (122) having a 90 - degree orientation.

8. The method according to any one of claims 1 - 3, wherein the selected orientation (126) includes at least 12.5% to 20% of the plies (122) having a 90 - degree orientation.

9. The method according to any one of claims 1 - 3, wherein the selected orientation (126) includes 40% to 50% of the plies (122) having a 45 - degree orientation.

10. The method according to any one of claims 1 - 3, wherein the composite part (104) is a skin panel, a fairing, an engine case, a stringer, a door, a wing, and a panel.

11. A composite part system (115), comprising: A computer system (112); And A composite part designer (110) in the computer system (112), wherein the composite part designer (110) is configured to perform the method according to any one of claims 1 to 10.

12. A product management system (1500), comprising: Manufacturing equipment (1508); And A controller (140) in communication with the manufacturing equipment (1508), wherein the controller (140) is configured to control the manufacturing equipment (1508) to manufacture the composite part (104) using a part design in which the plies (122) in the composite part (104) have a selected orientation (126) in a stacking sequence (120), which results in the composite part (104) having warpage (116) at an acceptable level (114) of the warpage (116) and a desired strength (124), wherein the warpage (116) is a variation in the composite part (104) that deviates from the design specification (119) of the composite part (104) during manufacture; And A composite part designer (110), wherein the composite part designer (110) is configured to perform the method according to any one of claims 1 to 10.

13. The product management system according to claim 12, wherein the composite part designer (110) is further configured to identify the warpage (116) of the acceptable level (114) of the composite part (104); and select an orientation (118) in the stacking sequence (120) to form the selected orientation (126) of the plies (122) in the composite part (104), such that manufacturing the composite part (104) using the selected orientation (126) in the stacking sequence (120) results in the composite part (104) having the warpage (116) of the acceptable level (114) and the desired strength (124).

Images