Multilayer sheet lamination system

Abstract

A multilayer sheet lamination system, and a method of forming a multilayer sheet laminate. The first cutting system cuts the first set of layers and moves the first set of layers to a temporary position. The placement robot picks up the first set of plies from the temporary location and places the first set of plies to the laying surface to form a first ply of the multi-ply laminate, changing the orientation of the fibers from the initial orientation to a desired orientation of the first ply. A second cutting system cuts and moves a second set of layers to a temporary position while the placement robot picks up and places the first set of layers. The placement robot picks up the second set of plies from the temporary location and places the second set of plies to the laying surface to form a second ply of the multi-ply laminate after the first ply has been formed, changing the orientation of the fibers from the initial orientation to a desired orientation of the second ply.

Description

Technical Field

[0001] The present disclosure relates generally to composite material manufacturing, and in particular to multi-ply lamination of elongated composite material portions. Background Art

[0002] Aircraft are designed and manufactured using an increasing percentage of composite materials. Composite materials are used in aircraft to reduce the weight of the aircraft. This reduced weight can improve performance characteristics (such as payload capacity and fuel efficiency). In addition, composite materials provide longer service life for various components in aircraft.

[0003] Composite materials can be tough, lightweight materials created by combining two or more functional components. For example, a composite material can include reinforcing fibers (e.g., carbon fiber reinforced polymer (CFRP)) bound in a polymer resin matrix. The fibers can be unidirectional (e.g., tape or tow), or can be multidirectional (e.g., woven cloth or fabric). The fibers and resin can be arranged and cured to form a composite structure.

[0004] The use of composite materials to create aerospace composite structures can enable parts of an aircraft to be manufactured in larger blocks or sections. For example, a fuselage in an aircraft can be created in cylindrical sections to form the fuselage of the aircraft. Other examples include, but are not limited to, wing parts connected to form a wing or stabilizer parts connected to form a stabilizer.

[0005] When making a composite structure, layers of composite material can be laid up on a tool. The layers of composite material can include fibers in sheets. These sheets can take the form of, for example, but not limited to, fabrics, strips, tows, or other suitable configurations for sheets. In some cases, resin can be injected or pre-impregnated into the sheets. These types of sheets are commonly referred to as prepregs.

[0006] Different layers of prepreg can be laid up in different orientations and different numbers of layers can be used, depending on the desired thickness of the composite structure being manufactured. The layers can be laid up by hand or using automated lamination equipment such as a tape laminator or fiber placement system.

[0007] After the different layers have been laid up on the tool, the layers can consolidate and cure when exposed to temperature and pressure, forming the final composite structure. Summary of the invention

[0008] An embodiment of the present disclosure provides a multi-layer sheet lamination system, which includes a first cutting system, a second cutting system, a placement robot, and a controller. The first cutting system and the second cutting system are each configured to independently cut a material having fibers oriented in an initial orientation to form a course and move the course to a temporary position. The controller communicates with the first cutting system, the second cutting system, and the placement robot. The controller is configured to control the first cutting system to cut a first set of layers and move the first set of layers to a temporary position. The controller is configured to control the placement robot to pick up and place the first set of layers from a temporary position to a laying surface to form a first layer of a multi-layer sheet laminate, changing the orientation of the fibers from the initial orientation to the desired orientation of the first layer. The controller is configured to control the second cutting system to cut a second set of layers and move the second set of layers to a temporary position while the placement robot is picking up and placing the first set of layers. The controller is configured to control the placement robot to pick up a second set of plies from a temporary location and place the second set of plies onto a layup surface to form a second ply of the multi-ply laminate after the first ply has been formed, thereby changing the orientation of the fibers from an initial orientation to a desired orientation of the second ply.

[0009] Another embodiment of the present disclosure provides a multi-layer sheet lamination system, which includes a first cutting system, a second cutting system, a placement robot, an automatic tape laying machine, and a controller. The first cutting system and the second cutting system are each configured to independently cut a material having fibers oriented in an initial orientation to form layers and move the layers to a temporary position. The automatic tape laying machine is positioned to place the material having fibers in the initial orientation onto a laying surface. The controller communicates with the first cutting system, the second cutting system, the placement robot, and the automatic tape laying machine. The controller is configured to control the first cutting system to cut a first group of layers and move the first group of layers to a temporary position. The controller is configured to control the placement robot to pick up the first group of layers from a temporary position and place the first group of layers onto the laying surface to form a first layer of a multi-layer sheet laminate, thereby changing the orientation of the fibers from the initial orientation to the desired orientation of the first layer. The controller is configured to control the second cutting system to cut a second group of layers and move the second group of layers to a temporary position while the placement robot picks up and places the first group of layers. The controller is configured to control the placement robot to pick up a second set of plies from a temporary location and place the second set of plies onto a layup surface to form a second ply of the multi-ply laminate after the first ply has been formed, thereby changing the orientation of the fibers from the initial orientation to a desired orientation of the second ply. The controller is configured to control the automated tape placement machine to place material to form plies of the multi-ply laminate, wherein the plies have fibers oriented in the initial orientation.

[0010] Yet another embodiment of the present disclosure provides a method for forming a multi-layer laminate. A first cutting system is controlled to cut a first set of layers and move the first set of layers to a temporary position. A placement robot is controlled to pick up the first set of layers from the temporary position and place the first set of layers on a laying surface to form a first layer of the multi-layer laminate, thereby changing the orientation of the fibers from an initial orientation to a desired orientation of the first layer. A second cutting system is controlled to cut a second set of layers and move the second set of layers to a temporary position while the placement robot picks up and places the first set of layers. The placement robot is controlled to pick up a second set of layers from a temporary position and place the second set of layers on a laying surface to form a second layer of the multi-layer laminate after the first layer has been formed, thereby changing the orientation of the fibers from an initial orientation to a desired orientation of the second layer. An automatic strip laying machine is controlled to place material to form a third layer of the multi-layer laminate, wherein the third layer has fibers oriented in the initial orientation.

[0011] Clause 1. A multi-layer sheet lamination system (102, 200, 400), comprising:

[0012] a first cutting system (120) and a second cutting system (122), each of the first cutting system (120) and the second cutting system (122) being configured to independently cut a material (121) having fibers (123) oriented in an initial orientation (125) to form a layer (131) and to move the layer (131) to a temporary position (141);

[0013] placing a robot (124, 214, 420); and

[0014] a controller (114) in communication with the first cutting system (120) and the second cutting system (122) and the placement robot (124, 214, 420), wherein the controller (114) is configured to:

[0015] Controlling the first cutting system (120) to cut a first set of layers (131) and to place the first set of layers (131)

[0016] A set of layers (131) is moved to the temporary position (141);

[0017] controlling the placement robot (124, 214, 420) to pick up the first set of plies (131) from the temporary location (141) and place the first set of plies (131) onto a layup surface (127, 234, 320, 416) to form a first ply (130) of a multi-ply laminate (128), changing the orientation of the fibers (123) from the initial orientation (125) to a desired orientation (146) of the first ply (130);

[0018] Controlling the second cutting system (122) to place the robot (124, 214, 420)

[0019] While the first set of layers (131) is being picked up and placed, the second set of layers (131) is being cut and

[0020] The second set of layers (131) is moved to the temporary position (141); and

[0021] The placement robot (124, 214, 420) is controlled to pick up the second group of layers (131) from the temporary position (141) and place the second group of layers (131) onto the laying surface (127, 234, 320, 416) to form the second layer (134) of the multi-layer laminate (128) after the first layer (130) has been formed, changing the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) of the second layer (134).

[0022] Clause 2. The multi-layer sheet lamination system (102, 200, 400) according to clause 1, further comprising:

[0023] An automated tape laying machine (126) positioned to place a material (145) having fibers (148) in the initial orientation (125) onto the laying surface (127, 234, 320, 416), wherein the controller (114) is configured to:

[0024] The automatic tape placement machine (126) is controlled to place the material to form a third ply (136) of the multi-ply laminate (128), wherein the third ply (136) has the fibers (148) oriented in the initial orientation (125).

[0025] Clause 3. The multi-layer sheet lamination system (102, 200, 400) of Clause 1, wherein the first cutting system (120) comprises:

[0026] a first cutter (132, 202, 132) configured to cut the layer (131); and

[0027] a first conveyor (133, 204, 302, 412) configured to move the layer (131) cut by the first cutter (132, 202, 132) to the temporary position (141) in the initial orientation (125), and

[0028] The second cutting system (122) comprises:

[0029] A second cutting machine (122, 207, 413), wherein the second cutting machine (122, 207, 413) is

[0030] configured to cut the layer (131); and

[0031] The second conveyor (139, 208, 304, 414), the second conveyor (139, 208,

[0032] The method further comprises: a first cutting machine (304, 414) configured to move the layer (131) cut by the second cutting machine (122, 207, 413) to the temporary position (141) in the initial orientation (125).

[0033] Clause 4. The multi-layer sheet lamination system (102, 200, 400) according to clause 3, wherein at least one of the first cutter and the second cutter (122, 207, 413) is configured to cut the layer (131) from a material roll.

[0034] Clause 5. The multi-layer sheet lamination system (102, 200, 400) according to clause 1, further comprising:

[0035] A laying conveyor, wherein the laying surface (127, 234, 320, 416) is on the laying conveyor.

[0036] Clause 6. The multi-layer sheet lamination system (102, 200, 400) according to clause 1, further comprising:

[0037] A laying table, wherein the laying surface (127, 234, 320, 416) is on the laying table.

[0038] Clause 7. The multi-layer sheet lamination system (102, 200, 400) according to clause 1, further comprising:

[0039] An inspection system (149) is configured to determine whether any of the layers (131) have an out-of-tolerance anomaly (155).

[0040] Clause 8. The multi-ply lamination system (102, 200, 400) of clause 7, wherein the inspection system (149) comprises a robot camera (152) coupled to the placement robot (124, 214, 420), wherein the robot camera (152) is positioned to generate a top image (153) of a top surface of the layer (131);

[0041] and wherein the controller (114) is configured to:

[0042] generating the top image (153) of the top surface of the layer (131) in response to the placement robot (124, 214, 420) moving to pick up the layer (131);

[0043] analyzing the top image (153) for the anomalies (155) that are out of tolerance; and

[0044] The placement robot (124, 214, 420) is controlled to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0045] Clause 9. The multi-ply lamination system (102, 200, 400) of clause 7, wherein the inspection system (149) comprises an upward camera (160) connected to a camera station, wherein the upward camera (160) is positioned to generate a bottom image (162) of a bottom surface of the layer (131) held by the placement robot (124, 214, 420),

[0046] The controller (114) is configured to:

[0047] generating the bottom image (162) of the bottom surface of the layer (131);

[0048] analyzing the bottom image (162) for the anomalies (155) that are out of tolerance; and

[0049] The placement robot (124, 214, 420) is controlled to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0050] Clause 10. The multi-ply lamination system (102, 200, 400) of Clause 7, wherein the inspection system (149) includes a cutting camera system (170), wherein the cutting camera system (170) is positioned to generate a top image (153) of a top surface of the layer (131) cut by the first cutting system (120) and the second cutting system (122), wherein the controller (114) is configured to:

[0051] generating the top image (153) of the layer (131) in response to the first cutting

[0052] system (120) and said second cutting system (122) are cutting said layer (131);

[0053] analyzing the top image (153) for the anomalies (155) that are out of tolerance; and

[0054] The placement robot (124, 214, 420) is controlled to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0055] Clause 11. The multi-layer sheet lamination system (102, 200, 400) according to clause 10, further comprising:

[0056] A plurality of scrap robots (180) are positioned to remove the layer (131) having the anomaly (155) exceeding the tolerance cut by the first cutting system (120) and the second cutting system (122) to the scrap location (154).

[0057] Item 12. A multi-layer sheet lamination system (102, 200, 400) according to Item 7, wherein the inspection system (149) includes at least one of the following items: a camera system, a thermal imager, an infrared camera, a visible light camera, a laser scanner, an x-ray imaging machine and a laser shear imaging system.

[0058] Clause 13. The multi-layer sheet lamination system (102, 200, 400) of clause 1, further comprising:

[0059] Spare cutting machine (132,409);

[0060] And wherein the controller (114) is configured to synchronize operation of the backup cutter (132, 409) to cut the layer (131) in response to swapping the backup cutter (132, 409) with a cutter in one of the first cutting system (120) and the second cutting system (122).

[0061] Item 14. A multi-layer sheet lamination system (102, 200, 400) according to Item 1, wherein the desired orientation of the layer (131) is selected from the group consisting of: 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees and 90 degrees relative to the initial orientation (125).

[0062] Clause 15. The multi-ply lamination system (102, 200, 400) of Clause 14, wherein the desired orientation (146) of the first ply (130) is different than the desired orientation (146) of the second ply (134).

[0063] Clause 16. A multilayer sheet lamination system (102, 200, 400) according to clause 1, wherein the multilayer sheet laminate (128) is used for charging, and the charging is used to form a part selected from the group consisting of: a slender composite part, a wing stringer, a fuselage stringer, a tail, a stringer, a floor beam, a wing wing spars and a tail wing spars.

[0064] Clause 17. The multi-ply lamination system (102, 200, 400) of clause 1, wherein the placement robot (124, 214, 420) is configured to change the orientation of the fibers (123) in at least one of the plies (131) by reorienting the plies as they are picked up from a temporary location and placed on the layup surface (127, 234, 320, 416) to form a ply;

[0065] wherein the ply has a width defined by an outer edge of the ply; and

[0066] The ply is reoriented so that one or more cut edges of the ply form a portion of an outer edge of the ply when placed on the laying surface (127, 234, 320, 416).

[0067] Clause 18. A multi-layer sheet lamination system (102, 200, 400), comprising:

[0068] a first cutting system (120) and a second cutting system (122), each of the first cutting system (120) and the second cutting system (122) being configured to independently cut a material (121) having fibers (123) oriented in an initial orientation (125) to form layers (131) and to move the layers (131) to a temporary position (141);

[0069] Place robot (124, 214, 420);

[0070] an automated tape placement machine (126) positioned to place material (145) having fibers (148) in said initial orientation (125) onto said placement surface (127, 234, 320, 416); and

[0071] a controller (114) in communication with the first cutting system (120), the second cutting system (122), the placement robot (124, 214, 420), and the automatic tape laying machine (126), wherein the controller (114) is configured to:

[0072] Controlling the first cutting system (120) to cut a first set of layers (131) and to place the first set of layers (131)

[0073] A set of layers (131) is moved to the temporary position (141);

[0074] controlling the placement robot (124, 214, 420) to pick up the first set of plies (131) from the temporary location (141) and place the first set of plies (131) onto a layup surface (127, 234, 320, 416) to form a first ply (130) of a multi-ply laminate (128), changing the orientation of the fibers (123) from the initial orientation (125) to a desired orientation (146) of the first ply (130);

[0075] Controlling the second cutting system (122) to place the robot (124, 214, 420)

[0076] While the first set of layers (131) is being picked up and placed, the second set of layers (131) is being cut and

[0077] The second set of layers (131) moves to the temporary position (141);

[0078] controlling the placement robot (124, 214, 420) to pick up the second set of plies (131) from the temporary location (141) and place the second set of plies (131) onto the layup surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply laminate (128) after the first ply (130) has been formed, changing the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) of the second ply (134); and

[0079] controlling the automatic tape placement machine (126) to place the material (145) to form plies of the multi-ply laminate (128), wherein the plies have the initial orientation (125)

[0080] The fibers (148) are oriented.

[0081] Clause 19. A method of forming a multi-ply laminate (128), the method comprising:

[0082] controlling (800) the first cutting system (120) to cut the first set of plies (131) and move the first set of plies (131) to a temporary position (141);

[0083] controlling (802) a placement robot (124, 214, 420) to pick up the first set of plies (131) from the temporary location (141) and place the first set of plies (131) onto a layup surface (127, 234, 320, 416) to form a first ply (130) of the multi-ply laminate (128), changing the orientation of the fibers (123) from an initial orientation (125) to a desired orientation (146) of the first ply (130);

[0084] controlling (804) a second cutting system (122) to cut a second set of plies (131) and move the second set of plies (131) to the temporary location (141) while the placement robot (124, 214, 420) is picking up and placing the first set of plies (131);

[0085] controlling (806) the placement robot (124, 214, 420) to pick up the second set of plies (131) from the temporary location (141) and place the second set of plies (131) onto the layup surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply laminate (128) after the first ply (130) has been formed, changing the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) of the second ply (134); and

[0086] An automatic tape placement machine (126) is controlled (900) to place material (145) to form a third ply (136) of the multi-ply laminate (128), wherein the third ply has the fibers (123) oriented in the initial orientation (125).

[0087] Clause 20. The method of Clause 19, wherein each subsequent ply is formed by placing at least some of the material of each subsequent ply to at least partially overlap a previous ply.

[0088] Clause 21. The method of clause 19, wherein the orientation of the fibers (123) in at least one of the plies (131) is changed by reorienting the plies as they are picked up from a temporary location and placed on the layup surface (127, 234, 320, 416) to form a ply;

[0089] wherein the ply has a width defined by an outer edge of the ply; and

[0090] The ply is reoriented so that one or more cut edges of the ply form a portion of an outer edge of the ply when placed on the laying surface (127, 234, 320, 416).

[0091] Clause 22. The method according to clause 19, further comprising:

[0092] generating (1000) a top image (153) of a top surface of the layer (131) using a robot camera (152) coupled to the placement robot (124, 214, 420) in response to the placement robot (124, 214, 420) being moved to pick up the layer (131);

[0093] analyzing (1002) the top image (153) for out-of-tolerance anomalies (155); and

[0094] The placement robot (124, 214, 420) is controlled (1004) to move any of the layers (131) having the anomaly (155) outside the tolerance to a scrap location (154).

[0095] Clause 23. The method according to clause 19, further comprising:

[0096] generating (1100) a bottom image (162) of a bottom surface of the layer (131) held by the placement robot (124, 214, 420) using an upward camera (160) connected to a camera station;

[0097] analyzing (1102) the bottom image (162) for out-of-tolerance anomalies (155); and

[0098] The placement robot (124, 214, 420) is controlled (1104) to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0099] Clause 24. The method according to clause 19, further comprising:

[0100] generating (1200) a top image (153) of the layer (131) using a cutting camera system (170) in response to cutting the layer (131) by the first cutting system (120) and the second cutting system (122);

[0101] analyzing (1202) the top image (153) for out-of-tolerance anomalies (155); and

[0102] The robot is controlled (1204) to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0103] Clause 25. The method according to clause 19, further comprising:

[0104] replacing (1300) a cutting machine in one of a first cutting machine (132, 202, 132) in the first cutting system (120) and a second cutting machine (122, 207, 413) in the second cutting system (122) with a spare cutting machine (132, 409) in response to one of the first cutting machine (132, 202, 132) and the second cutting machine (122, 207, 413) requiring maintenance; and

[0105] Synchronizing (1302) operation of the backup cutter (132, 409) to cut the layer (131) in response to exchanging the backup cutter (132, 409) with one of the first cutter (132, 202, 132) and the second cutter (122, 207, 413).

[0106] These features and functions can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments, in which further details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0107] The features which are believed to be the novel characteristics of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments together with the preferred mode of use, further objects and features thereof will be best understood by reference to the following detailed description of illustrative embodiments of the present disclosure when read in conjunction with the accompanying drawings, in which:

[0108] Figure 1 is an illustration of a block diagram of a composite material manufacturing environment according to an illustrative embodiment;

[0109] Figure 2 is an illustration of a schematic diagram of a multi-ply sheet layup according to an illustrative embodiment;

[0110] Figure 3is an illustration of a schematic diagram of an inspection system according to an illustrative embodiment;

[0111] Figure 4 is a pictorial illustration of a multi-layer sheet lamination system according to an illustrative embodiment;

[0112] Figure 5 is a pictorial illustration of ply laying by an automated strip laying machine in a ply laying system according to an illustrative embodiment;

[0113] Figure 6 is a pictorial illustration of ply laying by a placement robot in a ply laying system in accordance with an illustrative embodiment;

[0114] Figure 7 is a pictorial illustration of ply laying by a placement robot in a ply laying system in accordance with an illustrative embodiment;

[0115] Figure 8 is an illustration of a flow chart of a process for forming a limited multilayer sheet in accordance with an illustrative embodiment;

[0116] Fig. 9 is an illustration of a flow chart of a process for laying up a third ply in a multi-ply laminate according to an illustrative embodiment;

[0117] Fig.10 is an illustration of a flow chart of a process for inspecting a layer according to an illustrative embodiment;

[0118] Fig.11 is an illustration of a flow chart of a process for inspecting a layer according to an illustrative embodiment;

[0119] Fig.12 is an illustration of a flow chart of a process for inspecting a layer according to an illustrative embodiment;

[0120] Fig.13 is an illustration of a flow chart of a process for providing redundancy in a multi-ply sheet lamination system according to an exemplary embodiment;

[0121] Fig.14 is an illustration of a block diagram of a data processing system according to an illustrative embodiment;

[0122] Fig.15 is an illustration of an aircraft manufacturing and service method according to an illustrative embodiment; and

[0123] Fig.16 is an illustration of a block diagram of an aircraft in which an illustrative embodiment may be implemented. DETAILED DESCRIPTION

[0124] The illustrative embodiments recognize and take into account one or more different considerations. For example, the different illustrative embodiments recognize and take into account that increasing the speed at which composite parts can be manufactured is an important factor in manufacturing aircraft. The speed at which multi-layer laminates are formed is generally a limitation to the high rate production of long, narrow, elongated composite parts. The process of forming multi-layer laminates for elongated composite parts (such as wing or fuselage stringers) can be particularly inefficient and can form a bottleneck in the aircraft manufacturing process. Because forming multi-layer laminates generally involves laying down separate layers with fibers in different orientations, inefficiencies can occur.

[0125] As used herein, a layer is a single piece of cut material. A ply is a series of layers having the same fiber orientation that are laid or placed adjacent to each other.

[0126] In addition, the sequence includes all layers and plies in a given orientation. In the sequence, all plies can be laid together before performing a comprehensive inspection. The sequence can include plies of multiple fiber orientations. In some examples, the sequence can be where all plies have the same fiber orientation.

[0127] Currently, conventional tape laminators cut and move the laminating head multiple times during the layup process. In addition, rework and idle time also cause delays in the manufacture of slender composite parts, such as wing stringers. Therefore, current lamination systems idle a lot of time due to inspection and rework. There is also an undesirable amount of idle time for material loading and machine maintenance.

[0128] Therefore, it would be desirable to have a method, apparatus, system, and computer program product that results in at least one of the following: reducing the time required to place non-zero layer pieces, reducing offline inspection and rework, or avoiding material loading and maintenance downtime. 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 can be used, and only one of each item in the list may be required. In other words, "at least one of..." means that any combination of items and numbers of items from the list can be used, but not all items in the list are required. An item can be a specific object, thing, or category.

[0129] For example, but not limited to, "at least one of item A, item B, or item C" may include item A, item A and item B, or item B. This 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 exist. In some illustrative 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.

[0130] In an illustrative example, a multi-layer sheet lamination system includes a first cutting system, a second cutting system, a placement robot, and a controller. The first cutting system and the second cutting system are each configured to independently cut a material having fibers oriented in an initial orientation to form a layer, and move the layer to a temporary position. The controller communicates with the first cutting system, the second cutting system, and the placement robot. The controller is configured to control the first cutting system to cut a first group of layers and move the first group of layers to a temporary position. The controller is configured to control the placement robot to pick up the first group of layers from a temporary position and place the first group of layers on a laying surface to form a first layer of a multi-layer sheet laminate, thereby changing the orientation of the fibers from the initial orientation to the desired orientation of the first layer. The controller is configured to control the second cutting system to cut the second group of layers while the placement robot picks up and places the first group of layers and moves the second group of layers to a temporary position. The controller is configured to control the placement robot to pick up a second set of plies from a temporary location and place the second set of plies onto a layup surface to form a second ply of the multi-ply laminate after the first ply has been formed, thereby changing the orientation of the fibers from an initial orientation to a desired orientation of the second ply.

[0131] In this example and in other examples, reference to "first ply" refers to the first ply formed from placing plies to form a plurality of plies of a multi-ply laminate. The first ply is not necessarily the exact first or the exact last ply in a multi-ply laminate formed by placing plies in forming the plies.

[0132] Reference now Figure 1 , depicts an illustration of a block diagram of a composite material manufacturing environment, according to an illustrative embodiment. As depicted, multi-ply lamination system 102 operates to produce multi-ply laminate 128. In this example, multi-ply laminate 128 is used in a charge for forming component 105. Component 105 may be selected from the group consisting of: an elongated composite component, a wing stringer, a fuselage stringer, an empennage stringer, a floor beam, a wing spar, and an empennage spar. The component may be entirely comprised of composite materials, or may be a mixture of composite materials and non-composite materials.

[0133] In this example, the multi-ply lamination system 102 includes a number of different components. As shown, the multi-ply lamination system 102 includes a first cutting system 120, a second cutting system 122, a placement robot 124, an automatic tape laying machine 126, and a controller 114.

[0134] As depicted, the first cutting system 120 includes a first cutter 132 and a first conveyor 133. Additionally, in this example, the second cutting system 122 includes a second cutter 138 and a second conveyor 139.

[0135] In this example, first cutting system 120 and second cutting system 122 are each configured to independently cut material 121 having fibers 123 oriented in initial orientation 125 to form layer 131 and move layer 131 to temporary position 141. Material 121 may be, for example, a carbon fiber fabric containing fibers 123. The material may be in the form of a fabric, a strip, or some other form. In some illustrative examples, a resin may be injected into material 121. Additionally, material 121 may be in the form of a roll.

[0136] In this example, the temporary location 141 is a location from which the placement robot 124 can pick up the layer 131 and place the layer 131 on the laying surface 127. In this example, the temporary location 141 is a location on the first conveyor 133 and the second conveyor 139.

[0137] For example, in the first cutting system 120, the first cutter is configured to cut the layer 131, and the first conveyor 133 is configured to move the layer 131 cut by the first cutter 132 to a temporary position 141 on the first conveyor 133 in an initial orientation 125. In the second cutting system 122, the second cutter 138 is configured to cut the layer 131, and the second conveyor 139 is configured to move the layer 131 cut by the second cutter 138 to a temporary position 141 on the second conveyor 139 in an initial orientation 125. In addition, at least one of the first cutter 132 or the second cutter 138 is configured to cut the layer 131 from the material roll.

[0138] In this example, controller 114 communicates with first cutting system 120, second cutting system 122, placement robot 124, and automated tape laying machine 126. In this illustrative example, controller 114 may be implemented in software, hardware, firmware, or a combination thereof.

[0139] When software is used, the operations performed by the controller 114 may be implemented with program instructions configured to run on hardware (e.g., a processor unit). When firmware is used, the operations performed by the controller 114 may be implemented with program instructions and data and stored in a persistent memory to run on a processor unit. When hardware is employed, the hardware may include circuits that operate to perform the operations in the controller 114.

[0140] In an illustrative example, the hardware can take the form of at least one selected from the following items: a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware configured to perform multiple operations. Through a programmable logic device, the device can be configured to perform multiple operations. The device can be reconfigured at a later time, or can be permanently configured to perform multiple operations. Programmable logic devices include, for example, programmable logic arrays, programmable array logic, field programmable logic arrays, field programmable gate arrays, and other suitable hardware devices. Additionally, the process can be implemented in organic components integrated with inorganic components, and can completely include organic components that do not include humans. For example, the process can be implemented as a circuit in an organic semiconductor.

[0141] As used herein, "plurality" when used with respect to items refers to one or more items. For example, "plurality of operations" is one or more operations.

[0142] The computer system 112 is a physical hardware system and includes one or more data processing systems. When there is more than one data processing system in the computer system 112, these data processing systems communicate with each other using a communication medium. The communication medium may be a network. The data processing system may be selected from at least one of the following: a computer, a server computer, a tablet computer, a programmable logic (PLC) controller, or some other suitable data processing system.

[0143] As depicted, computer system 112 includes a plurality of processor units 116 that are capable of executing program instructions 118 to implement the processes in the illustrative example. In other words, program instructions 118 are computer-readable program instructions.

[0144] As used herein, a processor unit in plurality of processor units 116 is a hardware device and includes hardware circuits (such as those on an integrated circuit) that respond to and process instructions and program codes to operate a computer.

[0145] When multiple processor units 116 execute program instructions 118 for a process, multiple processor units 116 can be one or more processor units in the same computer or in different computers. In other words, the process can be distributed between processor units 116 on the same or different computers in computer system 112.

[0146] In addition, the plurality of processor units 116 may be processor units of the same type or of different types. For example, the plurality of processor units 116 may be selected from at least one of the following: a single-core processor, a dual-core processor, a multi-processor core, a general-purpose central processing unit (CPU), a graphics processing unit (GPU), a digital signal processor (DSP), or some other type of processor unit.

[0147] In this example, the controller 114 controls the first cutting system 120 to cut the first set of plies 131 and move the first set of plies 131 to a temporary location 141. In this example, the first set of plies 131 is cut by the first cutter 132 and moved to the first conveyor 133. The temporary location 141 for the first set of plies is on the first conveyor 133.

[0148] The controller 114 controls the placement robot 124 to pick up the first set of plies 131 from the temporary location 141 and place the first set of plies 131 on the laying surface 127, thereby forming the first ply 130 of the multi-ply laminate 128. In this example, the placement robot 124 can be implemented using any suitable type of robot that can pick up the plies 131 and place them on the laying surface 127. For example, the placement robot 124 can be selected from at least one of the following items: a robot arm, a gantry robot, a mobile robot arm, and other suitable types of robots that can pick up the plies from the cutting system and place the plies on the laying surface 127.

[0149] In this example, the laying surface 127 can be on or part of different types of objects. For example, the laying surface 127 can be on a laying table. In another example, the laying surface 127 can be on a laying conveyor. In yet another illustrative example, the laying surface 127 can be positioned on a mobile or motorized cart.

[0150] As part of picking up and placing the first group of plies 131, the placement robot 124 changes the orientation of the fibers 123 from the initial direction 125 to the desired orientation 146 of the first ply 130 (substantially by reorienting (i.e., rotating) the plies as they are transported from the temporary location 141 to the laying surface 127). For example, if the plies are cut from a roll of material in the form of a wide cargo, the fibers in the plies may initially be in an orientation aligned with the direction of the rolled material (sometimes referred to as a 0 degree orientation) and then rotated and placed by the placement robot so that the fibers have a desired orientation 146 (e.g., 45 degrees relative to the initial orientation). In this example, the desired orientation of the plies 131 is selected from a group consisting of 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees, 90 degrees, and other orientations relative to the initial orientation 125. Relative to the initial orientation means that these degrees can be positive or negative. The desired orientation can be determined based on the design or other information that specifies the orientation of the plies used to form the multi-ply laminate 128.

[0151] The controller 114 also controls the second cutting system 122 to cut the second set of plies 131 and move the second set of plies 131 to a temporary location 141 while the placement robot 124 picks up and places the first set of plies 131. In this example, the second set of plies 131 is cut by the second cutter 138 and moved to the second conveyor 139. The temporary location 141 for the second set of plies 131 is on the second conveyor 139.

[0152] In this example, the cutters may include one or more different types of cutters. For example, the cutters may include ultrasonic cutters, blade cutters, rotary cutters, and other suitable types of cutters. The cutters may cut material from a source (e.g., a wide cargo on a roll), or otherwise cut material at any desired angle. In this example, the desired angle is relative to the rolling direction.

[0153] In addition, the controller 114 controls the placement robot 124 to pick up the second set of plies 131 from the temporary location 141 and place the second set of plies 131 on the layup surface 127 to form a second ply 134 of the multi-ply laminate 128 after the first ply 130 has been formed. In this example, the movement of picking up and placing the first set of plies changes the orientation of the fibers 123 from the initial orientation 125 to a desired orientation 146 of the second ply 134. In this example, the desired orientation 146 of the first ply 130 may be different from the desired orientation 146 of the second ply 134.

[0154] In the illustrative example, the placement robot 124 is configured to change the orientation of the fibers 123 in at least one ply by reorienting the ply when picking it up from a temporary location and placing it on the layup surface 127 to form a ply. The ply has a width defined by the outer edge of the ply. The ply can be reoriented so that one or more cut edges of the ply form a portion of the outer edge of the ply when placed on the layup surface 127.

[0155] Additionally, in this example, an automatic tape laying (ATL) machine 126 is positioned to place a material 145 having fibers 148 in an initial orientation 125 onto the layup surface 127. In this example, the controller 114 controls the automatic tape laying machine 126 to place the material 145 onto the layup surface 127 to form a third ply 136 of the multi-ply laminate 128, wherein the third ply 136 has fibers 148 oriented in the initial orientation 125. In some examples, the automatic tape laying machine 126 is configured to move along the layup surface 127. By way of example, the 0 degree ply can be a continuous piece of material laid by the automatic tape laying machine 126 as the machine moves along the layup surface 127.

[0156] In this illustrative example, placing layers and other materials onto paved surface 127 may be placing at least one of the layers or materials directly onto paved surface 127. In other words, at least one of the layers or materials may be in physical contact with paved surface 127. In this illustrative example, placing may also refer to placing layers and materials onto a paved surface where other layers and materials have already been laid onto paved surface 127. **

[0157] For example, a ply may be placed onto the paved surface 127 by placing it on top of another ply already placed onto the paved surface 127. In other words, placing a ply or material onto the paved surface 127 does not mean placing the ply material into direct contact with the paved surface 127.

[0158] In one non-limiting example, the first layer is 45 degrees, the second layer is -45 degrees, the third layer is 90 degrees, and the fourth layer is laid at 0 degrees by the automatic tape laying machine 126. In this example, the 0 degree layer can be laid continuously along the length of the lay by the automatic tape laying machine 126 moving along or on the laying surface 127.

[0159] In this illustrative example, controller 114 communicates with first cutting system 120, second cutting system 122, placement robot 124, and automated tape laying machine 126 using information 129. In this example, controller 114 may send information 129 (e.g., program code, commands, data, and other information used to control the operation of these components).

[0160] Additionally, the multi-ply lamination system 102 can improve the speed and accuracy of laying up the plies through integrated inspection that is performed as part of the process of picking and placing the plies 131. In one illustrative example, the multi-ply lamination system 102 includes an inspection system 149 configured to inspect the plies 131. The inspection system 149 can include at least one of the following: a camera system, a thermal imager, an infrared light camera, a visible light camera, a laser scanner, an x-ray imager, a laser shearography system, or some other suitable inspection system.

[0161] In this example, inspection system 149 includes camera system 150. In this example, camera system 150 is configured to generate image 151 of layer 131. Camera system 150 may include at least one of the following: a thermal imager, an infrared camera, a visible light camera, or some other suitable type of camera. Inspection system 149 may use other types of equipment in addition to or in place of camera system 150. For example, inspection system 149 may include a laser scanning system, an x-ray system, a blue light sensor system, or other suitable sensor system that can detect anomaly 155.

[0162] In this example, camera system 150 may be used to perform an inspection of plies 131 cut by first and second cutting systems 120, 122 before placing the plies 131 on paving surface 127. The inspection may be performed to determine if any of plies 131 have anomalies 155 that are out of tolerance.

[0163] Anomaly 155 may be at least one of: foreign debris (FOD), wrinkles, pockets, defects, worn edges, material inconsistencies, or other types of anomalies in layer 131. In this example, the tolerances for anomaly 155 may be based on manufacturing standards, design tolerances, regulations, industry standards, government regulations, and other sources. This type of inspection may reduce rework or other problems that may occur as a result of laying up layers with anomalies.

[0164] In one illustrative example, camera system 150 includes a robotic camera 152 connected to placement robot 124. Robotic camera 152 is positioned to generate a top image 153 of a top surface of layer 131 as cut by first cutting system 120 and second cutting system 122. These inspections can be performed with layer 131 moved to or in temporary location 141.

[0165] The robot camera in robot camera 152 can be connected to or be in any position near the end effector of the mechanical arm for placing robot or other robot.In one example, the robot camera can generate an image of the top surface of the layer before picking up the layer for placement.

[0166] In this example, the controller 114 controls the generation of a top image 153 of the top surface of the layer 131 in response to the placement robot 124 moving to pick up the layer 131. The controller 114 receives the top image 153 and analyzes the top image 153 for out-of-tolerance anomalies 155. The controller 114 controls the operation of the placement robot 124 to move any of the layer 131 having the out-of-tolerance anomalies to a scrap location 154.

[0167] Additionally, the camera system 150 can include an upward camera 160 connected to a camera station. The camera station can be any structure to which the upward camera 160 can be connected and positioned to generate a bottom image 162. In this example, the upward camera 160 is positioned to generate a bottom image 162 of the bottom surface of the layer 131 held by the placement robot 124.

[0168] Controller 114 controls generation of bottom image 162 of the bottom surface of layer 131 via upward camera 160. In one illustrative example, bottom image 162 may be generated by upward camera 160 in response to placement robot 124 moving layer 131 to upward camera 160.

[0169] In this example, the controller 114 analyzes the bottom image 162 for out-of-tolerance anomalies 155. The controller 114 controls the placement robot 124 to move any of the layers 131 having the out-of-tolerance anomalies 155 to the scrap location 154.

[0170] In yet another example, the camera system 150 can include a cutting camera system 170. By way of example, the cutting camera system 170 is positioned to generate a top image 153 of a top surface of the layer 131 in response to the first cutting system 120 and the second cutting system 122 cutting the layer 131.

[0171] By way of example, the controller 114 generates a top image 153 of the layer 131 using the cutting camera system 170 in response to the first cutting system 120 and the second cutting system 122 cutting the layer 131. The controller 114 analyzes the top image 153 received from the cutting camera system 170 for out-of-tolerance anomalies 155. The controller 114 moves any layer 131 having out-of-tolerance anomalies 155 to the scrap location 154.

[0172] In this example, a robot other than the placement robot 124 may be used to perform the movement of the plies 131 from the cutting system to the scrap location 154 to increase the speed and efficiency with which the multi-ply laminate 128 can be formed. In other examples, the conveyor may move the plies 131 having out-of-tolerance anomalies 155 to a scrap bin located at the end of the conveyor. In this case, these plies are not picked up by the placement robot 124 for use in forming the multi-ply laminate 128.

[0173] For example, the multi-sheet lamination system 102 may include a plurality of scrap robots 180 positioned to remove the layer 131 having anomalies 155 that are out of tolerance cut by the first cutting system 120 and the second cutting system 122 to a scrap location 154. The scrap robot 180 may be, for example, a robot arm, a delta arm, a drone, or some other suitable type of robot. In yet other illustrative examples, the cutting camera system 170 may also include a camera positioned to generate a bottom image 162 of the layer 131 cut by one of the cutting systems. The inspection may be performed before the inspection using the image 151 generated by the robot camera 152.

[0174] In this illustrative example, image 151 is analyzed by controller 114. The analysis may be performed using object detection 164, such as machine vision algorithm 163. This type of algorithm may perform image preprocessing, feature extraction, object detection, segmentation, classification, and recognition. The processes implemented by machine vision algorithm 163 may identify specific objects or patterns or features in image 151 that may be anomalies 155.

[0175] In another illustrative example, the inspection system 149 may include a lap-gap inspection system 171 that is used after all of the plies in the ply are placed on the paving surface 127. The lap-gap inspection system 171 can be used to measure the gaps between the plies 131. The lap-gap inspection system 171 can be connected to or at any location near the end effector of a robotic arm for a placement robot or other robot. In this example, the lap-gap inspection system 171 may include at least one of the following: a laser profiler, a camera, a thermal imager, an infrared camera, a visible light camera, a laser scanner, an x-ray imager, a laser shear imaging system, or some other suitable inspection system.

[0176] In this example, every other ply 131 is placed simultaneously onto the paving surface 127 by the placement robot 124, followed by placement of the remaining plies 131, after which the robot uses its lap gap inspection system to measure the gaps between the plies.

[0177] In an illustrative example, a profilometer can be used to measure the gap width between adjacent plies. The tool can also be used to check the location of the entire ply boundary. This check can be used for both internal boundary edges and boundary edges outside the net trim line.

[0178] For example, the placement robot 124 places all plies of a sequence of plies. The placement robot 124 scans the nominal inter-ply gaps of all plies using a profilometer and records gap measurement data generated by the profilometer along the gap length. In addition, the placement robot 124 scans the entire nominal boundary of all plies of the sequence with a profilometer. In this example, a single edge is detected with a profilometer, and in combination with the robot tool center point (TCP) position data, ply boundary position data can be determined.

[0179] By way of example, if the gap and boundary position measurements are within tolerance, then the layup continues with the next sequence. Otherwise, an intervention may be performed to correct the tolerance error. The intervention may include layer removal and restarting or replacing a layer.

[0180] In yet another illustrative example, spare parts may be used to achieve efficiency in forming the multi-ply laminate 128. For example, the multi-ply lamination system 102 may include a spare cutter 185 that is used in response to one of the first cutter 132 and the second cutter 138 requiring maintenance. For example, the maintenance may be replacing a roll of material used to cut plies, replacing a blade, scheduled maintenance, or other maintenance operations.

[0181] The spare cutter 185 can be used to replace one of the cutters. The process can be a hot swap process, where there is no need to start and reinitialize the cutting process. In other words, the spare cutter 185 can pick up where the previous cutter stopped. In one example, the controller 114 synchronizes the operation of the spare cutter 185 to cut the layer 131 in response to swapping the spare cutter 185 with a cutter in one of the first cutting system 120 and the second cutting system 122.

[0182] Furthermore, in the illustrative example, interruptions in cutting and placing layers can be minimized when the backup cutter 185 is heat swappable. Such heat swapping can be accomplished using features or components that enable instant mechanical alignment with the conveyor. For example, mechanisms for quick connection of electrical and communication cables and integration of automatic controllers in the cutting system can be used.

[0183] Therefore, in one illustrative example, there are one or more solutions that overcome the problem of undesirable time to lay up layers when manufacturing composite parts. Therefore, one or more technical solutions can provide an increased speed when laying up layers by using a placement robot to lay up layers for plies at the same time.

[0184] Compared to current techniques for laying up layers of composite parts (e.g., those that may be long and narrow), one or more illustrative examples achieve increased efficiency in placing layers, thereby forming plies with increased efficiency and speed. The illustrative examples avoid moving the laminating head multiple times during the layup process as with current techniques. In addition, by using a camera to generate images to analyze the layers for out-of-tolerance anomalies, manual inspections may be reduced or avoided.

[0185] In an illustrative example, layers may be cut simultaneously while other (already cut) layers are being placed by the placement robots. There are multiple cutters such that each cutter can cut layers for a specific orientation, and / or synchronize with each other and / or with the operation of the placement robots. The layers cut by each cutter have an orientation based on the sequence of layers in the composite part design. Thus, once the placement robots have completed placing layers in one orientation (e.g., to complete a layer of a multi-ply laminate), the placement robots can begin placing layers of the next orientation (e.g., to assemble the next layer of a multi-ply laminate) without waiting or delay.

[0186] In an illustrative example, a placement robot may be used to perform simultaneous placement of multiple layers. In addition, when at least one of material loading or other maintenance is required, a swap of equipment may be formed to reduce downtime. In an illustrative example, for a wing stringer, the loading lamination process may be reduced from 12 hours to 1 hour.

[0187] Furthermore, inspections can be performed as the plies are picked up for placement. These inspections are performed automatically and can reduce or avoid the need for manual inspection of the plies used to assemble the plies.

[0188] Figure 1 The illustration of composite material manufacturing environment 100 in the illustrative embodiment is not meant to imply physical or architectural limitations on the manner in which the illustrative embodiments may be implemented. Other components in addition to or in place of the components shown may be used. Some components may be unnecessary. In addition, blocks are presented to illustrate some functional components. When implemented in the illustrative embodiments, one or more of these blocks may be combined, divided, or combined and divided into different blocks.

[0189] For example, the automatic tape laying machine 126 can be an optional component and can be omitted from the multi-layer sheet lamination system 102 in some examples. As another example, in addition to the first cutting system 120 and the second cutting system 122, there can also be one or more cutting systems for cutting the layer 131. In addition, in different illustrative examples, the placement robot 124 can be the same type of robot or can be a different type of robot. For example, a portion of the placement robot 124 can be a robotic arm in a fixed position, while another portion of the placement robot 124 can be a mobile robotic arm that can be moved to different positions.

[0190] Next reference Figure 2 , depicts an illustration of a schematic diagram of a multi-ply layup according to an illustrative embodiment. The multi-ply lamination system 200 is Figure 1 An example of one implementation of a mid-layer sheet lamination system 102 .

[0191] As depicted, a multi-layer sheet lamination system 200 has a first cutter 202 that cuts a material 203 to form layers 206 having an initial orientation on a first conveyor 204. In this example, the material is in the form of a wide load on a roller mill, and the initial orientation is 0 degrees, with the fibers in the direction indicated by arrow 221. In other words, the fibers in the material are oriented in the direction in which the material rolls on the roller mill. The layers can be cut by the first cutter 202 to have different sizes and shapes, but have the same initial orientation.

[0192] The multi-layer sheet lamination system 200 also has a second cutter 207 that cuts the material 201 (which is also shown in this example as a wide cargo on a roller machine) to form layers 206 that also have an initial orientation on a second conveyor 208. These layers can also have different sizes and shapes and initial orientations. As depicted, the first conveyor 204 and the second conveyor 208 are parallel to each other.

[0193] In this example, the multi-ply lamination system 200 also includes a placement robot 214. As depicted, there are nine placement robots: placement robot 216, placement robot 218, placement robot 220, placement robot 222, placement robot 224, placement robot 226, placement robot 228, placement robot 230, and placement robot 232.

[0194] The first conveyor 204, the second conveyor 208, and the placement robot 214 are positioned so that the placement robot 214 can pick up the layer 206 and place the layer 206 on the paving surface 234 on the conveyor 236. In addition, the type and configuration of the placement robot 214 are selected to be able to pick up the layer 206 from the first conveyor 204 and the second conveyor 208 and place these layer pieces on the paving surface 234 on the conveyor 236 as part of forming a layer sheet (e.g., layer sheet 240). The first conveyor 204, the second conveyor 208, and the placement robot 214 are positioned so that the placement robot 214 can pick up the layer 206 and place the layer 206 on the paving surface 234 on the conveyor 236.

[0195] In this example, the multi-ply lamination system 200 also includes an automatic tape laying machine 213. The automatic tape laying machine cuts the plies with an initial orientation, which in this example is 0 degrees.

[0196] During operation of the multi-ply lamination system 200, the first cutting machine 202 cuts the plies 206, which form an array of plies 206 on the first conveyor 204. The plies are moved by the first conveyor 204 to a temporary position on the first conveyor 204 relative to the placement robot 214. When the plies 206 have been cut and moved to the temporary position on the first conveyor 204, the placement robot 214 picks up the plies 206 from the first conveyor 204 and places the plies on the laying surface 234 on the conveyor 236.

[0197] When the layer 206 is picked up from the first conveyor 204 by the placement robot 214 and placed on the paving surface 234, the second cutter 207 cuts the layer 206, which is moved on the second conveyor 208 relative to the placement robot 214 to a temporary position on the second conveyor 208. The time of cutting the layer 206 by these cutters can be selected so that the placement robot 214 always has the layer 206 in a temporary position ready to be placed on the paving surface 234.

[0198] Once the placement robots 214 have completed picking up and placing the plies 206 from temporary locations on the first conveyor 204, the placement robots 214 begin picking up the plies 206 from temporary locations on the second conveyor 208 and placing the plies 206 from these temporary locations onto the paving surface 234. In some examples, some of the placement robots 214 may begin picking up and placing the plies 206 from the second conveyor 208 before other placement robots 214 have completed picking up and placing the first set of plies 206.

[0199] In this example, once the first set of plies 206 have been picked up and placed on the layup surface 234, the first cutter 202 begins cutting new plies. These new plies may be placed on the layup surface 234 in the same or different orientation than the plies 206 that were picked up from the temporary location on the second conveyor 208 and placed on the layup surface 234. The orientation is selected based on the design of the composite part, which identifies the orientation of the plies that are placed to form the plies of the composite part.

[0200] This process can be repeated: the layers are cut on alternating cutters and placed on the laying surface 234 by the placement robot 214. This placement can result in the laying of multiple layers. This alternating cutting, picking up and placing of layers with desired orientation can improve the efficiency and speed of laying layers and multiple layers for composite parts. For example, the first layer can be laid at 45 degrees, the second layer can be laid at -45 degrees, and the third layer is 90 degrees. In this example, the fourth layer is laid at 0 degrees by the automatic tape laying machine 126. In this example, the 0 degree layer can be laid continuously along the length of the laying by the automatic tape laying machine 213 moving along the laying surface 234 or on the laying surface 234.

[0201] In this example, when the plies have the same desired orientation as the initial orientation (e.g., 0 degrees), the plies can be placed on the laying surface 234 using the automatic tape laying machine 213. The automatic tape laying machine 213 can move along the conveyor 236 in the direction of arrow 221. The automatic tape laying machine 213 can provide improved performance and efficiency when laying plies having a 0° orientation compared to using the placement robot 214 to lay plies having a 0° orientation.

[0202] In the depicted example, some layers may have a wider width than other layers optimized for tab out. For example, layer 270 is wider than layer 272.

[0203] A diagram of a multi-layer sheet lamination system 200 is shown to illustrate Figure 1 1. The multi-layer sheet lamination system 102 in FIG. 1 can be implemented in one manner. This illustration is not intended to limit the manner in which the multi-layer sheet lamination system 102 can be implemented. For example, the automatic tape laying machine 213 is an optional component and can be omitted in some embodiments. When the automatic tape laying machine 213 is not present, the orientation of the layer 206 can also include a desired orientation that is the same as the initial orientation.

[0204] Next reference Figure 3 , an illustration of a schematic diagram of an inspection system is depicted in accordance with an illustrative embodiment. In this example, the inspection system 300 is Figure 1An example of an implementation of the inspection system 149 is shown in FIG. As depicted, the inspection system 300 includes cameras that are used at various steps in the process of cutting material to form plies and placing plies to form a ply.

[0205] As depicted in this example, the inspection system 300 includes a camera positioned to generate images of the ply for analysis during different times from when the ply is cut to when the ply is placed on a laying surface.

[0206] In this illustrative example, the placement robot 310 has a robot camera 311, and the placement robot 312 has a robot camera 313. These robot cameras are connected to the placement robot. When one component is "connected" to another component, the connection is a physical connection. For example, a first component (robot camera 311) can be considered to be physically connected to a second component (placement robot 310) by at least one of the following items: fixed to the second component, coupled to the second component, mounted to the second component, welded to the second component, fastened to the second component, or connected to the second component in some other suitable manner. The first component can also be connected to the second component using a third component. The first component can also be considered to be physically connected to the second component by forming a part of the second component, an extension of the second component, or both.

[0207] These robot cameras can be used to generate images of the top surface of the layer before or as part of the placement robot picking up the layer for placement from the first conveyor 302 or the second conveyor 304. The top surface of these images can be analyzed for anomalies that are out of tolerance on the top surface of the layer.

[0208] Additionally, the inspection system 300 also includes upward cameras (e.g., upward camera 315 and upward camera 317). Upward camera 315 is positioned within reach of the placement robot 310. Upward camera 317 is positioned within reach of the placement robot 312. In this illustrative example, these upward cameras are used to generate images of the bottom surface of the layer picked up and held by the placement robot. These images can be analyzed to determine whether there are out-of-tolerance anomalies on the bottom surface of the layer.

[0209] For example, the placement robot 310 may move to pick up the layer 330. This movement of the placement robot 310 causes the robot camera 311 to be positioned on the layer 330. The robot camera 311 may generate an image of the top surface 332 of the layer 330. The image may be analyzed to determine if there are one or more out-of-tolerance anomalies on the top surface 332 of the layer 330.

[0210] If there is an out-of-tolerance anomaly on the top surface 332 of the layer 330, the placement robot 310 picks up the layer 330 and places the layer 330 in the scrap bin 340. If there is no out-of-tolerance anomaly on the top surface 332, the placement robot 310 picks up the layer 330. The placement robot 310 moves the layer 330 to a position above the upward camera 315. The upward camera 315 generates an image of the bottom surface (not shown) of the layer 330. The image is analyzed to determine whether there is an out-of-tolerance anomaly on the bottom surface of the layer 330. If there is an out-of-tolerance anomaly, the layer 330 is placed in the scrap bin 340. If there is no out-of-tolerance anomaly on the surface of the layer 330, the placement robot 310 moves and places the layer 330 on the laying surface 320 of the conveyor 321.

[0211] The placement robot 312 can generate an image of the top surface of the layer using the robot camera 313 and generate an image of the bottom surface of the layer using the upward camera 317 for analysis to determine if there are out-of-tolerance anomalies. In this example, the placement robot 312 places the layer with the out-of-tolerance anomalies in a scrap bin 342. In this example, the scrap bin 344 can be used by the placement robot 312 or another robot.

[0212] Additionally, before the placement robot moves to pick up the layer, an inspection of the layer can be performed. For example, cutting machine 350 has a cutting system camera 351, and cutting machine 352 has a cutting system camera 353. In this example, cutting system camera 351 is connected to cutting machine 350, and cutting system camera 353 is connected to cutting machine 352.

[0213] These cutting system cameras can move with the movement of the cutter, or can move independently of the cutter to generate images of the top surface of the layer cut by the cutter. These images can be analyzed for anomalies. In this example, in addition to anomalies that may exist on the surface of the layer, the anomalies can also include the shape and size of the layer. If anomalies exist, the scrap robot 360 picks up the layer with the anomaly and places the layer into one of the scrap bin 340, scrap bin 342, scrap bin 344, or any other scrap bin.

[0214] The analysis can be made while the plies are being cut or after the plies have been cut. If problems with size and plies are identified while the plies are being cut, the cutter can cut the material to form an unfinished ply that can be discarded. In this way, reduced waste of material such as fabric or tape can occur. Furthermore, inspecting the plies before laying them on a laying surface to form a ply can reduce the time and problems involved in discovering inconsistencies later when processing the ply.

[0215] In another example, the scrap robot 360 may be omitted. In this example, one of the placement robot 310 and the placement robot 312 may be used in place of the scrap robot 360. In another example, the layer pieces with out-of-tolerance anomalies remain on the first conveyor 302 and the second conveyor 304 and are moved to fall directly into a large scrap bin (not shown) at the far end of the conveyor.

[0216] Next reference Figure 4 , depicts a pictorial representation of a multi-layer sheet lamination system according to an illustrative embodiment. The multi-layer sheet lamination system 400 is Figure 1 An example of one implementation of a multi-ply lamination system 102 is shown in block form in FIG.

[0217] The multi-sheet lamination system 400 includes a first cutter 411 having a first conveyor 412. Additionally, a second cutter 413 and a second conveyor 414 are positioned parallel to the first cutter 411 and the first conveyor 412.

[0218] In this example, the placement robots 420 include placement robots 421, 422, 423, 424, 425, 426, 427, and 428. In this example, the placement robots 420 are robotic arms that can pick up plies at temporary locations on both the first conveyor 412 and the second conveyor 414 and place the plies onto the laying surface 416 on the ply conveyor 417. Additionally, an automatic tape laying (ATL) machine 430 is positioned to move and lay the plies onto the laying surface 416.

[0219] In addition, a scrap robot 440 is positioned by the first cutter 411 and the second cutter 413. The scrap robot can place layers that have been cut incorrectly or have other types of anomalies into a scrap bin 441.

[0220] In addition, in this example, there is a waste bin 450 for use by the placement robot 420. The waste bin 450 includes a waste bin 451, a waste bin 452, a waste bin 453, and a waste bin 454. The placement robot 420 may include a camera for inspecting the layer pieces that the placement robot 420 moves to pick up. Layer pieces with abnormalities that exceed tolerances may be placed in the waste bin 450 by the placement robot 420.

[0221] Furthermore, in this example, the backup cutter 409 can be hot-swapped with the first cutter 411 or the second cutter 413. This hot-swap can be performed to allow for continuous cutting and positioning of plies as needed, thereby providing a continuous supply of plies for the placement robot 420 to form plies on the laying surface 416.

[0222] Figure 5-Figure 7 is a pictorial illustration of a process for laying up layers according to an illustrative embodiment. Figure 5 , depicts a pictorial representation of laying plies by an automatic tape laying machine in a ply laying system according to an illustrative embodiment. As depicted, the automatic tape laying machine 430 moves in the direction of arrow 500 to lay a 0 degree ply 501 on the laying surface 416.

[0223] exist Figure 6 , a pictorial illustration of laying plies by a placement robot in a ply laying system is depicted according to an illustrative embodiment. As depicted in the figure, a placement robot 420 has picked up plies from a first conveyor 412 and placed the plies onto a laying surface 416 in a staggered arrangement 600 with gaps. As shown, there is a gap at every other position.

[0224] In this figure, the second cutter 413 is cutting the layer moved by the second conveyor 414 to the temporary position on the second conveyor 414, and the placement robot 420 picks up the layer from the temporary position on the first conveyor 412 for placement.

[0225] Next go to Figure 7 , depicts a pictorial illustration of laying plies by placing robots in a ply laying system according to an illustrative embodiment. In the figure, the placing robot 420 has picked up a ply from the first conveyor 412 and placed the ply into a gap in the staggered arrangement 600 of plies on the laying surface 416.

[0226] In this illustrative example, when the robot vacuum cup end effector is larger than the placement length of the layer, the missing placement can be performed between the layers. Otherwise, if the robot attempts to place directly adjacent layers at the same time, the end effector of the placement robot may potentially collide.

[0227] At this point, the placement robot 420 can use its onboard lap gap inspection system to measure the gap between adjacent layers. For example, the placement robot 420 can include a measuring device such as a profilometer that can be used to perform gap assessment to ensure that adjacent layers are close enough to each other.

[0228] As depicted in this example, the second cutting machine 413 has completed cutting the plies, which are now in a temporary position on the second conveyor 414. The plies are ready for the placement robot 420 to pick up and place on the laying surface 416.

[0229] This cycle of ply cutting and placement onto the layup surface 416 can be performed until the multi-layer ply of the composite part has been completed. This process for laying up plies reduces the idle time of the placement robot 420 because the placement robot 420 does not need to wait for new plies to become available for placement. Instead, the placement robot 420 can continue to place plies picked up from locations on the first conveyor 412 and the second conveyor 414.

[0230] In addition, inspection of the layer may be performed before and after the layer is picked up by the placement robot 420. Layers with anomalies that are out of tolerance may be discarded, and new layers may be recut and placed in a location to be picked up and placed by the placement robot 420.

[0231] Figure 4-Figure 7 The multi-layer sheet lamination system 400 is shown as Figure 1 An example of a multi-layer sheet lamination system 102. This illustration is not intended to limit the way in which other illustrative examples can be implemented. For example, in addition to the 8 placement robots depicted in this example, other number of placement robots can also be used. For example, 4 placement robots, 20 placement robots or some other number of placement robots can be used. In addition, in addition to the first cutter 411 and the second cutter 413 and the second conveyor 414 with the first conveyor 412, one or more cutters and conveyors can also be used. These cutters and conveyors can be placed so that the placement robot 420 can reach the layer parts cut by these conditions.

[0232] In another illustrative example, another set of placement robots, cutters, and conveyors can be positioned in a mirror configuration on the opposite side of the paving surface 416 and conveyor 417. With this configuration, all placement robots can place layers onto the paving surface 416 under the coordination of the controller 114.

[0233] In still other illustrative examples, the inspection system can be omitted. Or the inspection can be performed by the placement robot 420 instead of by the cutting machine. In still other illustrative examples, there can be one or more laying surfaces on the conveyor in addition to the laying surface 416 on the conveyor 417. With the additional laying surfaces, the placement robot 420 can place layers for multiple composite parts. In addition, in other illustrative examples, it is not necessary to place the layers on the laying surface 416 in a staggered position.

[0234] Next go to Figure 8 , an illustration of a flowchart of a process for forming a finite multilayer sheet is depicted in accordance with an illustrative embodiment. Figure 8The processes in may be implemented in hardware, software, or both. When implemented in software, the processes may take the form of program instructions that are executed by one of a plurality of processor units in one or more hardware devices located in one or more computer systems. For example, the processes may be implemented in Figure 1 The invention is implemented in the controller 114 in the computer system 112 in the embodiment.

[0235] The process controls the first cutting system to cut the first set of plies and move the first set of plies to a temporary location (operation 800). The process controls the placement robot to pick up the first set of plies from the temporary location and place the first set of plies on a layup surface to form a first ply of a multi-ply laminate, changing the orientation of the fibers from an initial orientation to a desired orientation of the first ply (operation 802).

[0236] When the placement robot picks up and places the first set of plies, the process controls the second cutting system to cut the second set of plies and move the second set of plies to a temporary location (operation 804). The process controls the placement robot to pick up the second set of plies from the temporary location and place the second set of plies on the layup surface to form a second ply of the multi-ply laminate after the first ply has been formed, changing the orientation of the fibers from the initial orientation to the desired orientation of the second ply (operation 806). The process then terminates.

[0237] exist Figure 8 In an example of a process in which each subsequent ply of a multi-ply laminate is formed by placing at least some material of each subsequent ply to at least partially overlap a previous ply in the multi-ply laminate. In addition, the orientation of fibers in at least one ply is changed by reorienting the plies as they are picked up from a temporary location and placed on a layup surface to form the plies. In addition, the plies have a width defined by an outer edge of the ply. The plies are reoriented so that one or more cut edges of the ply form a portion of an outer edge of the ply when placed on the layup surface.

[0238] Next go to Fig. 9 , depicts an illustration of a flow chart of a process for laying up a third ply in a multi-ply laminate according to an illustrative embodiment. The process shown in this figure is a process that can be used Figure 8 An example of additional operations that can be performed using the operations in .

[0239] The process controls the automated tape placement machine to place material to form a third ply of the multi-ply laminate, wherein the third ply has fibers oriented in the initial orientation (operation 900). The process then terminates.

[0240] Reference now Fig.10 , an illustration of a flowchart of a process for inspecting a layer component is depicted in accordance with an illustrative embodiment. The process in the figure is a flowchart that can be used Figure 8 An example of additional operations that can be performed using the operations in .

[0241] The process generates a top image of a top surface of a layer using a robot camera coupled to a placement robot in response to the placement robot moving to pick up the layer (operation 1000). The process analyzes the top image for out-of-tolerance anomalies (operation 1002).

[0242] The process controls the placement robot to move any of the layer pieces having out-of-tolerance anomalies to a scrap location (operation 1004). The process then terminates.

[0243] Next, in Fig.11 In the figure, an illustration of a flow chart of a process for inspecting a layer is depicted according to an illustrative embodiment. The process in the figure is a flow chart that can be used Figure 8 An example of additional operations that can be performed using the operations in .

[0244] The process generates a bottom image of a bottom surface of a layer held by a placement robot using an upward camera connected to a camera station (operation 1100). The process analyzes the bottom image for out-of-tolerance anomalies (operation 1102).

[0245] The process controls the placement robot to move any of the layer pieces having out-of-tolerance anomalies to a scrap location (operation 1104). The process then terminates.

[0246] Go to Fig.12 , depicts an illustration of a flowchart of a process for inspecting a layer according to an illustrative embodiment. The process depicted in the flowchart may be used Figure 8 An example of additional operations that can be performed using the operations in .

[0247] The process generates a top image of the layer using a cutting camera system in response to the first cutting system and the second cutting system cutting the layer (operation 1200). The process analyzes the top image for out-of-tolerance anomalies (operation 1202).

[0248] The process controls the robot to move any one of the layer pieces with anomalies that exceed the tolerance to a waste position (operation 1204). The process then terminates. In operation 1204, the robot that moves the layer piece with anomalies to its copy can take a number of different forms. For example, these robots can be placement robots. In other illustrative examples, the waste robot is configured to remove the layer piece with anomalies. These waste robots are robots that are separate from the placement robot. The waste robot can be, for example, a mechanical arm, a delta arm, a drone, or some other suitable robot.

[0249] refer to Fig.13, depicts an illustration of a flowchart of a process for providing redundancy in a multi-layer sheet lamination system according to an illustrative embodiment. The process depicted in the flowchart is a process that can be used Figure 8 An example of additional operations that can be performed using the operations in .

[0250] The process replaces a cutter in one of a first cutter in a first cutting system and a second cutter in a second cutting system with a spare cutter in response to one of the first cutter and the second cutter requiring maintenance (operation 1300). The process analyzes operation of the spare cutter to cut a layer in response to exchanging the spare cutter with one of the first cutter and the second cutter (operation 1302). The process then terminates.

[0251] The flow charts and block diagrams in the different depicted embodiments illustrate some possible architectures, functions and operations of apparatus and methods in illustrative embodiments. In this regard, each block in a flow chart or block diagram can represent at least one of a part of a module, a fragment, a function or an operation or a step. For example, one or more blocks can be implemented as a combination of program instructions, hardware or program instructions and hardware. When implemented with hardware, the hardware can, for example, take the form of an integrated circuit, which is manufactured or configured to perform one or more operations in a flow chart or block diagram. When implemented as a combination of program instructions and hardware, the implementation can take the form of firmware. Each block in a flow chart or block diagram can be implemented using a dedicated hardware system, which performs different operations or a combination of dedicated hardware and the program instructions run by the dedicated hardware.

[0252] In some alternative implementations of the illustrative embodiments, a function or functions shown in a block may not appear in the order shown in the figure. For example, in some cases, two blocks shown in succession may be executed substantially simultaneously, or the blocks may sometimes be executed in reverse order, depending on the functions involved. In addition, other blocks may be added in addition to the blocks shown in the flow chart or block diagram.

[0253] Now go to Fig.14 , depicts a block diagram of a data processing system according to an illustrative embodiment. Data processing system 1400 may be used to implement Figure 1 14. In this illustrative example, data processing system 1400 includes communications framework 1402, which provides communications between processor unit 1404, memory 1406, persistent storage 1408, communications unit 1410, input / output (I / O) unit 1412, and display 1414. In this example, communications framework 1402 takes the form of a bus system.

[0254] Processor unit 1404 is used to execute software instructions that can be loaded into memory 1406. Processor unit 1404 includes one or more processors. For example, processor unit 1404 can be selected from at least one of the following items: a multi-core processor, a central processing unit (CPU), a graphics processing unit (GPU), a physical processing unit (PPU), a digital signal processor (DSP), a network processor, or some other suitable type of processor. In addition, processor unit 1404 can be implemented using one or more heterogeneous processor systems, in which a main processor is present on a single chip with an auxiliary processor. As another illustrative example, processor unit 1404 may be a symmetric multi-processor system that includes multiple processors of the same type on a single chip.

[0255] Memory 1406 and persistent storage 1408 are examples of storage devices 1416. A storage device is any piece of hardware capable of storing information (such as, for example, but not limited to, at least one of data, program instructions in functional form, or other suitable information) on a temporary basis, a permanent basis, or both a temporary basis and a permanent basis. In these illustrative examples, storage devices 1416 may also be referred to as computer-readable storage devices. In these examples, memory 1406 may be, for example, a random access memory or any other suitable volatile or non-volatile storage device. Persistent storage 1408 may take various forms, depending on the particular implementation.

[0256] For example, persistent storage 1408 may include one or more components or devices. For example, persistent storage 1408 may be a hard drive, a solid state drive (SSD), flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination thereof. The medium used by persistent storage 1408 may also be removable. For example, a removable hard drive may be used for persistent storage 1408.

[0257] In these illustrative examples, communications unit 1410 provides for communications with other data processing systems or devices. In these illustrative examples, communications unit 1410 is a network interface card.

[0258] Input / output unit 1412 allows for input and output of data through other devices that may be connected to data processing system 1400. For example, input / output unit 1412 may provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Additionally, input / output unit 1412 may send output to a printer. Display 1414 provides a mechanism for displaying information to a user.

[0259] Instructions for at least one of an operating system, applications, or programs may be located in storage devices 1416, which are in communication with processor unit 1404 through communications framework 1402. The processes of the different embodiments may be performed by processor unit 1404 using computer-implemented instructions, which may be located in a memory, such as memory 1406.

[0260] These instructions are referred to as program instructions, computer usable program instructions, or computer readable program instructions, which may be read and executed by a processor in processor unit 1404. The program instructions in different embodiments may be embodied on different physical or computer readable storage media (e.g., memory 1406 or persistent storage 1408).

[0261] Program instructions 1418 are located in functional form on computer readable medium 1420, which is selectively removable and can be loaded onto or transferred to data processing system 1400 for execution by processor unit 1404. In these illustrative examples, program instructions 1418 and computer readable medium 1420 form computer program product 1422. In the illustrative examples, computer readable medium 1420 is computer readable storage medium 1424.

[0262] Computer readable storage medium 1424 is a physical or tangible storage device for storing program instructions 1418, rather than a medium for propagating or transmitting program instructions 1418. Computer readable storage medium 1424 can be at least one of the following: an electronic storage medium, a magnetic storage medium, an optical storage medium, an electromagnetic storage medium, a semiconductor storage medium, a mechanical storage medium, or other physical storage medium. Some known types of storage devices that include these media include: a floppy disk, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), a static random access memory (SRAM), a compact disk read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanical encoding device (such as a punch card or pits / land formed in a major surface of a disk), or any suitable combination thereof.

[0263] Computer-readable storage medium 1424 (as that term is used in this disclosure) should not be construed as a storage medium in the form of a transitory signal itself (e.g., at least one of a radio wave or other freely propagating electromagnetic wave, an electromagnetic wave propagating through a waveguide, an optical pulse transmitted through a fiber optic cable, an electrical signal transmitted through an electrical wire, or other transmission medium).

[0264] In addition, during the normal operation of the storage device, data may be moved at certain occasional points in time. These normal operations include access, defragmentation, or garbage collection. However, these operations do not present the storage device as transient because the data is not transient when it is stored in the storage device.

[0265] Alternatively, program instructions 1418 may be transmitted to data processing system 1400 using a computer readable signal medium. A computer readable signal medium is a signal, and may be, for example, a propagated data signal containing program instructions 1418. For example, a computer readable signal medium may be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals may be transmitted via a connection, such as a wireless connection, a fiber optic cable, a coaxial cable, an electrical wire, or any other suitable type of connection.

[0266] In addition, as used herein, "computer-readable medium 1420" may be singular or plural. For example, program instructions 1418 may be located in computer-readable medium 1420 in the form of a single storage device or system. In another example, program instructions 1418 may be located in computer-readable medium 1420 distributed in multiple data processing systems. In other words, some instructions in program instructions 1418 may be located in one data processing system, while other instructions in program instructions 1414 may be located in one data processing system. For example, a portion of program instructions 1418 may be located in computer-readable medium 1420 in a server computer, while another portion of program instructions 1418 may be located in computer-readable medium 1420, which is located in a group of client computers.

[0267] The different components described for data processing system 1400 are not meant to provide architectural limitations to the manner in which the different embodiments may be implemented. In some illustrative examples, one or more components may be incorporated into or otherwise form a part of another component. For example, in some illustrative examples, memory 1406 or portions thereof may be incorporated into processor unit 1404. The different illustrative embodiments may be implemented in a data processing system that includes components in addition to or in place of those described for data processing system 1400. Fig.14 Other components shown in the can be varied from the illustrative examples shown. The different embodiments can be implemented using any hardware device or system capable of executing program instructions 1418.

[0268] Illustrative embodiments of the present disclosure may be used in Fig.15 Aircraft manufacturing and service method 1500 is shown and Fig.16The description will be made in the context of the illustrated aircraft 1600. Fig.15 , an illustration of an aircraft manufacturing and service method is depicted in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method 1500 may include Fig.16 Specification and design 1502 of aircraft 1600 and material procurement 1504.

[0269] During production, Fig.16 Component and subassembly manufacturing 1506 and system integration 1508 of aircraft 1600 occurs. Thereafter, Fig.16 The aircraft 1600 in may be certified and delivered 1510 so as to be placed in service 1512. While the customer is in service 1512, Fig.16 Aircraft 1600 is scheduled for routine maintenance and service 1514, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

[0270] Each of the processes of aircraft manufacturing and service method 1500 can be performed or carried out by a system integrator, a third party, an operator, or some combination thereof. In these examples, the operator may be 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 vendors, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0271] Reference now Fig.16 , depicts a diagram of an aircraft in which an illustrative embodiment may be implemented. In this example, aircraft 1600 is a Fig.15 16. Aircraft manufacturing and service method 1500 is shown and may include fuselage 1602 having multiple systems 1604 and interior 1606. Examples of systems 1604 include one or more of propulsion system 1608, electrical system 1610, hydraulic system 1612, and environmental system 1614. Any number of other systems may be included. Although an aerospace example is shown, different illustrative embodiments may be applied to other industries (e.g., automotive industry).

[0272] The apparatus and methods embodied herein may be used in Fig.15 The invention is employed during at least one of the stages of aircraft manufacturing and service method 1500.

[0273] In an illustrative example, Fig.15 The components and subassemblies produced in 1506 may be manufactured in a manner similar to that in Fig.15The method of manufacturing or producing a component or subassembly in the same manner as that of producing a component or subassembly when the aircraft 1600 is in service 1512. As another example, one or more apparatus embodiments, method embodiments, or a combination thereof may be produced during a production phase (e.g., Fig.15 One or more apparatus embodiments, method embodiments, or a combination thereof may be used while the aircraft 1600 is in service 1512, during component and subassembly manufacturing 1506 and system integration 1508. Fig.15 During maintenance and service 1514 in the aircraft 1600, or while the aircraft 1600 is in service 1512 and during Fig.15 The use of a number of different illustrative embodiments may substantially speed up the assembly of aircraft 1600, reduce the cost of aircraft 1600, or both speed up the assembly of aircraft 1600 and reduce the cost of aircraft 1600.

[0274] In the illustrative example, the components and subassemblies are used during at least one of manufacturing 1506 and maintenance and service 1514. Figure 1 The multilayer sheet lamination system 102 in the embodiment of the present invention can speed up the assembly and maintenance of the aircraft 1600. The manner in which the multilayer sheet lamination system 102 cuts and places plies to form multilayer sheet laminates used in forming charges to manufacture composite parts reduces idle time of the cutting system and placement robots within the multilayer sheet lamination system 102 and increases throughput when placing plies to form plies.

[0275] Thus, one or more illustrative examples provide a method, apparatus, system, and computer program product for laying up plies to form a ply.

[0276] Compared to current techniques for laying up layers of composite parts (e.g., those that may be long and narrow), one or more illustrative examples achieve increased efficiency in placing layers, thereby forming plies with increased efficiency and speed. The illustrative examples avoid moving the laminating head multiple times during the layup process as by current techniques. In addition, by using a camera to generate images to analyze the layers for out-of-tolerance anomalies, manual inspection is avoided.

[0277] In an illustrative example, simultaneous placement of multiple layers can be performed using placement robots. In addition, when material loading and other maintenance are required, equipment swaps can be performed to reduce downtime. In an illustrative example, for a wing stringer, the loading lamination process can be reduced from 12 hours to 1 hour.

[0278] The description of different illustrative embodiments has been presented for the purpose of illustration and description and is not intended to be exhaustive or limited to the embodiments of the disclosed forms. Different illustrative examples describe components that perform actions or operations. In the illustrative embodiments, the components can be configured to perform the described actions or operations. For example, the component can have a configuration or design of a structure that provides the component with the ability to perform the actions or operations described as being performed by the component in the illustrative examples. In addition, in the context of using the terms "includes", "including", "has", "contains" and their variations in this article, such terms are intended to be inclusive in a manner similar to the term "comprises" as an open transition word, without excluding any additional or other elements.

[0279] The present disclosure includes example embodiments according to the following clauses:

[0280] Clause 1. A multi-layer sheet lamination system (102, 200, 400), comprising:

[0281] a first cutting system (120) and a second cutting system (122), each of the first cutting system (120) and the second cutting system (122) being configured to independently cut a material (121) having fibers (123) oriented in an initial orientation (125) to form a layer (131) and to move the layer (131) to a temporary position (141);

[0282] placing a robot (124, 214, 420); and

[0283] A controller (114) in communication with the first cutting system (120) and the second cutting system (122) and the placement robot (124, 214, 420), wherein the controller (114) is configured to:

[0284] controlling the first cutting system (120) to cut the first set of plies (131) and move the first set of plies (131) to a temporary position (141);

[0285] controlling a placement robot (124, 214, 420) to pick up the first set of plies (131) from a temporary location (141) and place the first set of plies (131) onto a layup surface (127, 234, 320, 416) to form a first ply (130) of a multi-ply laminate (128), changing the orientation of the fibers (123) from an initial orientation (125) to a desired orientation (146) of the first ply (130);

[0286] The second cutting system (122) is controlled to cut the second set of layers (131) and place the second set of layers (131) while the placement robot (124, 214, 420) is picking up and placing the first set of layers (131).

[0287] The member (131) is moved to a temporary position (141); and

[0288] A placement robot (124, 214, 420) is controlled to pick up a second set of layers (131) from a temporary location (141) and place the second set of layers (131) onto a laying surface (127, 234, 320, 416) to form a second layer (134) of a multi-layer laminate (128) after the first layer (130) has been formed, changing the orientation of the fibers (123) from an initial orientation (125) to a desired orientation (146) of the second layer (134).

[0289] Clause 2. The multi-layer sheet lamination system (102, 200, 400) according to clause 1, further comprising:

[0290] An automatic tape laying machine (126) is positioned to place a material (145) having fibers (148) in an initial orientation (125) onto a laying surface (127, 234, 320, 416), wherein a controller (114) is configured to control the automatic tape laying machine (126) to place the material to form a third ply (136) of a multi-ply laminate (128), wherein the third ply (136) has fibers (148) oriented in the initial orientation (125).

[0291] Clause 3. The multi-layer sheet lamination system (102, 200, 400) according to clause 1 or 2,

[0292] Wherein, the first cutting system (120) comprises:

[0293] A first cutting machine (132, 202, 132) is provided.

[0294] A cutting layer (131); and

[0295] a first conveyor (133, 204, 302, 412) configured to move a layer (131) cut by a first cutter (132, 202, 132) to a temporary position (141) in an initial orientation (125); and

[0296] The second cutting system (122) comprises:

[0297] A second cutting machine (122, 207, 413) is provided.

[0298] A cutting layer (131); and

[0299] A second conveyor (139, 208, 304, 414) is configured to move the layer (131) cut by the second cutter (122, 207, 413) to a temporary position (141) in an initial orientation (125).

[0300] Clause 4. The multi-ply lamination system (102, 200, 400) of Clause 3, wherein at least one of the first cutter and the second cutter (122, 207, 413) is configured to cut the plies (131) from the roll of material.

[0301] Clause 5. The multi-ply lamination system (102, 200, 400) of any one of Clauses 1-4, further comprising a layup conveyor, wherein the layup surface (127, 234, 320, 416) is on the layup conveyor.

[0302] Clause 6. The multi-ply lamination system (102, 200, 400) of any one of clauses 1-5, further comprising a layup table, wherein the layup surface (127, 234, 320, 416) is on the layup table.

[0303] Clause 7. The multi-layer sheet lamination system (102, 200, 400) of any one of clauses 1-6, further comprising an inspection system (149) configured to determine whether any of the layers (131) have an out-of-tolerance anomaly (155).

[0304] Clause 8. The multi-layer sheet lamination system (102, 200, 400) of clause 7, wherein the inspection system (149) comprises a robot camera (152) connected to a placement robot (124, 214, 420);

[0305] wherein the robotic camera (152) is positioned to generate a top image (153) of a top surface of the layer (131); and

[0306] The controller (114) is configured to:

[0307] generating a top image (153) of a top surface of a layer (131) in response to a placement robot (124, 214, 420) moving to pick up the layer (131);

[0308] analyzing the top image (153) for the anomalies (155) that are out of tolerance; and

[0309] The placement robot (124, 214, 420) is controlled to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0310] Clause 9. The multi-layer sheet lamination system (102, 200, 400) of clause 7 or 8, wherein the inspection system (149) comprises an upward camera (160) connected to a camera station;

[0311] wherein the upward camera (160) is positioned to generate a bottom image (162) of a bottom surface of the layer (131) held by the placement robot (124, 214, 420); and

[0312] The controller (114) is configured to:

[0313] generating the bottom image (162) of the bottom surface of the layer (131);

[0314] analyzing the bottom image (162) for the anomalies (155) that are out of tolerance; and

[0315] The placement robot (124, 214, 420) is controlled to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0316] Clause 10. The multi-layer sheet lamination system (102, 200, 400) according to any one of clauses 7 to 9,

[0317] wherein the inspection system (149) includes a cutting camera system (170),

[0318] wherein the cutting camera system (170) is positioned to generate a top image (153) of a top surface of the layer (131) cut by the first cutting system (120) and the second cutting system (122), and

[0319] The controller (114) is configured to:

[0320] generating the top image (153) of the layer (131) in response to the first cutting system (120) and the second cutting system (122) cutting the layer (131);

[0321] analyzing the top image (153) for the anomalies (155) that are out of tolerance; and

[0322] The placement robot (124, 214, 420) is controlled to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0323] Clause 11. The multi-layer sheet lamination system (102, 200, 400) according to clause 10, further comprising:

[0324] A plurality of scrap robots (180) are positioned to remove layers (131) having out-of-tolerance anomalies (155) cut by the first cutting system (120) and the second cutting system (122) to a scrap location (154).

[0325] Clause 12. A multilayer sheet lamination system (102, 200, 400) according to any one of clauses 7-11, wherein the inspection system (149) includes at least one of the following items: a camera system, a thermal imager, an infrared camera, a visible light camera, a laser scanner, an x-ray imaging machine and a laser shear imaging system.

[0326] Clause 13. The multi-layer sheet lamination system (102, 200, 400) according to any one of clauses 1-12, further comprising:

[0327] Spare cutting machine (132,409);

[0328] And wherein the controller (114) is configured to synchronize operation of the backup cutter (132, 409) to cut the layer (131) in response to swapping the backup cutter (132, 409) with a cutter in one of the first cutting system (120) and the second cutting system (122).

[0329] Clause 14. A multilayer sheet lamination system (102, 200, 400) according to any one of clauses 1-13, wherein the desired orientation of the layer (131) is selected from the group consisting of: 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees and 90 degrees relative to the initial orientation (125).

[0330] Clause 15. The multi-ply lamination system (102, 200, 400) of Clause 14, wherein the desired orientation (146) of the first ply (130) is different than the desired orientation (146) of the second ply (134).

[0331] Clause 16. A multilayer sheet lamination system (102, 200, 400) according to any one of clauses 1-15, wherein the multilayer sheet laminate (128) is used for charging, which is used to form a part selected from the group consisting of: a slender composite part, a wing stringer, a fuselage stringer, a tail, a stringer, a floor beam, a wing wing spars and a tail wing spars.

[0332] Clause 17. The multi-layer sheet lamination system (102, 200, 400) according to any one of clauses 1 to 16,

[0333] wherein the placement robot (124, 214, 420) is configured to change the orientation of the fibers (123) in at least one of the plies (131) by reorienting the ply as it is picked up from a temporary location and placed on a layup surface (127, 234, 320, 416) to form a ply;

[0334] wherein the ply has a width defined by an outer edge of the ply; and

[0335] The ply is reoriented so that one or more cut edges of the ply form a portion of an outer edge of the ply when placed on the laying surface (127, 234, 320, 416).

[0336] Clause 18. A multi-layer sheet lamination system (102, 200, 400), comprising:

[0337] a first cutting system (120) and a second cutting system (122), each configured to independently cut a material (121) having fibers (123) oriented in an initial orientation (125) to form layers (131) and to move the layers (131) to a temporary location (141);

[0338] Place robot (124, 214, 420);

[0339] an automated tape laying machine (126) positioned to place material (145) having fibers (148) in said initial orientation (125) onto said laying surface (127, 234, 320, 416); and

[0340] A controller (114) in communication with the first cutting system (120), the second cutting system (122), the placement robot (124, 214, 420), and the automatic tape laying machine (126), wherein the controller (114) is configured to:

[0341] Controlling the first cutting system (120) to cut a first set of layers (131) and to separate the first

[0342] The assembly member (131) moves to the temporary position (141);

[0343] controlling the placement robot (124, 214, 420) to pick up the first set of plies (131) from the temporary location (141) and place the first set of plies (131) onto a layup surface (127, 234, 320, 416) to form a first ply (130) of a multi-ply laminate (128), changing the orientation of the fibers (123) from the initial orientation (125) to a desired orientation (146) of the first ply (130);

[0344] Controlling the second cutting system (122) to place the robot (124, 214, 420)

[0345] While the first set of layers (131) is being picked up and placed, the second set of layers (131) is being cut and

[0346] The second set of layers (131) is moved to the temporary position (141);

[0347] controlling the placement robot (124, 214, 420) to pick up the second set of plies (131) from the temporary location (141) and place the second set of plies (131) onto the layup surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply laminate (128) after the first ply (130) has been formed, changing the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) of the second ply (134);

[0348] and

[0349] controlling the automatic tape placement machine (126) to place the material (145) to form plies of the multi-ply laminate (128), wherein the plies have the initial orientation (125)

[0350] The fibers (148) are oriented.

[0351] Clause 19. A method of forming a multi-ply laminate (128), the method comprising:

[0352] controlling (800) the first cutting system (120) to cut the first set of plies (131) and move the first set of plies (131) to a temporary position (141);

[0353] controlling (802) a placement robot (124, 214, 420) to pick up the first set of plies (131) from the temporary location (141) and place the first set of plies (131) onto a layup surface (127, 234, 320, 416) to form a first ply (130) of the multi-ply laminate (128), changing the orientation of the fibers (123) from an initial orientation (125) to a desired orientation (146) of the first ply (130);

[0354] controlling (804) a second cutting system (122) to cut a second set of plies (131) and move the second set of plies (131) to the temporary location (141) while the placement robot (124, 214, 420) is picking up and placing the first set of plies (131);

[0355] controlling (806) the placement robot (124, 214, 420) to pick up the second set of plies (131) from the temporary location (141) and place the second set of plies (131) onto the layup surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply laminate (128) after the first ply (130) has been formed, changing the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) of the second ply (134); and

[0356] An automatic tape placement machine (126) is controlled (900) to place material (145) to form a third ply (136) of the multi-ply laminate (128), wherein the third ply has the fibers (123) oriented in the initial orientation (125).

[0357] Clause 20. The method of Clause 19, wherein each subsequent ply is formed by placing at least some of the material of each subsequent ply to at least partially overlap a previous ply.

[0358] Clause 21. A method according to clause 19 or 20,

[0359] wherein said orientation of said fibers (123) in at least one of said plies (131) is changed by reorienting said ply as it is picked up from a temporary location and placed on said layup surface (127, 234, 320, 416) to form a ply;

[0360] wherein the ply has a width defined by an outer edge of the ply; and

[0361] The ply is reoriented so that one or more cut edges of the ply form a portion of an outer edge of the ply when placed on the laying surface (127, 234, 320, 416).

[0362] Clause 22. The method according to any one of clauses 19-21, further comprising:

[0363] generating (1000) a top image (153) of a top surface of the layer (131) using a robot camera (152) coupled to the placement robot (124, 214, 420) in response to the placement robot (124, 214, 420) being moved to pick up the layer (31);

[0364] analyzing (1002) the top image (153) for out-of-tolerance anomalies (155); and

[0365] The placement robot (124, 214, 420) is controlled (1004) to move any of the layers (131) having the anomaly (155) outside the tolerance to a scrap location (154).

[0366] Clause 23. The method according to any one of clauses 19-22, further comprising:

[0367] generating (1100) a bottom image (162) of a bottom surface of the layer (131) held by the placement robot (124, 214, 420) using an upward-facing camera (160) connected to a camera station;

[0368] analyzing (1102) the bottom image (162) for out-of-tolerance anomalies (155); and

[0369] The placement robot (124, 214, 420) is controlled (1104) to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0370] Clause 24. The method according to any one of clauses 19-23, further comprising:

[0371] generating (1200) a top image (153) of the layer (131) using a cutting camera system (170) in response to the first cutting system (120) and the second cutting system (122) cutting the layer (131);

[0372] analyzing (1202) the top image (153) for out-of-tolerance anomalies (155); and

[0373] The robot is controlled (1204) to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

[0374] Clause 25. The method according to any one of clauses 19-24, further comprising:

[0375] replacing (1300) a cutting machine in one of a first cutting machine (132, 202, 132) in a first cutting system (120) and a second cutting machine (122, 207, 413) in a second cutting system (122) with a spare cutting machine (132, 409) in response to one of the first cutting machine (132, 202, 132) and the second cutting machine (122, 207, 413) requiring maintenance; and

[0376] Operation of the backup cutter (132, 409) is synchronized (1302) to cut the layer (131) in response to exchanging the backup cutter (132, 409) with one of the first cutter (132, 202, 132) and the second cutter (122, 207, 413).

[0377] Many modifications and variations will be apparent to those of ordinary skill in the art. In addition, different illustrative embodiments may provide different features than other desired embodiments. The selected embodiment or embodiments are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure of various embodiments with various modifications as are suitable for the particular use contemplated.

Claims

1. A multi-layer sheet lamination system (102, 200, 400), comprising: a first cutting system (120) and a second cutting system (122), each of the first cutting system (120) and the second cutting system (122) being configured to independently cut a material (121) having fibers (123) oriented in an initial orientation (125) to form a layer (131) and to move the layer (131) to a temporary position (141); placing a robot (124, 214, 420); and a controller (114) in communication with the first cutting system (120) and the second cutting system (122) and the placement robot (124, 214, 420), wherein the controller (114) is configured to: controlling the first cutting system (120) to cut a first set of plies (131) and to move the first set of plies (131) to the temporary position (141); Controlling the placement robot (124, 214, 420) to pick up the first set of plies (131) from the temporary location (141) and place the first set of plies (131) on the laying surface (127, 234, 320, 416), to form a first ply (130) of a multi-ply laminate (128), changing the orientation of the fibers (123) from the initial orientation (125) to a desired orientation (146) of the first ply (130); controlling the second cutting system (122) to cut the second set of plies (131) and move the second set of plies (131) to the temporary position (141) while the placement robot (124, 214, 420) is picking up and placing the first set of plies (131); and The placement robot (124, 214, 420) is controlled to pick up the second group of layers (131) from the temporary position (141) and place the second group of layers (131) onto the laying surface (127, 234, 320, 416) to form the second layer (134) of the multi-layer laminate (128) after the first layer (130) has been formed, changing the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) of the second layer (134).

2. The multi-layer sheet lamination system (102, 200, 400) according to claim 1, further comprising: An automated tape laying machine (126) positioned to place a material (145) having fibers (148) in the initial orientation (125) onto the laying surface (127, 234, 320, 416), wherein the controller (114) is configured to: The automatic tape placement machine (126) is controlled to place the material to form a third ply (136) of the multi-ply laminate (128), wherein the third ply (136) has the fibers (148) oriented in the initial orientation (125).

3. The multi-layer sheet lamination system (102, 200, 400) according to claim 1, wherein the first cutting system (120) comprises: a first cutter (132, 202, 132) configured to cut the layer (131); and a first conveyor (133, 204, 302, 412) configured to move the layer (131) cut by the first cutter (132, 202, 132) to the temporary position (141) in the initial orientation (125), and The second cutting system (122) comprises: a second cutter (122, 207, 413), the second cutter (122, 207, 413) being configured to cut the layer (131); and a second conveyor (139, 208, 304, 414), the second conveyor (139, 208, 304, 414) being configured to convey the second cutting machine (122, 207, 413) to move the layer (131) cut to the temporary position (141).

4. The multi-ply lamination system (102, 200, 400) according to claim 3, wherein at least one of the first cutter and the second cutter (122, 207, 413) is configured to cut the layer (131) from a material roll.

5. The multi-layer sheet lamination system (102, 200, 400) according to claim 1, further comprising: A laying conveyor, wherein the laying surface (127, 234, 320, 416) is on the laying conveyor.

6. The multi-layer sheet lamination system (102, 200, 400) according to claim 1, further comprising: A laying table, wherein the laying surface (127, 234, 320, 416) is on the laying table.

7. The multi-layer sheet lamination system (102, 200, 400) according to claim 1, further comprising: An inspection system (149) is configured to determine whether any of the layers (131) have an out-of-tolerance anomaly (155).

8. The multi-ply lamination system (102, 200, 400) of claim 7, wherein the inspection system (149) comprises a robot camera (152) coupled to the placement robot (124, 214, 420), wherein the robot camera (152) is positioned to generate a top image (153) of a top surface of the ply (131); and wherein the controller (114) is configured to: generating the top image (153) of the top surface of the layer (131) in response to the placement robot (124, 214, 420) moving to pick up the layer (131); analyzing the top image (153) for the anomalies (155) that are out of tolerance; and The placement robot (124, 214, 420) is controlled to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

9. The multi-ply lamination system (102, 200, 400) of claim 7, wherein the inspection system (149) includes an upward camera (160) connected to a camera station, wherein the upward camera (160) is positioned to generate a bottom image (162) of a bottom surface of the layer (131) held by the placement robot (124, 214, 420), The controller (114) is configured to: generating the bottom image (162) of the bottom surface of the layer (131); analyzing the bottom image (162) for the anomalies (155) that are out of tolerance; and The placement robot (124, 214, 420) is controlled to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

10. The multi-ply lamination system (102, 200, 400) of claim 7, wherein the inspection system (149) comprises a cutting camera system (170), wherein the cutting camera system (170) is positioned to generate a top image (153) of a top surface of the ply (131) cut by the first cutting system (120) and the second cutting system (122), wherein the controller (114) is configured to: generating the top image (153) of the layer (131) in response to the first cutting system (120) and the second cutting system (122) cutting the layer (131); analyzing the top image (153) for the anomalies (155) that are out of tolerance; and The placement robot (124, 214, 420) is controlled to move any of the layers (131) having the anomaly (155) that is out of tolerance to a scrap location (154).

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