Method and system for manufacturing a laminate of a composite part

Abstract

The invention relates to a method and a system for manufacturing a stack of composite parts. A method of manufacturing a composite part includes: identifying out-of-tolerance inconsistencies in a current ply of a stack for the composite part; and placing the replacement tow onto the substrate to rework out-of-tolerance inconsistencies in the current plies of the stack for the composite part. In another example, the method includes placing a tow onto a substrate using a multi-channel automated fiber placement device to form a first ply; upon identifying the out-of-tolerance inconsistency in the first ply, placing a replacement tow using a single-channel automatic fiber placement device to rework the out-of-tolerance inconsistency; and placing additional tows onto the substrate using the multi-channel automated fiber placement device to form a second ply covering the first ply. A system for manufacturing a stack of composite parts includes a multi-channel automated fiber placement device and a single-channel automated fiber placement device.

Description

Technical Field

[0001] The present disclosure relates generally to the manufacture of layups for composite parts, and particularly to the rework of a single tow within a current ply of a layup during a manufacturing process. Various techniques are contemplated for automatically detecting material placement errors of a single tow. Various techniques are also contemplated for automatically reworking (e.g., removing and replacing) unacceptable portions of a single tow. Background Art

[0002] Multi-pass automated fiber placement heads are often used during composite part manufacturing. For example, if one pass of a 16-pass head laying a 0.25" tow experiences a material placement error, it would be impossible to use the multi-pass head to go back and lay a single 0.25" tow of composite material.

[0003] Accordingly, those skilled in the art continue research and development efforts to improve techniques for making layups of composite parts, particularly the reworking of tows having material placement errors during the manufacture of such layups. Summary of the invention

[0004] Examples of methods and systems for making layups of composite parts are disclosed.The following is a non-exhaustive list of examples that may or may not be claimed in accordance with the disclosed subject matter.

[0005] In an example, a method for manufacturing a layup for a composite part is disclosed that includes: (1) identifying an out-of-tolerance inconsistency in a current ply of the layup for the composite part, the current ply comprising a plurality of tows covering a substrate; and (2) placing a replacement tow onto the substrate to rework the out-of-tolerance inconsistency in the current ply of the layup for the composite part.

[0006] In another example, the disclosed method for manufacturing a layup for a composite part includes: (1) in conjunction with the manufacture of the layup for the composite part, using a multi-channel automatic fiber placement device to place a first plurality of tows onto a substrate to form a first ply covering the substrate; (2) after identifying that one or more out-of-tolerance inconsistencies in the first ply are to be reworked and specified, using a single-channel automatic fiber placement device to place one or more replacement tows onto the substrate to rework one or more out-of-tolerance inconsistencies in the first ply; and (3) in conjunction with the manufacture of the layup for the composite part, using a multi-channel automatic fiber placement device to place a second plurality of tows onto the substrate to form a second ply covering the first ply.

[0007] In an example, a disclosed system for manufacturing a layup of a composite part includes a multi-channel automated fiber placement device and a single-channel automated fiber placement device. The multi-channel automated fiber placement device is configured to place a first plurality of tows onto a substrate to form a first ply covering the substrate in conjunction with the manufacture of a layup for a composite part. The single-channel automated fiber placement device is configured to place one or more replacement tows onto the substrate to rework one or more out-of-tolerance inconsistencies in the first ply. One or more out-of-tolerance inconsistencies have been previously identified and rework has been specified. The multi-channel automated fiber placement device is configured to place a second plurality of tows onto the substrate to form a second ply covering the first ply in conjunction with the manufacture of a layup for a composite part.

[0008] Other examples of the disclosed method and system for fabricating composite parts will become apparent from the following detailed description, the accompanying drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a flow chart of an example of a method for manufacturing a layup of a composite part;

[0010] Figure 2 is a functional diagram of an example of a multi-filament bundle for a ply of a layup showing several examples of out-of-tolerance inconsistencies;

[0011] Figure 3 For rework Figure 2 Functional diagram of an example of an out-of-tolerance inconsistent replacement tow in a multi-tow;

[0012] Figure 4 It shows that according to Figure 1 A flowchart of an example of a method of "determining out-of-tolerance inconsistency";

[0013] Figure 5 It is shown from Figure 1 A flowchart of an example of a method of "placing a replacement tow";

[0014] Figure 6 It is shown from Figure 1 A flowchart of another example of a method of "placing a replacement tow";

[0015] Figure 7 It is shown from Figure 1 A flowchart of another example of "Placing a Replacement Tow" of the method;

[0016] Figure 8 is a flow chart of another example of a method for manufacturing a layup of a composite part;

[0017] Fig. 9 It shows that according to Figure 8A flowchart of an example of a method of "determining one or more out-of-tolerance inconsistencies";

[0018] Fig.10 It is shown from Figure 8 A flowchart of an example of a method of "placing one or more replacement tows";

[0019] Fig.11 It is shown from Figure 8 A flowchart of another example of "placing one or more replacement tows" of the method;

[0020] Fig.12 It is shown from Figure 8 A flowchart of another example of a method of "placing one or more replacement tows";

[0021] Fig.13A is a functional diagram of an example of a multi-channel automated fiber placement apparatus for laying tows in four tow channels;

[0022] Fig. 13B is a functional diagram of an example of a tow removal tool for removing a portion of a tow that is close to an out-of-tolerance inconsistency;

[0023] Fig. 13C Is used for laying close to Fig. 13B Functional diagram of an example of a single-pass automated fiber placement device for replacing a tow with an out-of-tolerance inconsistency;

[0024] Fig.14A and Fig. 14B is a functional diagram showing another example of a multi-channel automated fiber placement apparatus for manufacturing a layup of a composite part;

[0025] Fig.15 and Fig.16 is a functional diagram illustrating an example of a single-pass automated fiber placement apparatus for reworking an out-of-tolerance inconsistency in a current ply during fabrication of a layup of a composite part;

[0026] Fig.17 It is a combination Figure 1 A flow chart of yet another example of a method for manufacturing a layup of a composite part;

[0027] Fig.18 It is a combination Figure 8 A flow chart of yet another example of a method for manufacturing a layup of a composite part;

[0028] Fig.19 It is a combination Figure 8 A flow chart of yet another example of a method for manufacturing a layup of a composite part;

[0029] Fig. 20is a block diagram of an aircraft production and service methodology that implements one or more examples of methods for manufacturing layups of composite parts disclosed herein; and

[0030] Fig.21 is a schematic diagram of an aircraft incorporating one or more parts fabricated using one or more of the examples of methods and systems for fabricating layups of composite parts disclosed herein. DETAILED DESCRIPTION

[0031] Various examples of methods 100, 800, 1700, 1800, 1900 and systems for manufacturing a laminate 200 of a composite part disclosed herein provide a technique for applying local heating to automatically place fibers as a rework method during the manufacture of a composite part by a multi-channel automatic fiber placement system. For example, the method may include detecting misplaced tows and removing the multi-channel automatic fiber placement device. Then, the misplaced tows can be removed, and the single-channel automatic fiber placement device can be brought into the manufacturing process. Next, a single-channel tow material can be laid to replace the removed material using a plasma heater to generate a plasma plume (e.g., 0.25 inch tow width multiplied by 0.75 inch tow length) on a single tow during placement. Then, the single-channel tow placement device can be replaced with a multi-channel tow placement device, and the laying of multi-channel tow materials can be restored. The heater provides enough heat to melt and consolidate. The heat source is an atmospheric pressure plasma device with a focused plasma plume. Intended targets include thermoplastic automated fiber placement, but it is conceivable that the process could be used for thermoset automated fiber placement. Existing automated fiber placement rework solutions require manual placement of individual tows. Atmospheric pressure plasma equipment can provide uniform heat application at a low cost. In addition, atmospheric pressure plasma equipment provides relatively instantaneous heating without the need for additional safety enclosures or being limited by line-of-sight limitations of other localized heating methods (such as laser and infrared heating).

[0032] Overall reference Figures 1 to 7 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B and Figures 15 to 17 As an example, the present disclosure relates to a method 100 , a method 1700 for manufacturing a layup 200 of a composite part. Figure 1 and Figures 4 to 7 Several examples of method 100 are disclosed. Figure 1 and Fig.17 Several examples of method 1700 are disclosed. Figure 2 An example of a multifilament bundle 206 for a ply 204 of a layup 200 is shown along with several examples of out-of-tolerance inconsistencies 202 . Figure 3An example of a replacement tow 302 for reworking an out-of-tolerance non-conformance 202 is shown. Fig.13A , Fig.14A and Fig. 14B Several examples of multi-channel automated fiber placement apparatus 1302 are shown. Fig. 13B is a functional diagram of an example of tow removal tool 1306 . Fig. 13C is a functional diagram of an example of a single-pass automated fiber placement apparatus 1304 .

[0033] Reference again Figure 1 , Figure 2 , Fig.14A and Fig. 14B In one or more examples, a method 100 for manufacturing a layup 200 of a composite part (see Figure 1 ) includes identifying 102 an out-of-tolerance inconsistency 202 in a current ply 204 of a layup 200 of a composite part. The current ply 204 includes a plurality of tows 206 covering a substrate 1402. At 104, a replacement tow 302 is placed onto the substrate 1402 to rework the out-of-tolerance inconsistency 202 in the current ply 204 of the layup 200 of the composite part.

[0034] Reference again Figure 1 , Figure 2 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B and Fig.17 In one or more examples, a method 1700 (see Fig.17 )include Figure 1 Method 100 and with Figure 1 At 1702, at least one course 208 of multifilament tows 206 for the current ply 204 of the stack 200 is placed onto the substrate 1402 using the multi-channel automated fiber placement device 1302. In some examples, the method 1700 may include: Figure 1 1702 continues to 102. Method 1700 can be from Figure 1 The method 1700 continues to 1704, where after identifying 102 the out-of-tolerance inconsistency 202, the multi-pass automated fiber placement device 1302 is removed from the stack 200. At 1706, the single-pass automated fiber placement device 1304 is provided to the stack 200. The method 1700 may be performed from Figure 1104 continues to 1708, where placement 104 to the layup 200 is performed using the single-pass automated fiber placement device 1304. At 1710, the single-pass automated fiber placement device 1304 is removed from the layup 200. At 1712, the multi-pass automated fiber placement device 1302 is provided to the layup 200. At 1714, placement of the courses 208 of the multi-tows 206 is resumed for the current ply 204 and / or subsequent plies 204 of the layup 200.

[0035] Reference again Figures 1 to 7 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 In another example of the method 100, the identification 102 of the out-of-tolerance inconsistency 202 is performed using at least one imaging sensor 1502. In another example, the identification 102 of the out-of-tolerance inconsistency 202 is performed in conjunction with laying the plurality of tows 206 associated with the current ply 204. In another further example, the at least one imaging sensor 1502 includes a single-channel scanner configured to scan a single tow 206 in the plurality of tows 206. In yet another further example, the at least one imaging sensor 1502 includes a multi-channel scanner configured to scan multiple tows 206 in the plurality of tows 206. In yet another further example, the at least one imaging sensor 1502 captures imaging data of a single tow 206 in the plurality of tows 206. In yet another further example, the at least one imaging sensor 1502 captures imaging data of multiple tows 206 in the plurality of tows 206. There are a variety of methods for scanning defects during layup. For example, scanning techniques can range from a single camera to five or more sensors scanning 16 rows. The number of scanners / sensors required depends on the resolution of the sensing device and the width of the route.

[0036] In yet another example of the method 100, the stack 200 includes one or more plies 204. The one or more plies 204 include the current ply 204. Each ply 204 includes one or more rows 208. Each row 208 includes multifilament bundles 206. The multifilament bundles of each row 208 are simultaneously overlaid on the substrate 1402.

[0037] In yet another example of the method 100 , the composite part includes a fiber reinforcement material, a matrix material, a carbon fiber material, a prepreg material, a thermoplastic material, a thermoset material, or any other suitable material for a composite part in any suitable combination.

[0038] In yet another example of the method 100 , the substrate 1402 includes a layup tool and at least one of the one or more previous plies 204 overlying the layup tool.

[0039] In another example of the method 100 , the plurality of tows 206 include fiber reinforcement tapes, fiber / polymer tapes, prepreg tapes, fiber reinforcement material strips, fiber / polymer material strips, prepreg material strips, or any other suitable material in any suitable combination.

[0040] In yet another example of the method 100 , the replacement tows 302 include fiber reinforcement tapes, fiber / polymer tapes, prepreg tapes, fiber reinforcement material strips, fiber / polymer material strips, prepreg material strips, or any other suitable material in any suitable combination.

[0041] In yet another example, the method 100 further includes determining 106 that the out-of-tolerance inconsistency 202 requires rework. In another example, it is determined 106 that the out-of-tolerance inconsistency 202 requires rework, and the placement 104 of the replacement tow 302 is performed before laying down the next layer 204. In another further example of the method 100, the determination 106 includes comparing 402 the out-of-tolerance inconsistency 202 with the tow standard of the layup 200 of the composite part relative to the acceptable tolerance of the tow standard (see Figure 4 At 404, it is determined that replacing the tow 302 requires reworking the out-of-tolerance inconsistency 202, wherein the out-of-tolerance inconsistency 202 is not within an acceptable tolerance of the tow standard.

[0042] In yet another example of the method 100 , the plurality of tows 206 in the current ply 204 are placed onto the substrate 1402 using the multi-pass automated fiber placement device 1302 in one or more passes of the multi-pass automated fiber placement device 1302 along the substrate 1402 .

[0043] In another example of method 100 , placement 104 of replacement tow 302 is performed using single-pass automated fiber placement device 1304 .

[0044] In yet another example, the method 100 further includes removing 108 at least a portion of one or more of the plurality of tows 206 in the current ply 204 in preparation for reworking the out-of-tolerance inconsistency 202. At least a portion of the one or more tows 206 is proximate the out-of-tolerance inconsistency 202. In another example, a replacement tow 302 is placed on the substrate 1402 to replace at least a portion of the one or more tows 206 removed from the current ply 204. In another further example, the removing 108 of at least a portion of the one or more tows 206 is performed using a tow removal tool 1306. In yet another additional example of the method 100, placing 104 the replacement tow 302 includes overlapping 502 the replacement tow 302 (see Figure 5) onto one or more remaining portions 304 from which at least a portion of one or more tows 206 have been removed. In yet another example of method 100, placing 104 replacement tow 302 includes splicing 504 replacement tow 302 to one or more remaining portions 304 from which at least a portion of one or more tows 206 have been removed.

[0045] In yet another example of the method 100, placing 104 the replacement tow 302 includes compacting 602 on the substrate 1402 (see Figure 6 ) replace the tow 302 to define the roller gap 1602. In another example, the compaction 602 of the replacement tow 302 is performed using a compaction roller 1604. The compaction roller 1604 and the substrate 1402 define the roller gap 1602.

[0046] In another example of method 100, placing 104 replacement tow 302 further includes projecting 604 an atmospheric pressure plasma plume 1608 near nip 1602 to heat at least one of replacement tow 302 and substrate 1402. In yet further examples, projecting 604 the atmospheric pressure plasma plume 1608 includes projecting the atmospheric pressure plasma plume 1608 at a divergence angle ranging from about 0 degrees to about 20 degrees, about 0 degrees to about 10 degrees, about 0 degrees to about 5 degrees, or any other suitable divergence angle range. In another yet further example, projecting 604 the atmospheric pressure plasma plume 1608 includes projecting the atmospheric pressure plasma plume 1608 at a pressure ranging from about 15 psi to about 50 psi. In yet another yet further example, the atmospheric pressure plasma plume 1608 has a width ranging from about 0.10 inches to about 0.40 inches, about 0.15 inches to about 0.35 inches, about 0.20 inches to about 0.30 inches, or any other suitable plume width range. In yet another example, the atmospheric pressure plasma plume 1608 has a length ranging from about 0.25 inches to about 1.5 inches, about 0.5 inches to about 1.0 inches, about 0.70 inches to about 0.80 inches, or any other suitable plume length range. In yet another example, the atmospheric pressure plasma plume 1608 is about 0.5 inches to about 0.8 inches from the nip 1602. In another example of the method 100, placing 104 the replacement tow 302 also includes cutting 606 the replacement tow 302 to a desired length in conjunction with projecting 604 the atmospheric pressure plasma plume 1608 and reworking the out-of-tolerance inconsistency 202.

[0047] Using a single tow device with a heating source avoids damaging the rest of the substrate during the rework process. If a 12-tow system is used that heats all 12 channels but only lays down one channel of material, the remaining 11 channels are subject to exposed rollers and heat, which can damage the substrate, expose the material to excessive heat, cause the rollers to wrap, or even pull up the entire charge. Rework of a single tow should be accomplished without damaging the remaining tows.

[0048] In yet another example of method 100, the out-of-tolerance inconsistency 202 in the layup 200 of the composite part is due to a missing segment 210 of one or more tows 206. In this example, placing 104 the replacement tow 302 includes: compacting 702 on the substrate 1402 (see Figure 7 ) replacement tow 302 is positioned to define nip 1602. Compaction using a single tow device allows for the same level of compaction as during the original layup. At 704, an atmospheric pressure plasma plume 1608 is projected near nip 1602 to heat at least one of replacement tow 302 and substrate 1402. At 706, replacement tow 302 is cut to a desired length in conjunction with projection 704 of atmospheric pressure plasma plume 1608.

[0049] Overall reference Figure 2 , Figure 3 , Figures 8 to 12 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 , Fig.16 , Fig.18 and Fig.19 As an example, the present disclosure relates to method 100 , method 1800 , method 1900 for manufacturing a layup 200 of a composite part. Figure 2 An example of a multifilament bundle 206 for a ply 204 of a layup 200 is shown along with several examples of out-of-tolerance inconsistencies 202 . Figure 3 An example of a replacement tow 302 for reworking an out-of-tolerance non-conformance 202 is shown. Figures 8 to 12 Several examples of method 800 are disclosed. Figure 8 and Fig.18 Several examples of method 1800 are disclosed. Figure 8 and Fig.18 Several examples of method 1800 are disclosed. Fig.13A , Fig.14A and Fig. 14B Several examples of multi-channel automated fiber placement apparatus 1302 are shown. Fig. 13B is a functional diagram of an example of tow removal tool 1306 . Fig. 13C is a functional diagram of an example of a single-pass automated fiber placement apparatus 1304 .

[0050] Reference again Figure 2 , Figure 3 , Figure 8 , FIG. 13A to FIG. 13C , Fig.14A and Fig. 14B In one or more examples, a method 800 (see Figure 8 ) includes placing 802 a first plurality of tows 206 onto a substrate 1402 using a multi-pass automated fiber placement device 1302 to form a first ply 204 covering the substrate 1402 in conjunction with the manufacture of a layup 200 for a composite part. At 804, after one or more out-of-tolerance inconsistencies 202 in the first ply 204 are identified and rework is specified, one or more replacement tows 302 are placed onto the substrate 1402 to rework the one or more out-of-tolerance inconsistencies 202 in the first ply 204 using a single-pass automated fiber placement device 1304. At 806, a second plurality of tows are placed onto the substrate 1402 using the multi-pass automated fiber placement device 1302 to form a second ply 204 covering the first ply 204 in conjunction with the manufacture of a layup 200 for a composite part.

[0051] Reference again Figure 2 , Figure 3 , Figure 8 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B and Fig.18 In one or more examples, a method 1800 (see Fig.18 )include Figure 8 The method 800 of , and continues from 802 to 1802, wherein, after one or more out-of-tolerance inconsistencies 202 are identified and rework is specified, the multi-pass automated fiber placement device 1302 is removed from the stack 200. At 1804, the single-pass automated fiber placement device 1304 is provided to the stack 200. The method 1800 continues from 1804 to Figure 8 of 804.

[0052] Reference again Figure 2 , Figure 3 , Figure 8 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B and Fig.19 In one or more examples, a method 1900 (see Fig.19 )include Figure 8The method 800 of 1904 and continues from 1904 to 1902, wherein after placing one or more replacement tows 302, the single-pass automated fiber placement device 1304 is removed from the stack 200. At 1904, the multi-pass automated fiber placement device 1302 is provided to the stack 200 to restore the placement of the multi-tows 206 of the stack 200. The method 1900 continues from 1904 to Figure 8 of 806.

[0053] Reference again Figure 2 , Figure 3 , Figures 8 to 12 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 In another example of the method 800 , the plurality of tows 206 include fiber reinforcement tapes, fiber / polymer tapes, prepreg tapes, fiber reinforcement material tapes, fiber / polymer material tapes, prepreg material tapes, or any other suitable material in any suitable combination.

[0054] In yet another example of the method 800 , the substrate 1402 includes a layup tool and at least one of the one or more previous plies 204 overlying the layup tool.

[0055] In yet another example of method 800, stack 200 includes a plurality of plies 204. The plurality of plies 204 include a first ply 204 and a second ply 204. The first ply 204 includes one or more rows 208. Each row 208 includes a multifilament bundle 206. The multifilament bundle 206 of each row 208 is simultaneously laid on substrate 1402 by multi-channel automated fiber placement device 1302.

[0056] In yet another example of method 800 , the composite part includes a fiber reinforcement material, a matrix material, a carbon fiber material, a prepreg material, a thermoplastic material, a thermoset material, or any other suitable material in any suitable combination.

[0057] In another example of method 800 , one or more replacement tows 302 include fiber reinforcement tapes, fiber / polymer tapes, prepreg tapes, fiber reinforcement material strips, fiber / polymer material strips, prepreg material strips, or any other suitable material in any suitable combination.

[0058] In yet another, method 800 further includes determining 808 that one or more out-of-tolerance inconsistencies 202 require rework. In another example, determining 808 that one or more out-of-tolerance inconsistencies 202 require rework, and placing 804 of one or more replacement tows 302 to form second ply 204 is performed prior to placing 806 second plurality of tows 206. In another further example of method 800, determining 808 includes comparing 902 the one or more out-of-tolerance inconsistencies 202 to a tow standard for the layup 200 of the composite part relative to an acceptable tolerance of the tow standard (see Fig. 9 At 904 , it is determined that one or more replacement tows 302 are needed to rework one or more out-of-tolerance inconsistencies 202 , wherein the one or more out-of-tolerance inconsistencies 202 are not within acceptable tolerances of the tow standard.

[0059] In yet another example, the method 800 further includes removing 810 at least a portion of one or more of the first plurality of tows 206 in the first ply 204 in preparation for reworking the one or more out-of-tolerance inconsistencies 202. At least a portion of the one or more tows 206 is proximate to the one or more out-of-tolerance inconsistencies 202. In another example, one or more replacement tows 302 are placed onto the substrate 1402 to replace at least a portion of the one or more tows 206 removed from the first ply 204. In another further example, the removing 810 of at least a portion of the one or more tows 206 is performed using a tow removal tool 1306. In yet another additional example of the method 800, placing 804 the one or more replacement tows 302 includes overlapping 1002 (see FIG. 10 ) the one or more replacement tows 302. Fig.10 ) onto one or more remaining portions 304 from which at least a portion of the one or more tows 206 have been removed. In yet another further example of method 800, placing 804 one or more replacement tows 302 includes splicing 1004 the one or more replacement tows 302 to the one or more remaining portions 304 from which at least a portion of the one or more tows 206 have been removed.

[0060] In yet another example of method 800, placing 804 one or more replacement tows 302 includes compacting 1102 on substrate 1402 (see Fig.11 ) one or more replacement tows 302 to define a roller gap 1602. In another example, the single-channel automated fiber placement device 1304 includes a compaction roller 1604. In this example, compaction 1102 of the one or more replacement tows 302 is performed using the compaction roller 1604. The compaction roller 1604 and the substrate 1402 define the roller gap 1602.

[0061] In another example of the method 800, placing 804 the one or more replacement tows 302 further includes projecting 1104 an atmospheric pressure plasma plume 1608 near the nip 1602 to heat at least one of the one or more replacement tows 302 and the substrate 1402. In a further example of the method 800, placing 804 the one or more replacement tows 302 further includes cutting 1106 the one or more replacement tows 302 to a desired length in conjunction with projecting 1104 the atmospheric pressure plasma plume 1608 and reworking the one or more out-of-tolerance inconsistencies 202.

[0062] In yet another example of method 800, one or more out-of-tolerance inconsistencies 202 in first ply 204 of layup 200 for a composite part are due to a missing segment 210 of one or more tows 206. In this example, placing 804 one or more replacement tows 302 includes: compacting 1202 on substrate 1402 (see Fig.12 ) one or more replacement tows 302 to define nip 1602. At 1204, an atmospheric pressure plasma plume 1608 is projected near nip 1602 to heat at least one of the one or more replacement tows 302 and substrate 1402. At 1206, the one or more replacement tows 302 are cut into desired lengths in conjunction with the projection 1204 of the atmospheric pressure plasma plume 1608.

[0063] Overall reference Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 As an example, the present disclosure relates to a system for manufacturing a layup 200 of a composite part. The present disclosure relates to a method 100, 1700 for manufacturing a layup 200 of a composite part. Figure 2 An example of a multifilament bundle 206 for a ply 204 of a layup 200 is shown along with several examples of out-of-tolerance inconsistencies 202 . Figure 3 An example of a replacement tow 302 for reworking an out-of-tolerance non-conformance 202 is shown. Fig.13A , Fig.14A and Fig. 14B Several examples of multi-channel automated fiber placement apparatus 1302 are shown. Fig. 13B is a functional diagram of an example of tow removal tool 1306 . Fig. 13C is a functional diagram of an example of a single-pass automated fiber placement apparatus 1304 .

[0064] Reference again Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 In one or more examples, a system for manufacturing a layup 200 for a composite part includes a multi-pass automated fiber placement device 1302 and a single-pass automated fiber placement device 1304. The multi-pass automated fiber placement device 1302 is configured to place a first plurality of tows 206 onto a substrate 1402 to form a first ply 204 covering the substrate 1402 in conjunction with manufacturing the layup 200 for a composite part. The single-pass automated fiber placement device 1304 is configured to place one or more replacement tows 302 onto the substrate 1402 to rework one or more out-of-tolerance inconsistencies 202 in the first ply 204. The one or more out-of-tolerance inconsistencies 202 have been previously identified and specified for rework. After reworking one or more out-of-tolerance inconsistencies 202 , multi-channel automated fiber placement apparatus 1302 is configured to place second plurality of tows 206 onto substrate 1402 to form second ply 204 overlying first ply 204 in conjunction with fabrication of layup 200 of a composite part.

[0065] In another example of a system, the plurality of tows 206 include fiber reinforcement tapes, fiber / polymer tapes, prepreg tapes, fiber reinforcement material tapes, fiber / polymer material tapes, prepreg material tapes, or any other suitable material in any suitable combination.

[0066] In yet another example of a system, the substrate 1402 includes a layup tool and at least one of the one or more previous plies 204 overlying the layup tool.

[0067] In yet another example of the system, the stack 200 includes a plurality of plies 204. The plurality of plies 204 include a first ply 204 and a second ply 204. The first ply 204 includes one or more rows 208. Each row 208 includes a multifilament bundle 206. The multifilament bundle 206 of each row 208 is simultaneously laid on the substrate 1402 by the multi-channel automatic fiber placement device 1302.

[0068] In yet another example of the system, the composite part includes a fiber reinforcement material, a matrix material, a carbon fiber material, a prepreg material, a thermoplastic material, a thermoset material, or any other suitable material in any suitable combination.

[0069] In another example of the system, one or more replacement tows 302 include fiber reinforcement tapes, fiber / polymer tapes, prepreg tapes, fiber reinforcement material tapes, fiber / polymer material tapes, prepreg material tapes, or any other suitable material in any suitable combination.

[0070] In yet another example of a system, the multi-channel automated fiber placement apparatus 1302 includes a plurality of tow placement machines 1404 configured to simultaneously place tows 206 onto the substrate 1402 to form the rows 208 of tows for the first ply 204. Each tow placement machine 1404 includes a layup tow material dispenser 1504, a layup feed mechanism 1506, a layup cutting mechanism 1508, a layup compaction roller 1510, a layup heat source 1512, and an imaging sensor 1502. The image sensor 1508 is configured to capture image data associated with the corresponding tow 206. The multi-channel automated fiber placement apparatus 1302 also includes a computing device 1406 configured to analyze the image data of the first ply 204. In another example, the plurality of tow layers 1404 includes two tow layers 1404, four tow layers 1404, eight tow layers 1404, sixteen tow layers 1404, or any other suitable number of tow layers 1404. In another further example, the computing device 1406 is configured to identify one or more out-of-tolerance inconsistencies 202 in the first ply 204 based on the image data of the first ply 204. In another further example, the computing device 1406 is configured to compare the image data of the one or more out-of-tolerance inconsistencies 202 in the first ply 204 with the tow standard of the layup 200 of the composite part relative to the acceptable tolerance of the tow standard. In this example, the computing device 1406 is configured to determine that one or more replacement tows 302 are needed to rework the one or more out-of-tolerance inconsistencies 202 in the first ply 204, wherein the one or more out-of-tolerance inconsistencies 202 are not within the acceptable tolerance of the tow standard.

[0071] In yet another example, the system further includes a tow removal tool 1306 configured to remove at least a portion of one or more tows 206 of the first plurality of tows 206 in the first ply 204 in preparation for reworking one or more out-of-tolerance inconsistencies 202. At least a portion of the one or more tows 206 is proximate to the one or more out-of-tolerance inconsistencies 202. In another example, the single-pass automated fiber placement device 1304 is configured to place one or more replacement tows 302 onto the substrate 1402 to replace at least a portion of the one or more tows 206 removed from the first ply 204. In another example of the system, the tow removal tool 1306 includes a seam splitting tool. In yet another further example, the single-pass automated fiber placement device 1304 is configured to place one or more replacement tows 302 onto the substrate 1402 to overlap the one or more replacement tows 302 onto one or more remaining portions 304 of the one or more tows 206 from which at least a portion has been removed. In yet another further example, the single-channel automated fiber placement device 1304 is configured to place one or more replacement tows 302 onto the substrate 1402 to splice the one or more replacement tows 302 with one or more retained portions 304 of one or more tows 206 from which at least a portion has been removed.

[0072] In yet another example of the system, the single-channel automated fiber placement device 1304 includes a compaction roller 1604 configured to compact one or more replacement tows 302 on the substrate 1402 to define a roller gap 1602. The compaction roller 1604 and the substrate 1402 define the roller gap 1602. In another example, the single-channel automated fiber placement device 1304 also includes an atmospheric pressure plasma heat source 1606, which is configured to project an atmospheric pressure plasma plume 1608 near the roller gap 1602 to heat at least one of the one or more replacement tows 302 and the substrate 1402. In a further example, the single-channel automated fiber placement device 1304 also includes a cutting mechanism 1610, which is configured to cut the one or more replacement tows 302 into a desired length in combination with the operation of the atmospheric pressure plasma heat source 1606 and the rework of the one or more out-of-tolerance inconsistencies 202. In a further example, the single-channel automatic fiber placement device 1304 also includes a tow material dispenser 1612 and a feeding mechanism 1614. The tow material dispenser 1612 is configured to hold and dispense bulk tow materials. The feeding mechanism 1614 is configured to advance the bulk tow materials from the tow material dispenser 1612 to the compacting roller 1604 via the cutting mechanism 1610.

[0073] In another example of the system, one or more out-of-tolerance inconsistencies 202 in the first ply 204 of the layup 200 for the composite part are due to a missing segment 210 of one or more tows 206. In this example, the single-pass automated fiber placement device 1304 includes a compaction roller 1604, an atmospheric pressure plasma heat source 1606, and a cutting mechanism 1610. The compaction roller 1604 is configured to compact the one or more replacement tows 302 on the substrate 1402 to define a roller gap 1602. The atmospheric pressure plasma heat source 1606 is configured to project an atmospheric pressure plasma plume 1608 near the roller gap 1602 to heat at least one of the one or more replacement tows 302 and the substrate 1402. The cutting mechanism 1610 is configured to cut the one or more replacement tows 302 into a desired length in conjunction with the projection of the atmospheric pressure plasma plume 1608.

[0074] In yet another example of a system, the single-channel automated fiber placement device 1304 includes a tow material dispenser 1612 , a feeding mechanism 1614 , a cutting mechanism 1610 , a compacting roller 1604 , and an atmospheric pressure plasma heat source 1606 .

[0075] Examples of methods 100, 800, 1700, 1800, 1900 and systems for manufacturing a layup 200 of composite materials may be related to or used in the context of aircraft manufacturing. Although aircraft examples are described, the examples and principles disclosed herein may be applied to other products in the aerospace industry and other industries, such as the automotive industry, the space industry, the construction industry, and other design and manufacturing industries. Thus, in addition to aircraft, the examples and principles disclosed herein may be applied to the use of composite products in the manufacture of various types of vehicles and the construction of various types of buildings.

[0076] The foregoing detailed description refers to the accompanying drawings, which illustrate specific examples described in the present disclosure. Other examples with different structures and operations do not depart from the scope of the present disclosure. In different drawings, the same reference numerals may refer to the same features, elements or parts. Throughout the present disclosure, any one of a plurality of projects may be referred to as a project individually, and a plurality of projects may be collectively referred to as a project and may be referred to with the same reference numerals. In addition, as used herein, the features, elements, parts or steps before the word "one" or "an" should be understood to not exclude a plurality of features, elements, parts or steps, unless such exclusion is explicitly stated.

[0077] The above provides illustrative, non-exhaustive examples according to the subject matter of the present disclosure, which may be but not necessarily are claimed. Reference to "example" herein means that one or more features, structures, elements, parts, characteristics and / or operating steps described in conjunction with the example are included in at least one aspect, embodiment and / or implementation of the subject matter of the present disclosure. Therefore, the phrases "example", "another example", "one or more examples" and similar language throughout the present disclosure may but may not refer to the same example. In addition, the subject matter representing any one example may but may not include the subject matter representing any other example. In addition, the subject matter representing any one example may but may not be combined with the subject matter representing any other example.

[0078] As used herein, a system, device, equipment, structure, article, element, component, or hardware that is "configured to" perform a specified function is indeed capable of performing the specified function without any changes, rather than having only the potential to perform the specified function after further modification. In other words, for the purpose of performing a specified function, a system, device, equipment, structure, article, element, component, or hardware that is "configured to" perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed. As used herein, "configured to" represents an existing characteristic of a system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform a specified function without further modification. For the purposes of this disclosure, a system, device, equipment, structure, article, element, component, or hardware that is described as "configured to" perform a particular function may be additionally or alternatively described as "suitable for" and / or "operable to" perform that function.

[0079] Unless otherwise indicated, the terms "first," "second," "third," etc. are used herein merely as labels and are not intended to impose order, position, or hierarchical requirements on the items to which these terms refer. Furthermore, reference to, for example, a "second" item does not require or preclude the presence of, for example, a "first" or lower numbered item and / or, for example, a "third" or higher numbered item.

[0080] 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 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, and item C" may include, but is not limited to, item A or item A and item B. This example may also include item A, item B, and item C or item B and item C. In other examples, "at least one" 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; and other suitable combinations. As used herein, the terms "and / or" and the " / " symbol include any and all combinations of one or more of the associated listed items.

[0081] As used herein, the terms "couple", "couple" and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, communicated or otherwise associated (e.g., mechanically, electrically, fluidically, optically, electromagnetically) with each other. In various examples, the elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. It should be understood that it is not necessary to represent all associations between the various disclosed elements. Therefore, there may also be couplers other than those shown in the figures.

[0082] As used herein, the term "approximately" refers to or represents a condition that is close to, but not exactly close to, a condition that still performs a desired function or achieves a desired result. As an example, the term "approximately" refers to a condition that is within an acceptable predetermined tolerance or accuracy, such as a condition within 10% of the condition. However, the term "approximately" does not exclude a condition that is exactly the condition. As used herein, the term "substantially" refers to a condition that is substantially the condition that performs a desired function or achieves a desired result.

[0083] In the above mentioned Figure 1 , Figures 4 to 12 and Figures 17 to 19 In the disclosure, the boxes may represent operations, steps and / or parts thereof, and the lines connecting the boxes do not imply any particular order or dependency of the operations or parts thereof. It should be understood that not all dependencies between the various disclosed operations are necessarily represented. Figure 1 , Figures 4 to 12 and Figures 17 to 19The attached disclosures describing the operations of the disclosed methods set forth herein should not be construed as necessarily determining the order in which the operations must be performed. On the contrary, although an illustrative order is indicated, it should be understood that the order of the operations can be modified when appropriate. Therefore, the operations shown can be modified, added and / or omitted, and certain operations can be performed in different orders or simultaneously. In addition, those skilled in the art will appreciate that it is not necessary to perform all the operations described.

[0084] exist Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 In the above, the above mentioned may represent functional elements, features or parts thereof, and does not necessarily imply any particular structure. Therefore, modifications, additions and / or omissions may be made to the structures shown. In addition, those skilled in the art will understand that not all of the above mentioned Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 All elements, features, and / or components described and shown in the present disclosure need to be included in every example, and not all elements, features, and / or components described herein need to be depicted in every illustrative example. Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 Some elements, features and / or components described and shown in the drawings may be combined in various ways without necessarily including Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 , other drawings and / or the accompanying disclosure, even if such combination or combinations are not explicitly indicated herein. Similarly, additional features not limited to the examples presented may be combined with some or all of the features shown and described herein. Unless explicitly stated otherwise, the above-mentioned Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16The schematic diagrams of the examples depicted in the drawings are not meant to imply structural limitations with respect to the illustrative examples. On the contrary, although an illustrative structure is indicated, it should be understood that the structure may be modified when appropriate. Therefore, modifications, additions and / or omissions may be made to the structures shown. In addition, elements, features and / or components serving similar or at least substantially similar purposes may be used in the drawings. Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 The same numerals are used in each of the embodiments, and such elements, features and / or components may not be referred to herein. Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 Similarly, all elements, features and / or components may not be present in Figure 2 , Figure 3 , FIG. 13A to FIG. 13C , Fig.14A , Fig. 14B , Fig.15 and Fig.16 Each of the reference numerals in FIG. 1 is labeled, but for consistency, the reference numerals associated therewith may be utilized herein.

[0085] In addition, references throughout this specification to features, advantages, or similar language used herein do not mean that all features and advantages that can be achieved with the examples disclosed herein should be or are in any single example. Instead, language referring to features and advantages is understood to mean that a particular feature, advantage, or characteristic described in conjunction with an example is included in at least one example. Therefore, discussions of features, advantages, and similar language used throughout this disclosure may, but do not necessarily, refer to the same example.

[0086] Examples of the subject matter disclosed herein can be found in Fig. 20 Aircraft manufacturing and service method 2000 is shown and Fig.212000 is described in the context of the aircraft 2100 shown. In one or more examples, the disclosed method and system for associating test data of a part under test with a final article coordinate system can be used in aircraft manufacturing. During pre-production, the maintenance method 2000 may include specification and design of the aircraft 2100 (box 2002) and material procurement (box 2004). During production, component and subassembly manufacturing (box 2006) and system integration (box 2008) of the aircraft 2100 may be performed. Thereafter, the aircraft 2100 may undergo certification and delivery (box 2010) to be put into service (box 2012). While in use, the aircraft 2100 may be scheduled for routine maintenance and repair (box 2014). Routine maintenance and repair may include modification, reconfiguration, refurbishment, etc. of one or more systems of the aircraft 2100.

[0087] Each of the processes of maintenance method 2000 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For 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 suppliers, subcontractors, and vendors; and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0088] like Fig.21 As shown, aircraft 2100 produced by maintenance method 2000 may include fuselage 2102 having multiple high-level systems 2104 and interior 2106. Examples of high-level systems 2104 include one or more of propulsion system 2108, electrical system 2110, hydraulic system 2112, and environmental system 2114. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Therefore, in addition to aircraft 2100, the principles disclosed herein may be applied to other vehicles, such as land vehicles, marine vehicles, spacecraft, etc.

[0089] The disclosed systems and methods for associating test data for a part under test with a final article coordinate system may be employed during any one or more stages of the manufacturing and service method 2000. For example, components or subassemblies corresponding to component and subassembly manufacturing (block 2006) may be manufactured or fabricated in a manner similar to components or subassemblies produced while the aircraft 2100 is in service (block 2012). In addition, one or more examples of the system, method, or combination thereof may be utilized during the production stage (blocks 2006 and 2008), for example, by significantly speeding up assembly of the aircraft 2100 or reducing the cost of the aircraft 2100. Similarly, for example, but not limited to, one or more examples of the system or method implementation or combination thereof may be utilized while the aircraft 2100 is in service (block 2012) and / or during maintenance and repair (block 2014).

[0090] This application involves the following terms:

[0091] 1. A method (100) for manufacturing a layup (200) of a composite part, the method comprising:

[0092] identifying (102) an out-of-tolerance inconsistency (202) in a current ply (204) of the layup (200) of the composite part, the current ply (204) comprising a plurality of tows (206) overlying a substrate (1402); and

[0093] A replacement tow (302) is placed (104) onto the substrate (1402) to rework the out-of-tolerance inconsistency (202) in the current ply (204) of the layup (200) of the composite part.

[0094] 2. The method (1700) of clause 1, further comprising:

[0095] placing (1702) at least one row (208) of multifilament tows (206) of the current ply (204) of the stack (200) onto the substrate (1402) using a multi-channel automated fiber placement device (1302);

[0096] After identifying (102) the out-of-tolerance inconsistency (202), removing (1704) the multi-channel automated fiber placement device (1302) from the layup (200);

[0097] providing (1706) a single-pass automated fiber placement device (1304) to the layup (200);

[0098] performing (1708) placing (104) the stack (200) using the single-pass automated fiber placement device (1304);

[0099] removing (1710) the single-pass automated fiber placement device (1304) from the layup (200);

[0100] providing (1712) the multi-channel automated fiber placement device (1302) to the layup (200); and

[0101] The placement of the course (208) of multifilament tows (206) is restored (1714) for the current ply (204) and / or subsequent plies (204) of the layup (200).

[0102] 3. The method of clause 1, wherein the identifying (102) of the out-of-tolerance inconsistency (202) is performed using at least one imaging sensor (1502).

[0103] 4. The method of clause 3, wherein the identifying (102) of the out-of-tolerance inconsistency (202) is performed in conjunction with laying down the plurality of tows (206) associated with the current ply (204).

[0104] 5. The method of clause 3, wherein the at least one imaging sensor (1502) comprises a single-channel scanner configured to scan a single tow (206) of the plurality of tows (206).

[0105] 6. The method of clause 3, wherein the at least one imaging sensor (1502) comprises a multi-channel scanner configured to scan multiple tows (206) of the plurality of tows (206).

[0106] 7. The method of clause 3, wherein the at least one imaging sensor (1502) captures imaging data of a single tow (206) of the plurality of tows (206).

[0107] 8. The method of clause 3, wherein the at least one imaging sensor (1502) captures imaging data of multiple tows (206) of the plurality of tows (206).

[0108] 9. A method according to claim 1, wherein the stack (200) includes one or more plies (204), the one or more plies (204) including the current ply (204), each ply (204) including one or more horizontal rows (208), each horizontal row (208) including multifilament bundles (206), and the multifilament bundles (206) of each horizontal row (208) are simultaneously covered on the substrate (1402).

[0109] 10. The method of clause 1, wherein the composite part comprises at least one of a fiber reinforcement material, a matrix material, a carbon fiber material, a prepreg material, a thermoplastic material, and a thermoset material.

[0110] 11. The method of clause 1, wherein the substrate (1402) comprises at least one of a layup tool and one or more previous plies (204) overlying the layup tool.

[0111] 12. The method of clause 1, wherein the plurality of tows (206) comprises at least one of a fiber reinforced tape, a fiber / polymer tape, a prepreg tape, a fiber reinforced material tape, a fiber / polymer material tape, and a prepreg material tape.

[0112] 13. The method of clause 1, wherein the replacement tow (302) comprises at least one of a fiber reinforced tape, a fiber / polymer tape, a prepreg tape, a fiber reinforced material tape, a fiber / polymer material tape, and a prepreg material tape.

[0113] 14. The method according to clause 1, further comprising:

[0114] It is determined (106) that the out-of-tolerance inconsistency (202) requires rework.

[0115] 15. The method of clause 14, wherein it is determined (106) that the out-of-tolerance inconsistency (202) requires rework, and the placement (104) of the replacement tow (302) is performed prior to laying down the next ply (204).

[0116] 16. The method of clause 14, wherein the determining (106) comprises:

[0117] comparing (402) the out-of-tolerance non-conformance (202) to a tow standard of the layup (200) of the composite part relative to an acceptable tolerance of the tow standard; and

[0118] It is determined (404) that the replacement tow (302) is needed to rework the out-of-tolerance inconsistency (202), wherein the out-of-tolerance inconsistency (202) is not within the acceptable tolerance of the tow standard.

[0119] 17. A method according to claim 1, wherein, in one or more passes of the multi-channel automatic fiber placement device (1302) along the substrate (1402), the multiple fiber bundles (206) in the current layer (204) are placed onto the substrate (1402) using the multi-channel automatic fiber placement device (1302).

[0120] 18. The method of clause 1, wherein the placing (104) of the replacement tow (302) is performed using a single-pass automated fiber placement device (1304).

[0121] 19. The method according to clause 1, further comprising:

[0122] At least a portion of one or more tows (206) of a plurality of tows (206) in the current ply (204) is removed (108) in preparation for reworking the out-of-tolerance inconsistency (202), the at least a portion of the one or more tows (206) being proximate to the out-of-tolerance inconsistency (202).

[0123] 20. The method of clause 19, wherein the replacement tow (302) is placed onto the substrate (1402) to replace at least a portion of the one or more tows (206) removed from the current ply (204).

[0124] 21. The method of clause 19, wherein the removing (108) of the at least a portion of the one or more tows (206) is performed using a tow removal tool (1306).

[0125] 22. The method of clause 19, wherein placing (104) the replacement tow (302) comprises:

[0126] The replacement tow (302) is overlapped (502) onto the one or more remaining portions (304) of the one or more tows (206) from which the at least a portion was removed.

[0127] 23. The method of clause 19, wherein placing (104) the replacement tow (302) comprises:

[0128] The replacement tow (302) is spliced ​​(504) with one or more remaining portions (304) of the one or more tows (206) from which the at least a portion has been removed.

[0129] 24. The method of clause 1, wherein placing (104) the replacement tow (302) comprises:

[0130] The replacement tow (302) is compacted (602) on the substrate (1402) to define a nip (1602).

[0131] 25. The method of clause 24, wherein the compacting (602) of the replacement tow (302) is performed using a compacting roller (1604), the compacting roller (1604) and the substrate (1402) defining the roller gap (1602).

[0132] 26. The method of clause 24, placing (104) the replacement tow (302) further comprising:

[0133] An atmospheric pressure plasma plume (1608) is projected (604) proximate the nip (1602) to heat at least one of the replacement tow (302) and the substrate (1402).

[0134] 27. The method of clause 26, wherein projecting (604) the atmospheric pressure plasma plume (1608) comprises projecting the atmospheric pressure plasma plume (1608) at a divergence angle ranging from at least one of about 0 degrees to about 20 degrees, about 0 degrees to about 10 degrees, and about 0 degrees to about 5 degrees.

[0135] 28. The method of clause 26, wherein projecting (604) the atmospheric pressure plasma plume (1608) comprises projecting the atmospheric pressure plasma plume (1608) at a pressure in a range of about 15 psi to about 50 psi.

[0136] 29. The method of clause 26, wherein the atmospheric pressure plasma plume (1608) has a width ranging from at least one of about 0.10 inches to about 0.40 inches, about 0.15 inches to about 0.35 inches, and about 0.20 inches to about 0.30 inches.

[0137] 30. The method of clause 26, wherein the atmospheric pressure plasma plume (1608) has a length ranging from at least one of about 0.25 inches to about 1.5 inches, about 0.5 inches to about 1.0 inches, and about 0.70 inches to about 0.80 inches.

[0138] 31. The method of clause 26, wherein the atmospheric pressure plasma plume (1608) is about 0.5 inches to about 0.8 inches from the nip (1602).

[0139] 32. The method of clause 26, placing (104) the replacement tow (302) further comprising:

[0140] In conjunction with the projection (604) of the atmospheric pressure plasma plume (1608) and reworking of the out-of-tolerance inconsistency (202), the replacement tow (302) is cut (606) to a desired length.

[0141] 33. The method of clause 1, wherein the out-of-tolerance inconsistency (202) in the layup (200) of the composite part is due to a missing segment (210) of one or more tows (206), and placing (104) the replacement tow (302) comprises:

[0142] compacting (702) the replacement tow (302) on the substrate (1402) to define a nip (1602);

[0143] projecting (704) an atmospheric pressure plasma plume (1608) proximate the nip (1602) to heat at least one of the replacement tow (302) and the substrate (1402); and

[0144] The replacement tow (302) is cut (706) to a desired length in conjunction with the projection (704) of the atmospheric pressure plasma plume (1608).

[0145] 34. A method (800) for manufacturing a layup (200) of a composite part, the method comprising:

[0146] placing (802) a first plurality of tows (206) onto a substrate (1402) using a multi-channel automated fiber placement device (1302) to form a first ply (204) covering the substrate (1402) in conjunction with fabrication of the layup (200) of the composite part;

[0147] After identifying one or more out-of-tolerance inconsistencies (202) in the first ply (204) and specifying rework, placing (804) one or more replacement tows (302) onto the substrate (1402) to rework the one or more out-of-tolerance inconsistencies (202) in the first ply (204) using a single-pass automated fiber placement device (1304); and

[0148] A second plurality of tows are placed (806) onto the substrate (1402) using the multi-channel automated fiber placement device (1302) to form a second ply (204) overlying the first ply (204) in conjunction with fabrication of the layup (200) of the composite part.

[0149] 35. The method (1800) of clause 34, further comprising:

[0150] After identifying the one or more out-of-tolerance inconsistencies (202) and specifying rework, removing (1802) the multi-pass automated fiber placement device (1302) from the layup (200); and

[0151] A single-pass automated fiber placement device (1304) is provided (1804) to the layup (200).

[0152] 36. The method (1900) of clause 34, further comprising:

[0153] After placing the one or more replacement tows (302), removing (1902) the single-pass automated fiber placement device (1304) from the layup (200); and

[0154] The multi-channel automated fiber placement device (1302) is provided (1904) to the layup (200) to restore placement of the multifilament tows (206) of the layup (200).

[0155] 37. The method of clause 34, wherein the plurality of tows (206) comprises at least one of a fiber reinforced tape, a fiber / polymer tape, a prepreg tape, a fiber reinforced material tape, a fiber / polymer material tape, and a prepreg material tape.

[0156] 38. The method of clause 34, wherein the substrate (1402) comprises at least one of a layup tool and one or more previous plies (204) overlying the layup tool.

[0157] 39. A method according to claim 34, wherein the stack (200) includes a plurality of plies (204), the plurality of plies (204) include the first ply (204) and the second ply (204), the first ply (204) includes one or more horizontal rows (208), each horizontal row (208) includes a multi-filament bundle (206), and the multi-filament bundle (206) of each horizontal row (208) is simultaneously covered on the substrate (1402) by the multi-channel automatic fiber placement device (1302).

[0158] 40. The method of clause 34, wherein the composite part comprises at least one of a fiber reinforcement material, a matrix material, a carbon fiber material, a prepreg material, a thermoplastic material, and a thermoset material.

[0159] 41. The method of clause 34, wherein the one or more replacement tows (302) comprise at least one of a fiber reinforced tape, a fiber / polymer tape, a prepreg tape, a fiber reinforced material tape, a fiber / polymer material tape, and a prepreg material tape.

[0160] 42. The method according to clause 34, further comprising:

[0161] It is determined (808) that the one or more out-of-tolerance inconsistencies (202) require rework.

[0162] 43. A method according to clause 42, wherein it is determined (808) that the one or more out-of-tolerance inconsistencies (202) require rework, and the placement (804) of the one or more replacement tows (302) is performed before placing (806) the second plurality of tows (206) to form the second layer (204).

[0163] 44. The method of clause 42, wherein the determining (808) comprises:

[0164] comparing (902) the one or more out-of-tolerance inconsistencies (202) to a tow standard of the layup (200) of the composite part relative to an acceptable tolerance of the tow standard; and

[0165] It is determined (904) that the one or more replacement tows (302) are needed to rework the one or more out-of-tolerance inconsistencies (202), wherein the one or more out-of-tolerance inconsistencies (202) are not within the acceptable tolerance of the tow standard.

[0166] 45. The method according to clause 34, further comprising:

[0167] Removing (810) at least a portion of one or more of the first plurality of tows (206) in the first ply (204) in preparation for reworking the one or more out-of-tolerance inconsistencies (202), the at least a portion of the one or more tows (206) being proximate to the one or more out-of-tolerance inconsistencies (202).

[0168] 46. ​​A method according to clause 45, wherein the one or more replacement tows (302) are placed on the substrate (1402) to replace at least a portion of the one or more tows (206) removed from the first layer (204).

[0169] 47. The method of clause 45, wherein the removing (810) of the at least a portion of the one or more tows (206) is performed using a tow removal tool (1306).

[0170] 48. The method of clause 45, wherein placing (804) the one or more replacement tows (302) comprises:

[0171] One or more replacement tows (302) are overlapped (1002) onto the one or more remaining portions (304) of the one or more tows (206) from which the at least a portion was removed.

[0172] 49. The method of clause 45, wherein placing (804) the one or more replacement tows (302) comprises:

[0173] The one or more replacement tows (302) are spliced ​​(1004) with the one or more remaining portions (304) of the one or more tows (206) from which the at least a portion has been removed.

[0174] 50. The method of clause 34, wherein placing (804) the one or more replacement tows (302) comprises:

[0175] The one or more replacement tows (302) are compacted (1102) on the substrate (1402) to define a nip (1602).

[0176] 51. A method according to claim 50, wherein the single-channel automatic fiber placement device (1304) includes a compaction roller (1604), wherein the compaction (1102) of the one or more replacement filament bundles (302) is performed using the compaction roller (1604), and the compaction roller (1604) and the substrate (1402) define the roller gap (1602).

[0177] 52. The method of clause 50, wherein placing (804) the one or more replacement tows (302) further comprises:

[0178] An atmospheric pressure plasma plume (1608) is projected (1104) proximate the nip (1602) to heat at least one of the one or more replacement tows (302) and the substrate (1402).

[0179] 53. The method of clause 52, placing (804) the one or more replacement tows (302) further comprising:

[0180] In conjunction with the projecting (1104) of the atmospheric pressure plasma plume (1608) and reworking of the one or more out-of-tolerance inconsistencies (202), the one or more replacement tows (302) are cut (1106) to a desired length.

[0181] 54. The method of clause 34, wherein the one or more out-of-tolerance inconsistencies (202) in the first ply (204) of the layup (200) for the composite part are due to a missing segment (210) of one or more tows (206), and placing (804) the one or more replacement tows (302) comprises:

[0182] compacting (1202) the one or more replacement tows (302) on the substrate (1402) to define a nip (1602);

[0183] projecting (1204) an atmospheric pressure plasma plume (1608) proximate the nip (1602) to heat at least one of the one or more replacement tows (302) and the substrate (1402); and

[0184] The one or more replacement tows (302) are cut (1206) to desired lengths in conjunction with the projection (1204) of the atmospheric pressure plasma plume (1608).

[0185] 55. A system for manufacturing a layup (200) of a composite part, the system comprising:

[0186] a multi-channel automated fiber placement device (1302) configured to place a first plurality of tows (206) onto a substrate (1402) to form a first ply (204) covering the substrate (1402) in conjunction with fabrication of the layup (200) of the composite part; and

[0187] a single-pass automated fiber placement device (1304) configured to place one or more replacement tows (302) onto the substrate (1402) to rework one or more out-of-tolerance inconsistencies (202) in the first ply (204), the one or more out-of-tolerance inconsistencies (202) having been previously identified and designated for rework;

[0188] Wherein, after reworking the one or more out-of-tolerance inconsistencies (202), the multi-channel automatic fiber placement device (1302) is configured to place a second plurality of filament bundles (206) onto the substrate (1402) to form a second layer (204) covering the first layer (204) in conjunction with the manufacture of the stack (200) of the composite part.

[0189] 56. A system according to clause 55, wherein the plurality of tows (206) include at least one of fiber reinforced tapes, fiber / polymer tapes, prepreg tapes, fiber reinforced material tapes, fiber / polymer material tapes, and prepreg material tapes.

[0190] 57. The system of clause 55, wherein the substrate (1402) comprises at least one of a layup tool and one or more previous plies (204) overlying the layup tool.

[0191] 58. A system according to claim 55, wherein the stack (200) includes a plurality of plies (204), the plurality of plies (204) include the first ply (204) and the second ply (204), the first ply (204) includes one or more horizontal rows (208), each horizontal row (208) includes a multi-filament bundle (206), and the multi-filament bundle (206) of each horizontal row (208) is simultaneously covered on the substrate (1402) by the multi-channel automatic fiber placement device (1302).

[0192] 59. The system of clause 55, wherein the composite part comprises at least one of a fiber reinforcement material, a matrix material, a carbon fiber material, a prepreg material, a thermoplastic material, and a thermoset material.

[0193] 60. A system according to clause 55, wherein the one or more replacement tows (302) include at least one of a fiber reinforced tape, a fiber / polymer tape, a prepreg tape, a fiber reinforced material tape, a fiber / polymer material tape, and a prepreg material tape.

[0194] 61. The system according to clause 55, wherein the multi-channel automatic fiber placement device (1302) comprises:

[0195] a plurality of tow placing machines (1404) configured to simultaneously place tows (206) onto the substrate (1402) to form rows (208) of tows for the first ply (204), each tow placing machine (1404) comprising:

[0196] Laying a tow material distributor (1504);

[0197] Laying feed mechanism (1506);

[0198] Laying out the cutting mechanism (1508);

[0199] Laying compaction rollers (1510);

[0200] Laying down a heat source (1512); and

[0201] an imaging sensor (1502) configured to capture image data associated with a corresponding tow (206); and

[0202] A computing device (1406) is configured to analyze the image data of the first ply (204).

[0203] 62. The system of clause 61, wherein the plurality of tow layers (1404) comprises at least one of two tow layers (1404), four tow layers (1404), eight tow layers (1404), and sixteen tow layers (1404).

[0204] 63. The system of clause 61, wherein the computing device (1406) is configured to identify the one or more out-of-tolerance inconsistencies (202) in the first ply (204) based on the image data of the first ply (204).

[0205] 64. The system of clause 63, wherein the computing device (1406) is configured to compare the image data of the one or more out-of-tolerance inconsistencies (202) in the first ply (204) to an acceptable tolerance of a tow standard of the layup (200) of the composite part relative to the tow standard,

[0206] wherein the computing device (1406) is configured to determine that the one or more replacement tows (302) are required to rework the one or more out-of-tolerance inconsistencies (202) in the first ply (204), wherein the one or more out-of-tolerance inconsistencies (202) are not within the acceptable tolerance of the tow standard.

[0207] 65. The system according to clause 55, further comprising:

[0208] A tow removal tool (1306) configured to remove at least a portion of one or more tows (206) of the first plurality of tows (206) in the first ply (204) in preparation for reworking the one or more out-of-tolerance inconsistencies (202), the at least a portion of the one or more tows (206) being proximate to the one or more out-of-tolerance inconsistencies (202).

[0209] 66. A system according to claim 65, wherein the single-channel automatic fiber placement device (1304) is configured to place the one or more replacement filament bundles (302) onto the substrate (1402) to replace at least a portion of the one or more filament bundles (206) removed from the first layer (204).

[0210] 67. The system of clause 65, wherein the tow removal tool (1306) comprises a seam cutting tool.

[0211] 68. A system according to claim 65, wherein the single-channel automatic fiber placement device (1304) is configured to place the one or more replacement filament bundles (302) onto the substrate (1402) to overlap the one or more replacement filament bundles (302) onto one or more retained portions (304) of the one or more filament bundles (206) from which at least a portion has been removed.

[0212] 69. A system according to claim 65, wherein the single-channel automatic fiber placement device (1304) is configured to place the one or more replacement filament bundles (302) onto the substrate (1402) to splice the one or more replacement filament bundles (302) with one or more retained portions (304) of the one or more filament bundles (206) from which at least a portion has been removed.

[0213] 70. The system according to clause 55, wherein the single-channel automatic fiber placement device (1304) comprises:

[0214] A compaction roller (1604) is configured to compact the one or more replacement tows (302) on the substrate (1402) to define a roller gap (1602), the compaction roller (1604) and the substrate (1402) defining the roller gap (1602).

[0215] 71. The system according to clause 70, wherein the single-channel automatic fiber placement device (1304) further comprises:

[0216] An atmospheric pressure plasma heat source (1606) is configured to project an atmospheric pressure plasma plume (1608) near the nip (1602) to heat at least one of the one or more replacement filament bundles (302) and the substrate (1402).

[0217] 72. The system according to clause 71, wherein the single-channel automatic fiber placement device (1304) further comprises:

[0218] A cutting mechanism (1610) configured to cut the one or more replacement tows (302) into desired lengths in conjunction with operation of the atmospheric pressure plasma heat source (1606) and reworking of the one or more out-of-tolerance inconsistencies (202).

[0219] 73. The system according to clause 72, wherein the single-channel automatic fiber placement device (1304) further comprises:

[0220] a tow material dispenser (1612) configured to hold and dispense bulk tow material; and

[0221] A feed mechanism (1614) is configured to advance the bulk tow material from the tow material dispenser (1612) to the compacting roller (1604) via the cutting mechanism (1610).

[0222] 74. The system of clause 55, wherein the one or more out-of-tolerance inconsistencies (202) in the first ply (204) of the layup (200) for the composite part are due to a missing segment (210) of one or more tows (206), the single-pass automated fiber placement apparatus (1304) comprising:

[0223] a compaction roller (1604) configured to compact the one or more replacement tows (302) on the substrate (1402) to define a roller gap (1602);

[0224] an atmospheric pressure plasma heat source (1606) configured to project an atmospheric pressure plasma plume (1608) proximate the nip (1602) to heat at least one of the one or more replacement filament bundles (302) and the substrate (1402); and

[0225] A cutting mechanism (1610) configured to cut the one or more replacement tows (302) into desired lengths in conjunction with the projection of the atmospheric pressure plasma plume (1608).

[0226] 75. The system according to clause 55, wherein the single-channel automatic fiber placement device (1304) comprises:

[0227] A tow material dispenser (1612);

[0228] Feed mechanism (1614);

[0229] Cutting mechanism (1610);

[0230] Compacting rollers (1604); and

[0231] Atmospheric pressure plasma heat source (1606).

[0232] The described features, advantages, and characteristics of one example may be combined in any suitable manner in one or more other examples. Those skilled in the relevant art will recognize that the examples described herein may be practiced without one or more specific features or advantages of a particular example. In other cases, additional features and advantages that may not be present in all examples may be recognized in certain examples. In addition, although various examples of methods 100, 800, 1700, 1800, 1900 and systems for manufacturing a stack 200 of composite parts have been shown and described, modifications may occur to those skilled in the art when reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

[0233] This application claims priority to U.S. Application No. 63 / 516,591, filed on July 31, 2023.

Claims

1. A method (100) for manufacturing a layup (200) of a composite part, the method comprising: identifying (102) an out-of-tolerance inconsistency (202) in a current ply (204) of the layup (200) of the composite part, the current ply (204) comprising a plurality of tows (206) overlying a substrate (1402); as well as A replacement tow (302) is placed (104) onto the substrate (1402) to rework the out-of-tolerance inconsistency (202) in the current ply (204) of the layup (200) of the composite part.

2. The method (1700) of claim 1, further comprising: placing (1702) at least one row (208) of multifilament tows (206) of the current ply (204) of the stack (200) onto the substrate (1402) using a multi-channel automated fiber placement device (1302); After identifying (102) the out-of-tolerance inconsistency (202), removing (1704) the multi-channel automated fiber placement device (1302) from the layup (200); providing (1706) a single-pass automated fiber placement device (1304) to the layup (200); performing (1708) placing (104) the stack (200) using the single-pass automated fiber placement device (1304); removing (1710) the single-pass automated fiber placement device (1304) from the layup (200); providing (1712) the multi-channel automated fiber placement device (1302) to the layup (200); and The placement of the rows (208) of multifilament tows (206) is restored (1714) for the current ply (204) and / or subsequent plies (204) of the layup (200).

3. The method according to claim 1, wherein: The identifying (102) of the out-of-tolerance inconsistency (202) is performed using at least one imaging sensor (1502).

4. The method according to claim 1, further comprising: It is determined (106) that the out-of-tolerance inconsistency (202) requires rework.

5. The method of claim 4, wherein the determining (106) comprises: comparing (402) the out-of-tolerance non-conformance (202) to a tow standard of the layup (200) of the composite part relative to an acceptable tolerance of the tow standard; as well as It is determined (404) that the replacement tow (302) is needed to rework the out-of-tolerance inconsistency (202), wherein the out-of-tolerance inconsistency (202) is not within the acceptable tolerance of the tow standard.

6. The method according to claim 1, wherein: The placing (104) of the replacement tow (302) is performed using a single-pass automated fiber placement device (1304).

7. The method according to claim 1, further comprising: At least a portion of one or more tows (206) of a plurality of tows (206) in the current ply (204) is removed (108) in preparation for reworking the out-of-tolerance inconsistency (202), the at least a portion of the one or more tows (206) being proximate to the out-of-tolerance inconsistency (202).

8. The method according to claim 7, wherein: The replacement tow (302) is placed onto the substrate (1402) to replace the at least a portion of the one or more tows (206) removed from the current ply (204).

9. The method according to claim 7, wherein: Placing (104) the replacement tow (302) includes: The replacement tow (302) is overlapped (502) onto the one or more remaining portions (304) of the one or more tows (206) from which the at least a portion was removed.

10. The method according to claim 7, wherein: Placing (104) the replacement tow (302) includes: The replacement tow (302) is spliced ​​(504) with one or more remaining portions (304) of the one or more tows (206) from which the at least a portion has been removed.

11. The method according to claim 1, wherein: Placing (104) the replacement tow (302) includes: The replacement tow (302) is compacted (602) on the substrate (1402) to define a nip (1602).

12. The method according to claim 11, wherein: Placing (104) the replacement tow (302) further comprises: An atmospheric pressure plasma plume (1608) is projected (604) proximate the nip (1602) to heat at least one of the replacement tow (302) and the substrate (1402).

13. The method according to claim 12, wherein: Projecting (604) the atmospheric pressure plasma plume (1608) includes projecting the atmospheric pressure plasma plume (1608) at a divergence angle ranging from at least one of 0 degrees to 20 degrees, 0 degrees to 10 degrees, and 0 degrees to 5 degrees.

14. The method according to claim 12, wherein: Projecting (604) the atmospheric pressure plasma plume (1608) includes projecting the atmospheric pressure plasma plume (1608) at a pressure in a range of 15 psi to 50 psi.

15. The method according to claim 12, wherein: The atmospheric pressure plasma plume (1608) has a width ranging from at least one of 0.10 inches to 0.40 inches, 0.15 inches to 0.35 inches, and 0.20 inches to 0.30 inches.

16. The method according to claim 12, wherein: The atmospheric pressure plasma plume (1608) has a length ranging from at least one of 0.25 inches to 1.5 inches, 0.5 inches to 1.0 inches, and 0.70 inches to 0.80 inches.

17. The method according to claim 12, wherein: The atmospheric pressure plasma plume (1608) is 0.5 inches to 0.8 inches from the nip (1602).

18. The method according to claim 1, wherein: The out-of-tolerance inconsistency (202) in the layup (200) of the composite part is due to a missing segment (210) of one or more tows (206), and placing (104) the replacement tow (302) includes: compacting (702) the replacement tow (302) on the substrate (1402) to define a nip (1602); projecting (704) an atmospheric pressure plasma plume (1608) proximate the nip (1602) to heat at least one of the replacement tow (302) and the substrate (1402); and The replacement tow (302) is cut (706) to a desired length in conjunction with the projection (704) of the atmospheric pressure plasma plume (1608).

19. A method (800) for manufacturing a layup (200) of a composite part, the method comprising: placing (802) a first plurality of tows (206) onto a substrate (1402) using a multi-channel automated fiber placement device (1302) to form a first ply (204) covering the substrate (1402) in conjunction with fabrication of the layup (200) of the composite part; After identifying one or more out-of-tolerance inconsistencies (202) in the first ply (204) and specifying rework, placing (804) one or more replacement tows (302) onto the substrate (1402) to rework the one or more out-of-tolerance inconsistencies (202) in the first ply (204) using a single-pass automated fiber placement device (1304); and A second plurality of tows are placed (806) onto the substrate (1402) using the multi-channel automated fiber placement device (1302) to form a second ply (204) overlying the first ply (204) in conjunction with fabrication of the layup (200) of the composite part.

20. A system for manufacturing a layup (200) of a composite part, the system comprising: a multi-channel automated fiber placement device (1302) configured to place a first plurality of tows (206) onto a substrate (1402) to form a first ply (204) covering the substrate (1402) in conjunction with fabrication of the layup (200) of the composite part; and a single-pass automated fiber placement device (1304) configured to place one or more replacement tows (302) onto the substrate (1402) to rework one or more out-of-tolerance inconsistencies (202) in the first ply (204), the one or more out-of-tolerance inconsistencies (202) having been previously identified and designated for rework; Wherein, after reworking the one or more out-of-tolerance inconsistencies (202), the multi-channel automatic fiber placement device (1302) is configured to place a second plurality of filament bundles (206) onto the substrate (1402) to form a second layer (204) covering the first layer (204) in conjunction with the manufacture of the stack (200) of the composite part.

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