Composite lamination system and method

Abstract

The invention relates to a composite lamination system and method. A system and method for indexing an automated fiber placement tip toward a surface of a substrate is provided. The system comprises: a first measurement system comprising a first plurality of sensors configured to scan a surface of a substrate; a second measurement system including a second plurality of sensors configured to position an automated fiber placement tip; and a data management device configured to generate a full resolution transformation using measurements from the first measurement system and to determine a position of the automated fiber placement tip using data from the second measurement system.

Description

Technical Field

[0001] The present disclosure relates generally to manufacturing and, more particularly, to composite lamination. Background Art

[0002] In manufacturing composite structures, layers of composite material are typically laid up on a mandrel or other target. The layers may be laid up in the form of tapes, tows, or other suitable forms. In some cases, resin may be infused or pre-impregnated into the fiber layers. Composite materials pre-impregnated with resin are commonly referred to as prepregs.

[0003] Different prepreg layers may be laid up in different orientations, and different numbers of layers may be used depending on the thickness of the composite structure being manufactured. The layers may be laid up using automated lamination equipment such as a tape laminating machine or a fiber placement system.

[0004] Composite lamination involves some variations. These variations are mixed in the composite material layers. The variations can create overlaps, gaps or other inconsistencies in the composite part.

[0005] Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the issues discussed above, as well as other possible issues. Summary of the invention

[0006] Embodiments of the present disclosure provide a system for indexing an automated fiber placement head to a surface of a substrate. The system includes: a first measurement system including a first plurality of sensors configured to scan the surface of the substrate; a second measurement system including a second plurality of sensors configured to locate the automated fiber placement head; and a data management device configured to generate a full resolution transform using measurements from the first measurement system and to determine a position of the automated fiber placement head using data from the second measurement system.

[0007] Another embodiment of the present disclosure provides a method for performing composite lamination. An initial mandrel scan of a substrate is performed within a manufacturing environment using a first measurement system. A position of an automated fiber placement head within the manufacturing environment is determined using a second measurement system. Results from the initial mandrel scan are used to generate a full resolution transform. Based on the full resolution transform and the position, a layup on the substrate is initiated by the automated fiber placement head.

[0008] Another embodiment of the present disclosure provides a method for performing composite lamination. Scan a surface of a substrate using a first plurality of sensors to generate a first measurement result. Use a second plurality of sensors to position an automated fiber placement head. Based on the first measurement result, index the automated fiber placement head toward the substrate. After indexing the automated fiber placement head, use the automated fiber placement head to lay down a composite material on the surface of the substrate.

[0009] The features and functions can be achieved independently in various embodiments of the present disclosure 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

[0010] The novel features or credited characteristics of the exemplary embodiments are set forth in the appended claims. However, the exemplary embodiments, together with the preferred modes of use, further objects and features thereof, will be best understood by reference to the following detailed description of exemplary embodiments of the present disclosure when read in conjunction with the accompanying drawings, wherein:

[0011] Figure 1 is an illustration of an aircraft according to an exemplary embodiment;

[0012] Figure 2 is an example block diagram of a manufacturing environment according to an example embodiment;

[0013] Figure 3 is an example isometric view of a manufacturing environment according to an example embodiment;

[0014] Figure 4 is an illustrative diagram of a first measurement system and a second measurement system in a manufacturing environment according to an illustrative embodiment;

[0015] Figure 5 is a flow chart of a method of performing composite lamination according to an exemplary embodiment;

[0016] Figure 6 is a flow chart of a method of performing composite lamination according to an exemplary embodiment;

[0017] Figure 7 is an illustration of an aircraft manufacturing and service method in block diagram form according to an illustrative embodiment; and

[0018] Figure 8 is an illustration, in block diagram form, of an aircraft in which illustrative embodiments may be implemented. DETAILED DESCRIPTION

[0019] The illustrative examples recognize and take into account a number of considerations. For example, the illustrative examples recognize and take into account that probing is currently performed on a mandrel prior to laying down composite material. The illustrative examples recognize and take into account that probing may take more than an hour on a large part. The illustrative examples recognize and take into account that probing only provides data at probe points. The probe points have spacing between each point. In some examples, the distance between probe points is between four and eight feet. In some examples, there may be as many as 50 probe points for a large tool. Currently, linear interpolation (transformation) occurs between probe points.

[0020] The illustrative examples recognize and take into account that increasing the accuracy of composite layups will reduce defects. The illustrative examples provide systems and methods that will reduce or eliminate linear interpolation of a mandrel. The illustrative examples increase the accuracy of composite layups by increasing the measurement accuracy of a mandrel. The illustrative examples provide an accuracy of at least 0.010". The illustrative examples provide an accuracy of values ​​sufficient to reduce or prevent gaps and overlaps in composite material laid up on the radius of a mandrel.

[0021] Now go to Figure 1 , an illustrative diagram of an aircraft is depicted, according to an illustrative embodiment. Aircraft 100 has wing 102 and wing 104 attached to body 106. Aircraft 100 includes engine 108 attached to wing 102, and engine 110 attached to wing 104.

[0022] The body 106 has a tail section 112. Attached to the tail section 112 of the body 106 are a horizontal stabilizer 114, a horizontal stabilizer 116, and a vertical stabilizer 118.

[0023] Aircraft 100 is an example of an aircraft that may have a composite component laid up using the illustrative examples. Aircraft 100 is an example of an aircraft that has a wing spar, stiffener, or other composite component laid up using the illustrative example method. Aircraft 100 is an example of an aircraft that has a wing spar, stiffener, or other composite component laid up using the illustrative example system.

[0024] Now go to Figure 2 , according to an exemplary embodiment, depicts an exemplary block diagram of a manufacturing environment. A system 202 in a manufacturing environment 200 can be used to lay up (layup) Figure 1 A composite component of an aircraft 100 .

[0025] System 202 may be used for indexing 258 automated fiber placement head 230 toward surface 234 of substrate 232. System 202 includes: first measurement system 204, second measurement system 206, and data management device 207. First measurement system 204 includes a first plurality of sensors 210 configured to scan surface 234 of substrate 232. In some illustrative examples, first measurement system 204 may be referred to as first metrology system 208.

[0026] Second measurement system 206 includes second plurality of sensors 214 configured to locate automated fiber placement head 230. In some illustrative examples, second measurement system 206 may be referred to as second metrology system 212. Data management device 207 is configured to generate full resolution transform 276 using measurements 246 from first measurement system 204 and to determine position 250 of automated fiber placement head 230 using data from second measurement system 206.

[0027] Unlike conventional probing, full resolution transformation 276 has enough measurements 246 provided by first measurement system 204 so that no interpolation is performed. In some illustrative examples, first plurality of sensors 210 has an accuracy of less than or equal to 0.005 inches. In some illustrative examples, scanning of substrate 232 is performed at a frame rate with an accuracy of 0.010 inches.

[0028] In some illustrative examples, first plurality of sensors 210 includes one or more of the following: light detection and ranging (LIDAR) device array 218, special phase imaging sensor array 220, time of flight sensor array 222, stereo camera array 224, light field camera array 226, and high resolution camera array 228. In some illustrative examples, second plurality of sensors includes one or more of the following: light detection and ranging (LIDAR) device array 218, special phase imaging sensor array 220, time of flight sensor array 222, stereo camera array 224, light field camera array 226, and high resolution camera array 228.

[0029] Substrate 232 may take the form of mandrel 236 having layup surface 238 or composite layer 240 positioned on mandrel 236. When substrate 232 includes composite layer 240, first measurement system 204 scans surface 242 of composite layer 240. When substrate 232 is mandrel 236, first measurement system 204 scans layup surface 238 of mandrel 236. In some illustrative examples, composite layer 240 is a partial ply, and both surface 242 and exposed portions of layup surface 238 are scanned by first measurement system 204.

[0030] The first measurement system 204 performs an initial mandrel scan 256 on the substrate 232. After performing the initial mandrel scan 256, a full resolution transform 276 is performed using the measurements 246 from the initial mandrel scan 256.

[0031] Since the initial mandrel scan 256 takes less time than physically probing the mandrel 236, indexing 258 the automated fiber placement head 230 to the substrate 232 is performed using much less time 260 than conventional procedures. The time 260 for indexing 258 can be much less than indexing using probing.

[0032] In some illustrative examples, second measurement system 206 directly tracks automated fiber placement head 230 in manufacturing environment 200. In some illustrative examples, tracking target 252 is coupled to automated fiber placement head 230. In these illustrative examples, second plurality of sensors 214 is configured to track a position of tracking target 252. For example, tracking target 252 may be a reflector.

[0033] In some illustrative examples, substrate 232 is composite layer 240 on mandrel 236, and data management device 207 is configured to determine thickness 241 of composite layer 240 using measurements 246 from first plurality of sensors 210. Thickness 241 of composite layer 240 may be used to modify first layup plan 264 in these illustrative examples.

[0034] First layup plan 264 includes first tool path 266 and compactions 268. In some illustrative examples, at least one of first tool path 266 and compactions 268 may be modified based on thickness 241 of composite layer 240. By modifying first layup plan 264, accumulation of inconsistencies in the composite part may be reduced or prevented. By modifying first layup plan 264, additional inconsistencies in the composite part may be reduced.

[0035] In some illustrative examples, substrate 232 is composite ply 240 on mandrel 236, and data management device 207 is configured to form model 278 of composite ply 240 in near real-time in response to generation of measurements 246 by first measurement system 204. By forming model 278 in near real-time in response to generation of measurements 246, model 278 may be used for real-time monitoring 262. In some illustrative examples, model 278 of composite ply 240 is accurate 280 to within approximately 0.005 inches for composite ply 240. In some illustrative examples, future layup plan 270 is modified based on model 278.

[0036] In some illustrative examples, substrate 232 is mandrel 236, and data management device 207 is further configured to index automated fiber placement head 230 to mandrel 236 using full resolution transform 276 and position 250 of automated fiber placement head 230. In some illustrative examples, data 248 from second measurement system 206 has a higher accuracy than that of machine controller 254.

[0037] In some illustrative examples, first measurement system 204 is configured to perform both indexing 258 and real-time monitoring 262. In terms of real-time monitoring 262, measurements 246 may be taken of composite material 244 laid down as composite material 244 on substrate 232 by automated fiber placement head 230. In some illustrative examples, composite material 244 may be used to modify future layup plan 270.

[0038] Future layup plan 270 includes second tool path 272 and compaction 274. In some illustrative examples, at least one of second tool path 272 and compaction 274 may be modified based on the layup of composite material 244. By modifying future layup plan 270, accumulation of inconsistencies in the composite part may be reduced or prevented. By modifying future layup plan 270, additional inconsistencies in the composite part may be reduced.

[0039] In some illustrative examples, second measurement system 206 is configured to perform real-time monitoring 262. Real-time monitoring 262 of automated fiber placement head 230 may continuously track position 250 of automated fiber placement head 230. Real-time monitoring 262 of automated fiber placement head 230 may have a higher accuracy than tracking by machine controller 254 of automated fiber placement head 230.

[0040] In some illustrative examples, system 202 may be described as including plurality of sensors 216 configured to perform initial mandrel scan 256 and position automated fiber placement head 230. In these illustrative examples, first plurality of sensors 210 and second plurality of sensors 214 are sensors within sensors 216.

[0041] Figure 2 The illustrated manufacturing environment 200 is not meant to imply physical or structural limitations on the manner in which the illustrative embodiments may be implemented. Other components may be used in addition to or in place of the illustrated components. Some components may be unnecessary. Moreover, the blocks are presented to illustrate some functional components. When implemented in the illustrative embodiments, one or more of the blocks in these blocks may be combined, divided, or combined and divided into different blocks.

[0042] In some illustrative examples, multiple successive layers of composite material may be laid up on mandrel 236. In some illustrative examples, there are additional layup plans for laying up additional layers of composite material on mandrel 236.

[0043] Now go to Figure 3 , according to an exemplary embodiment, depicts an exemplary isometric view of a manufacturing environment. The manufacturing environment 300 is Figure 2 Various parts of aircraft 100 may be manufactured in manufacturing environment 300 .

[0044] Automated fiber placement head 302 is present in manufacturing environment 300. Automated fiber placement head 302 is configured to place composite material on a substrate, such as substrate 304. In this illustrative example, substrate 304 takes the form of mandrel 306.

[0045] A first measurement system 308 and a second measurement system 310 are present in the manufacturing environment 300. The first measurement system 308 and the second measurement system 310 can be used to improve the accuracy of the composite layup on the substrate 304. The first measurement system 308 can be used to index the automated fiber placement head 302 to the mandrel 306. The first measurement system 308 can be used to monitor the composite material being laid down on the mandrel 306 in real time.

[0046] Second measurement system 310 is configured to determine the position of automated fiber placement head 302. Second measurement system 310 may be used to index automated fiber placement head 302 to mandrel 306 prior to laying down the composite material. In some illustrative examples, second measurement system 310 may be used for real-time monitoring of automated fiber placement head 302.

[0047] The first measurement system 308 includes a first plurality of sensors 312 configured to scan the surface of the substrate 304. The first plurality of sensors 312 include one or more of the following: an array of light detection and ranging (LIDAR) devices, an array of special phase imaging sensors, an array of time-of-flight sensors, an array of stereo cameras, an array of light field cameras, or an array of high-resolution cameras. The second measurement system 310 includes a second plurality of sensors 314 configured to locate the automated fiber placement head 302. The second plurality of sensors 314 include one or more of the following: an array of light detection and ranging (LIDAR) devices, an array of special phase imaging sensors, an array of time-of-flight sensors, an array of stereo cameras, an array of light field cameras, or an array of high-resolution cameras.

[0048] Now go to Figure 4 , an illustrative diagram of a first measurement system and a second measurement system in a manufacturing environment is depicted, according to an exemplary embodiment. In view 400, a first plurality of sensors 312 of a first measurement system 308 and a second plurality of sensors 314 of a second measurement system 310 are depicted from a longitudinal direction of a mandrel 306. As can be seen in view 400, the first plurality of sensors 312 and the second plurality of sensors 314 are deployed along the length of a substrate 304. By deploying the first plurality of sensors 312 along the length of the substrate 304, the entire substrate 304 can be scanned. By deploying the first plurality of sensors 312 along the length of the substrate 304, the accuracy of indexing is greater than detecting and performing interpolation as discrete positions.

[0049] By deploying the second plurality of sensors 314 along the length of the substrate 304, the automated fiber placement head 302 can be located at any processing location within the manufacturing environment 300. By deploying the second plurality of sensors 314 along the length of the substrate 304, the second plurality of sensors 314 can be used for initial indexing as well as real-time monitoring of the automated fiber placement head 302 along the length of the substrate 304.

[0050] As can be seen in view 400, first plurality of sensors 312 and second plurality of sensors 314 can be deployed on both sides of substrate 304. In view 400, first plurality of sensors 312 and second plurality of sensors 314 are deployed on sidewall 402 and sidewall 404. As depicted, substrate 304 is positioned between sidewall 402 and sidewall 404, and automated fiber placement head 302 is moved between sidewall 402 and sidewall 404 to layup composite material on substrate 304.

[0051] Although first plurality of sensors 312 and second plurality of sensors 314 are depicted as being mounted directly to sidewall 402 and sidewall 404, first plurality of sensors 312 and second plurality of sensors 314 may be mounted in other ways. In some illustrative examples, at least one sensor of at least one of first plurality of sensors 312 and second plurality of sensors 314 may be mounted to a bracket between sidewall 402 and sidewall 404.

[0052] Now go to Figure 5 , according to an exemplary embodiment, a flow chart of a method for performing composite lamination is depicted. The method 500 can be used to lay Figure 1 Composite components of aircraft 100. Figure 2 Method 500 can be implemented in system 202 in manufacturing environment 200. Figure 3 and Figure 4 Method 500 is implemented using first measurement system 308 and second measurement system 310 in manufacturing environment 300 of the present invention.

[0053] The method 500 uses a first measurement system to perform an initial mandrel scan of a substrate within a manufacturing environment (operation 502). The method 500 uses a second measurement system to determine a position of an automated fiber placement head within the manufacturing environment (operation 504). The method 500 uses the results from the initial mandrel scan to generate a full resolution transform (operation 506). The method 500 initiates a layup on the substrate by the automated fiber placement head based on the full resolution transform and the position (operation 508). Thereafter, the method 500 terminates.

[0054] In some illustrative examples, method 500 includes moving a mandrel into a manufacturing environment having an automated fiber placement head (operation 510). In some illustrative examples, performing an initial mandrel scan includes scanning a surface of the mandrel.

[0055] In some illustrative examples, performing an initial mandrel scan includes scanning composite plies present on the mandrel (operation 512). In some illustrative examples, performing an initial mandrel scan includes determining a thickness of the composite plies present on the mandrel.

[0056] In some illustrative examples, method 500 uses a second measurement system to monitor the position of the automated fiber placement head during layup (operation 514). In some illustrative examples, method 500 adjusts the position of the automated fiber placement head during layup based on the monitoring by the second measurement system (operation 516).

[0057] In some illustrative examples, method 500 scans the composite material laid down by the automated fiber placement head by the first measurement system while the automated fiber placement head performs the layup (operation 518). In some illustrative examples, by scanning the composite material laid down by the automated fiber placement head during layup, any inconsistencies of the composite material can be checked. In some illustrative examples, by scanning the composite material laid down by the automated fiber placement head during layup, future separate indexing steps can be reduced or eliminated. In some illustrative examples, by scanning the composite material laid down by the automated fiber placement head during layup, data of the substrate surface including the composite material is obtained during processing to reduce downtime.

[0058] In some illustrative examples, method 500 modifies a future layup plan based on a scan of the composite material laid by the automated fiber placement head (operation 520). For example, the future layup plan may be a plan for laying subsequent composite materials. Future tool paths for laying subsequent composite materials may be modified to account for the physical layup of the composite material. In these illustrative examples, by accounting for the location and size of the laid composite material, accumulation of inconsistent thickness of the composite layup may be reduced.

[0059] In some illustrative examples, performing the initial mandrel scan includes scanning the substrate using at least one of a light detection and ranging (LIDAR) device array, a special stage imaging sensor array, a time of flight sensor array, a stereo camera array, a light field camera array, or a high resolution camera array (operation 522). In some illustrative examples, the first measurement system accuracy is less than or equal to 0.005 inches, and wherein the initial mandrel scan is performed at a frame rate with an accuracy of 0.010 inches (operation 524).

[0060] Now go to Figure 6 , according to an exemplary embodiment, a flow chart of a method for performing composite lamination is depicted. The method 600 can be used to lay Figure 1 Composite components of aircraft 100. Figure 2 Method 600 can be implemented in system 202 in manufacturing environment 200. Figure 3 and Figure 4 Method 600 is implemented using first measurement system 308 and second measurement system 310 in manufacturing environment 300 of the present invention.

[0061] The method 600 uses a first plurality of sensors to scan a surface of a substrate to generate a first measurement result (operation 602). The method 600 uses a second plurality of sensors to position an automated fiber placement head (operation 604). The method 600 indexes the automated fiber placement head toward the substrate based on the first measurement result (operation 606). After indexing the automated fiber placement head, the method 600 uses the automated fiber placement head to lay down a composite material on the surface of the substrate (operation 608). Thereafter, the method 600 terminates.

[0062] In some illustrative examples, method 600 calculates a full-resolution transform that is used to move an automated fiber placement head to provide substantial design conformity between the first measurement and a layup plan of the automated fiber placement head (operation 610). In some illustrative examples, method 600 moves the automated fiber placement head according to the full-resolution transform (operation 612). In some illustrative examples, method 600 includes using the first measurement to modify a first layup plan of the automated fiber placement head, the first layup plan having a first tool path for laying up a composite material on a substrate (operation 614).

[0063] In some illustrative examples, the substrate is a mandrel, and wherein scanning the surface of the substrate includes scanning a layup surface of the mandrel (operation 616). In some illustrative examples, the substrate is a composite layer on the mandrel, and wherein scanning the surface of the substrate includes scanning the composite layer, and further including determining a thickness of the composite layer using measurements from the first plurality of sensors (operation 618).

[0064] In some illustrative examples, the first plurality of sensors has an accuracy of less than or equal to 0.005 inches, and wherein scanning is performed at a frame rate having an accuracy of 0.010 inches (operation 620). By having a desired accuracy, scanning using the first plurality of sensors can be used to improve the quality of a resulting composite part. By having a desired accuracy, the first plurality of sensors can be used to reduce inconsistencies in a resulting composite part.

[0065] As used herein, when used with a list of items, the phrase "at least one of..." means that different combinations of one or more of the listed items may be used, and only one of each item in the list may be required. For example, "at least one of item A, item B, or item C" may include, but is not limited to, item A, item A and item B, or item B. The example may also include item A, item B, and item C, or item B and item C. Of course, any combination of these items may be proposed. In other examples, "at least one of..." may be, for example, but not limited to, two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations. The item may be a special object, thing, or category. In other words, "at least one of..." means any combination of items, and the number of items may be used according to the list, but not all items in the list are required.

[0066] As used herein, "a number of" when used with reference to items means one or more items.

[0067] The flowcharts and block diagrams in different depicting embodiments illustrate some possible architectures, functions and operations of devices and methods in illustrative embodiments. In this regard, each box in a flowchart or block diagram may represent at least one of a module, a segment, a function or a part of an operation or a step.

[0068] In some alternative implementations of the illustrative embodiments, the functions mentioned in these boxes may appear outside the order mentioned in the figure. For example, in some cases, two boxes shown in succession may be executed substantially simultaneously, or sometimes these boxes may be executed in reverse order, depending on the functions involved. Moreover, in addition to the boxes illustrated in the flowchart or block diagram, other boxes may be added. Some boxes may be optional. For example, operations 510 to 524 may be optional. As another example, operations 610 to 620 may be optional.

[0069] Exemplary embodiments of the present disclosure may be implemented in Figure 7 Aircraft manufacturing and service method 700 and Figure 8 800 is described in the context of the aircraft 800 shown. Figure 7 , an illustrative diagram of an aircraft manufacturing and service method in block diagram form is depicted according to an illustrative embodiment. During pre-production, aircraft manufacturing and service method 700 may include Figure 8 Specification and design 702 of aircraft 800 and material procurement 704 .

[0070] During production, component and subassembly manufacturing 706 and system integration 708 of aircraft 800 may occur. Thereafter, aircraft 800 may undergo certification and delivery 710 to be placed in service 712. While in service 712 by a customer, aircraft 800 is scheduled for routine maintenance and service 714, which may include modification, reconfiguration, refurbishment, or other maintenance and service.

[0071] Each of the processes of the aircraft manufacturing and service method 700 may be performed or carried out by a system integrator, a third party, and / or an operator. In these examples, the operator may be a customer. For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of manufacturers, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0072] Now refer to Figure 8 , depicts an example diagram of an aircraft in block diagram form in which an illustrative embodiment may be implemented. In this example, aircraft 800 is Figure 7 8 and may include airframe 802 having multiple systems 804 and interior 806. Examples of systems 804 include one or more of propulsion system 808, electrical system 810, hydraulic system 812, and environmental system 814. Any number of other systems may be included.

[0073] Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method 700. One or more exemplary embodiments may be employed in Figure 7 The components and subassemblies are manufactured or used during at least one of manufacturing 706 , system integration 708 , in use 712 , and maintenance and service 714 .

[0074] The illustrative examples present systems and methods for composite lamination. The illustrative examples present better positioning of lamination tips relative to contour or corner portions during lamination and compaction.

[0075] The illustrative example may perform the following method: Move Layup Mandrel (LM) - Perform LM and Tip Scan - Generate Full Resolution Transform - Start Layup - Adjust Lamination Tip as Needed to Fit Part. The illustrative example provides a more accurate and fast method that constantly indexes the laminating equipment to the layup mandrel and as per the condition of the part. The illustrative example enables high rate composite manufacturing. The illustrative example reduces or eliminates probing as a time constraint.

[0076] For a linear flow production line, multiple indexing operations will be utilized. The illustrative examples enable rapid indexing. In some illustrative examples, indexing can be performed within about 15 minutes.

[0077] The illustrative examples provide full mesh resolution and eliminate the need for linear interpretation between probe points. The illustrative examples can continuously monitor in the event of any changes during the build (collision, movement, etc.). The varying compaction level of the contoured part affects the nominal surface definition. Continuous monitoring can monitor the nominal surface definition due to varying compaction levels. The illustrative examples can also monitor relative to the part itself (by condition) as opposed to the tool.

[0078] The system can be used to measure and monitor the position of the automated fiber placement tip at all times, which improves the accuracy of the tip. The illustrative examples can provide accurate machine-to-tool information and can compensate for any machine drift or variation. The illustrative examples can reduce costs by not using a probe tip and save time with high-rate procedures.

[0079] The illustrative examples can be compressed as needed when needed. The illustrative examples can take rescans when needed without affecting the flow. The illustrative examples enable fast indexing at the beginning of the process.

[0080] The illustrative examples provide measurements that can compensate for part thickness. The illustrative examples address surface quality and part stacking. The illustrative examples compensate for variations seen in composite lamination. The illustrative examples can reduce or eliminate overlap / gaps that would otherwise develop toward the end of a build.

[0081] The illustrative examples provide improvements in quality and process control for composite material manufacturing. The illustrative examples enable compaction to be used without affecting surface quality. The illustrative examples take into account that compaction on thick parts is very time sensitive.

[0082] This disclosure includes example implementations according to the following clauses:

[0083] Clause 1. A system (202) for indexing (258) an automated fiber placement head (230, 302) toward a surface (234) of a substrate (232, 304), the system (202) comprising:

[0084] a first measurement system (204, 308), the first measurement system (204, 308) comprising a first plurality of sensors (210, 312), the first plurality of sensors (210, 312) being configured to scan the surface (234) of the substrate (232, 304);

[0085] a second measurement system (206, 310), the second measurement system (206, 310) comprising a second plurality of sensors (214, 314), the second plurality of sensors (214, 314) being configured to locate the automated fiber placement head (230, 302); and

[0086] A data management device (207) configured to use measurements (246) from the first measurement system (204, 308) to generate a full resolution transform (276) and to use data from the second measurement system (206, 310) to determine a position (250) of the automated fiber placement head (230, 302).

[0087] Clause 2. A system (202) according to clause 1, wherein the first plurality of sensors (210, 312) includes one or more of the following: a light detection and ranging device array, i.e., LIDAR (218), a special phase imaging sensor array (220), a time-of-flight sensor array (222), a stereo camera array (224), a light field camera array (226), and a high-resolution camera array (228).

[0088] Clause 3. A system (202) according to clause 1, wherein the second plurality of sensors (214, 314) includes one or more of the following: a light detection and ranging device array, i.e., LIDAR (218), a special phase imaging sensor array (220), a time-of-flight sensor array (222), a stereo camera array (224), a light field camera array (226), and a high-resolution camera array (228).

[0089] Clause 4. The system (202) of clause 1, further comprising:

[0090] A tracking target (252) is connected to the automated fiber placement head (230, 302), and the second plurality of sensors (214, 314) are configured to track the position of the tracking target (252).

[0091] Clause 5. A system (202) according to clause 1, wherein the substrate is a composite layer (240) on a mandrel (236), and wherein the data management device (207) is configured to determine the thickness of the composite layer (240) using measurements from the first plurality of sensors (210, 312).

[0092] Clause 6. A system (202) according to clause 1, wherein the substrate is a composite layer (240) on a mandrel (236), and wherein the data management device (207) is configured to form a model of the composite layer (240) in near real time in response to measurement results (246) generated by the first measurement system (204, 308).

[0093] Clause 7. The system (202) of Clause 6, wherein the model (278) of the composite layer (240) is accurate (280) to within about 0.005 inches of the composite layer (240).

[0094] Clause 8. A system (202) according to clause 1, wherein the substrate (232) is a mandrel (236), and wherein the data management device (207) is further configured to use the full resolution transformation (276) and the position (250) of the automated fiber placement head (230, 302) to index the automated fiber placement head (230, 302) toward the mandrel (236).

[0095] Clause 9. The system (202) of clause 1, wherein the first measurement system (204, 308) is configured to perform both indexing (258) and real-time monitoring (262).

[0096] Clause 10. The system (202) of clause 1, wherein the second measurement system (206, 310) is configured to perform real-time monitoring (262).

[0097] Clause 11. A method (500) of performing composite lamination, the method (500) comprising the steps of:

[0098] Using a first metrology system (204, 308), performing an initial spindle (236) scan of a substrate within a manufacturing environment;

[0099] Using a second measurement system (206, 310), determining an initial position (250) of an automated fiber placement head (230, 302) within the manufacturing environment;

[0100] using results from the initial mandrel (236) scan to generate a full resolution transform (276); and

[0101] Based on the full resolution transformation (276) and the initial position (250), layup on the substrate is initiated by the automated fiber placement head (230, 302).

[0102] Clause 12. The method (500) of clause 11, wherein:

[0103] The step of performing the initial mandrel (236) scan includes scanning the composite layer (240) present on the mandrel (236).

[0104] Clause 13. The method (500) according to clause 11, further comprising the following steps:

[0105] Using a second measurement system (206, 310), a position (250) of the automated fiber placement head (230, 302) during layup is monitored.

[0106] Clause 14. The method (500) according to clause 13, further comprising the following steps:

[0107] Based on monitoring by a second measurement system (206, 310), a position (250) of the automated fiber placement head (230, 302) during layup is adjusted.

[0108] Clause 15. The method (500) according to clause 11, further comprising the following steps:

[0109] During a layup performed by the automated fiber placement head (230, 302), the composite material laid by the automated fiber placement head (230, 302) is scanned by the first measurement system (204, 308).

[0110] Clause 16. The method (500) according to clause 15, further comprising the following steps:

[0111] Future layup plans are modified based on a scan of the composite material laid down by the automated fiber placement head (230, 302).

[0112] Clause 17. The method (500) of clause 11, wherein the step of performing the initial mandrel (236) scan comprises:

[0113] The substrate is scanned using at least one of: a light detection and ranging device array, i.e., LIDAR (218), a special phase imaging sensor array (220), a time of flight sensor array (222), a stereo camera array (224), a light field camera array (226), and a high resolution camera array (228).

[0114] Clause 18. The method (500) of clause 11, wherein the accuracy of the first measurement system (204, 308) is less than or equal to 0.005 inches, and wherein the initial spindle (236) scan is performed at a frame rate with an accuracy of 0.010 inches.

[0115] Clause 19. A method (600) of performing composite lamination, the method (600) comprising the steps of:

[0116] scanning a surface (234) of a substrate (232, 304) using a first plurality of sensors (210, 312) to generate an initial mandrel scan (256, 246);

[0117] Using a second plurality of sensors (214, 314) to position an automated fiber placement head (230, 302);

[0118] indexing (258) the automated fiber placement head (230, 302) toward the substrate based on the initial mandrel scan (256, 246); and

[0119] After indexing (258) the automated fiber placement head (230, 302), composite material is laid on the surface (234) of the substrate (232, 304) using the automated fiber placement head (230, 302).

[0120] Clause 20. The method (600) according to clause 19, further comprising the following steps:

[0121] calculating a full resolution transform (276) for moving the automated fiber placement head (230, 302) to provide substantial design compliance between the initial mandrel scan (256, 246) and a layup plan of the automated fiber placement head (230, 302); and

[0122] The automated fiber placement head (230, 302) is moved according to the full resolution transformation (276).

[0123] Clause 21. The method (600) according to clause 19, further comprising the following steps:

[0124] The initial mandrel scan (256, 246) is utilized to modify a first layup plan (264) of the automated fiber placement head (230, 302), the first layup plan (264) having a first tool path (266) for laying down composite material on the substrate.

[0125] Clause 22. The method (600) of clause 19, wherein the substrate is a mandrel (236), and wherein the step of scanning the surface (234) of the substrate (232, 304) comprises scanning a blanket surface of the mandrel (236).

[0126] Clause 23. The method (600) of clause 19, wherein the substrate is a composite layer (240) on a mandrel (236), wherein the step of scanning the surface (234) of the substrate (232, 304) comprises: scanning the composite layer (240); and the method further comprises the steps of:

[0127] The thickness of the composite layer (240) is determined using measurements from the first plurality of sensors (210, 312).

[0128] Clause 24. The method (600) of clause 19, wherein the accuracy of the first plurality of sensors (210, 312) is less than or equal to 0.005 inches, and wherein the scanning is performed at a frame rate with an accuracy of 0.010 inches.

[0129] The descriptions of different exemplary embodiments have been presented for the purpose of illustration and description and are not intended to be exclusive or limited to the embodiments of the disclosed forms. Many modifications and variations will be apparent to those of ordinary skill in the art. In addition, different exemplary embodiments may provide different features compared to other exemplary embodiments. The embodiments and selected embodiments are selected and described to best illustrate the principles of the embodiments, practical applications, and to enable those of ordinary skill in the art to understand the present disclosure for various embodiments with various modifications as are suitable for the intended specific use.

Claims

1. A system (202) for indexing (258) an automated fiber placement head (230, 302) toward a surface (234) of a substrate (232, 304), the system (202) comprising: a first measurement system (204, 308), the first measurement system (204, 308) comprising a first plurality of sensors (210, 312), the first plurality of sensors (210, 312) being configured to scan the surface (234) of the substrate (232, 304); a second measurement system (206, 310), the second measurement system (206, 310) comprising a second plurality of sensors (214, 314), the second plurality of sensors (214, 314) being configured to locate the automated fiber placement head (230, 302); and A data management device (207) configured to use measurements (246) from the first measurement system (204, 308) to generate a full resolution transform (276) and to use data from the second measurement system (206, 310) to determine a position (250) of the automated fiber placement head (230, 302).

2. The system (202) of claim 1, wherein: The first plurality of sensors (210, 312) includes one or more of: a light detection and ranging device array, i.e., LIDAR (218), a special phase imaging sensor array (220), a time of flight sensor array (222), a stereo camera array (224), a light field camera array (226), and a high resolution camera array (228).

3. The system (202) of claim 1, wherein: The second plurality of sensors (214, 314) includes one or more of: a light detection and ranging device array, i.e., LIDAR (218), a special phase imaging sensor array (220), a time of flight sensor array (222), a stereo camera array (224), a light field camera array (226), and a high resolution camera array (228).

4. The system (202) of claim 1, further comprising: A tracking target (252) is connected to the automated fiber placement head (230, 302), and the second plurality of sensors (214, 314) are configured to track the position of the tracking target (252).

5. The system (202) of claim 1, wherein: The substrate is a composite layer (240) on a mandrel (236), and wherein the data management device (207) is configured to determine a thickness of the composite layer (240) using measurements from the first plurality of sensors (210, 312).

6. The system (202) of claim 1, wherein: The substrate is a composite layer (240) on a mandrel (236), and wherein the data management device (207) is configured to generate a model of the composite layer (240) in near real time for measurement results (246) generated by the first measurement system (204, 308), wherein the model (278) of the composite layer (240) is accurate (280) to within about 0.005 inches of the composite layer (240).

7. The system (202) of claim 1, wherein: The substrate (232) is a mandrel (236), and wherein the data management device (207) is further configured to index the automated fiber placement head (230, 302) toward the mandrel (236) using the full resolution transformation (276) and the position (250) of the automated fiber placement head (230, 302).

8. The system (202) of claim 1, wherein: The first measurement system (204, 308) is configured to perform both indexing (258) and real-time monitoring (262), and Wherein, the second measurement system (206, 310) is configured to perform real-time monitoring (262).

9. A method (500) for performing composite lamination, the method (500) comprising the following steps: Using a first metrology system (204, 308), performing an initial spindle (236) scan of a substrate within a manufacturing environment; Using a second measurement system (206, 310), determining an initial position (250) of an automated fiber placement head (230, 302) within the manufacturing environment; using results from the initial mandrel (236) scan to generate a full resolution transform (276); and Based on the full resolution transformation (276) and the initial position (250), layup on the substrate is initiated by the automated fiber placement head (230, 302).

10. The method (500) of claim 9, wherein: The step of performing the initial mandrel (236) scan includes scanning the composite layer (240) present on the mandrel (236).

11. The method (500) according to claim 9, further comprising the following steps: monitoring a position (250) of the automated fiber placement head (230, 302) during layup using a second measurement system (206, 310); and Based on the monitoring performed by the second measurement system (206, 310), the position (250) of the automated fiber placement head (230, 302) during layup is adjusted.

12. The method (500) according to claim 9, further comprising the following steps: During the layup performed by the automated fiber placement head (230, 302), the first measurement system (204, 308) scans the composite material laid by the automated fiber placement head (230, 302); as well as Future layup plans are modified based on a scan of the composite material laid down by the automated fiber placement head (230, 302).

13. The method (500) of claim 9, wherein: The step of performing said initial mandrel (236) scan comprises: The substrate is scanned using at least one of: a light detection and ranging device array, i.e., LIDAR (218), a special phase imaging sensor array (220), a time of flight sensor array (222), a stereo camera array (224), a light field camera array (226), and a high resolution camera array (228).

14. The method (500) of claim 9, wherein: The first measurement system (204, 308) has an accuracy of less than or equal to 0.005 inches, and wherein the initial mandrel (236) scan is performed at a frame rate with an accuracy of 0.010 inches.

15. A method (600) for performing composite lamination, the method (600) comprising the following steps: scanning a surface (234) of a substrate (232, 304) using a first plurality of sensors (210, 312) to generate an initial mandrel scan (256, 246); Using a second plurality of sensors (214, 314) to position an automated fiber placement head (230, 302); indexing (258) the automated fiber placement head (230, 302) toward the substrate based on the initial mandrel scan (256, 246); and After indexing (258) the automated fiber placement head (230, 302), composite material is laid on the surface (234) of the substrate (232, 304) using the automated fiber placement head (230, 302).

16. The method (600) according to claim 15, further comprising the following steps: calculating a full resolution transform (276) for moving the automated fiber placement head (230, 302) to provide substantial design compliance between the initial mandrel scan (256, 246) and a layup plan of the automated fiber placement head (230, 302); as well as The automated fiber placement head (230, 302) is moved according to the full resolution transformation (276).

17. The method (600) according to claim 15, further comprising the following steps: The initial mandrel scan (256, 246) is utilized to modify a first layup plan (264) of the automated fiber placement head (230, 302), the first layup plan (264) having a first tool path (266) for laying down composite material on the substrate.

18. The method (600) of claim 15, wherein: The substrate is a mandrel (236), and wherein the step of scanning the surface (234) of the substrate (232, 304) includes scanning a blanket surface of the mandrel (236).

19. The method (600) of claim 15, wherein: The substrate is a composite layer (240) on a mandrel (236), wherein the step of scanning the surface (234) of the substrate (232, 304) comprises: scanning the composite layer (240); and the method further comprises the steps of: The thickness of the composite layer (240) is determined using measurements from the first plurality of sensors (210, 312).

20. The method (600) of claim 15, wherein: The first plurality of sensors (210, 312) have an accuracy of less than or equal to 0.005 inches, and wherein the scanning is performed at a frame rate with an accuracy of 0.010 inches.

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