Printed fiducial system for accurate pick and place

Abstract

To provide a method and system for manufacturing composite parts.SOLUTION: A set of reference locations is identified for a set of fiducial markers on a composite ply from a ply shape model for a composite part. The set of fiducial markers is created at the set of reference locations on the composite ply. The composite ply is cut to have a shape defined by the ply shape model.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present disclosure relates generally to aircraft manufacturing, and more particularly to methods, apparatus, systems, and computer program products for manufacturing composite aircraft components. [Background technology]

[0002] The composite material composed of carbon fiber can be in a dry state or in the form of a prepreg, where the carbon fiber material is impregnated with a resin. The composite material can be in the form of plies. The plies can be cut to the desired shape and laid up on a tool. The plies in the tool can be cured to form a composite part.

[0003] This process of forming a composite part involves numerous steps of manipulating the plies. Workers can lay up the plies in a work area, such as a flatbed cutter, where a cutter can be used to shape the desired dimensions. When the cut size is large, a workman or workers remove the plies from the scrap material and transport the plies to another location for further processing or storage. This process can include rotating and folding the plies, when acceptable. One further process can be used to place the plies on a tool, where the boundaries of the ply are aligned with the laser projection.

[0004] This type of process utilizing labor can be slower and more tedious than desired. Additionally, the process is labor intensive and the plies are susceptible to damage during handling.

[0005] Automated systems can be used to handle the plies. For example, an end effector on a robotic system can perform a pick-and-place operation in which the end effector with an attachment surface, such as a vacuum, can move the plies to various locations and position them for processing. The automated systems can have errors in accurately positioning the composite plies during various operations. These errors can result in the final composite part being out of tolerance.

[0006] It would therefore be desirable to have a method and apparatus that takes into account at least some of the problems noted above, as well as other problems that may arise, such as overcoming the technical difficulties associated with placing composites within desired tolerances to produce composite parts. Summary of the Invention

[0007] One embodiment of the present disclosure provides a method for manufacturing a composite part, wherein a set of reference locations is identified for a set of fiducial markers on the composite plies from a ply shape model for the composite part, a set of fiducial markers is generated at the set of reference locations on the composite plies, and the composite plies are cut to have a shape defined by the ply shape model.

[0008] Another embodiment of the present disclosure provides a method for manufacturing a composite part, wherein composite plies are cut using automated manufacturing equipment to have a shape defined by a ply shape model for the composite part, and a set of fiducial markers are generated at a set of fiducial locations on the composite plies using the automated manufacturing equipment.

[0009] Yet another embodiment of the present disclosure provides a composite manufacturing system including manufacturing equipment and a manufacturing controller in a computer system, wherein the manufacturing controller controls the manufacturing equipment to identify, from a ply shape model for the composite part, a set of reference locations for a set of reference markers on the composite plies, generate a set of generated reference markers at the set of reference locations on the composite plies, and cut the composite plies to have a shape defined by the ply shape model.

[0010] Yet another embodiment of the present disclosure provides a composite manufacturing system including manufacturing equipment and a manufacturing controller in a computer system, wherein the manufacturing controller controls the manufacturing equipment to cut the composite plies to have a shape defined by a ply shape model for the composite part and to generate a set of fiducial markers at a set of fiducial locations on the composite plies.

[0011] According to one aspect of the present disclosure, a method for manufacturing a composite part includes identifying a set of reference locations for a set of reference markers on a composite ply from a ply shape model for the composite part, generating a set of reference markers at the set of reference locations on the composite ply, and cutting the composite ply to have a shape defined by the ply shape model.

[0012] Advantageously, the method further includes using the sensor system to identify a current position of the shaped composite ply using the set of reference markers, and generating instructions to a placement device to move the shaped composite ply from the current position to a desired position.

[0013] Preferably, in the method, generating instructions to the placement device to move the shaped composite ply from a current position to a desired position includes generating instructions to the placement device to perform a picking operation to pick up the composite ply from its current position and place the composite ply at the desired position.

[0014] Preferably, in the method, generating instructions to a placement device to move a shaped composite ply from a current position to a desired position includes generating instructions to the placement device to place the composite ply in a desired position on another composite ply as part of forming a composite charge.

[0015] Preferably, in the method, generating instructions for a placement device to move a shaped composite ply from a current position to a desired position includes generating instructions for the placement device to place the composite ply on a layup tool.

[0016] Preferably, the method further includes using the sensor system to determine a current position of a set of fiducial markers on the composite ply, and generating instructions to the placement device to move an end effector on the placement device from the current position to a desired position relative to the set of fiducial markers.

[0017] Preferably, in the method, cutting the composite ply to have a shape defined by the ply shape model comprises using a tool to cut the composite ply to have a shape defined by the ply shape model, and generating a set of fiducial markers at the set of reference locations on the composite ply comprises using a tool to generate the set of fiducial markers at the set of reference locations on the composite ply.

[0018] Preferably, in the method, generating the set of fiducial markers at the set of reference locations on the composite ply includes generating the set of fiducial markers at the set of reference locations on the composite ply after cutting the composite ply to have a shape defined by the ply shape model.

[0019] Preferably, in the method, generating a set of fiducial markers at a set of reference locations on the composite ply includes generating the set of fiducial markers at the set of reference locations on the composite ply before cutting the composite ply to have a shape defined by the ply shape model.

[0020] Preferably, in the method, generating the set of fiducial markers at the set of reference locations on the composite ply comprises generating the set of fiducial markers directly on the composite ply at the set of reference locations.

[0021] Preferably, in the method, generating the set of fiducial markers at the set of reference locations on the composite ply includes generating the set of fiducial markers directly on a backing for the composite ply at the set of reference locations.

[0022] Preferably, in the method, the set of fiducial markers comprises at least one of ink, reflective ink, magnetic ink, stickers, paint, or liquid chalk.

[0023] Preferably, in the method, the composite plies are processed to form a composite part for a platform selected from the group including a mobile platform, a fixed platform, a land structure, an aquatic structure, a space-based structure, an aircraft, a commercial aircraft, a rotorcraft, a tilt rotor aircraft, a tilt wing aircraft, a vertical take-off and landing aircraft, a powered vertical take-off and landing aircraft, a personal air vehicle, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, a motor vehicle, a power plant, a bridge, a dam, a house, a manufacturing facility, and a building.

[0024] According to another aspect of the present disclosure, a method of manufacturing a composite part includes using automated manufacturing equipment to cut a composite ply to have a shape defined by a ply shape model for the composite part, and generating, using the automated manufacturing equipment, a set of generation fiducial markers at a set of reference locations on the composite ply.

[0025] Advantageously, the method includes identifying a set of reference locations for a set of fiducial markers on the composite ply from the ply shape model.

[0026] Preferably, the method further includes using the sensor system to identify a current position of the shaped composite ply using the set of reference markers, and generating instructions to a placement device to move the shaped composite ply from the current position to a desired position.

[0027] Preferably, in the method, generating the set of generated fiducial markers at the set of reference locations on the composite ply using automated manufacturing equipment includes using the automated manufacturing equipment to cut the composite ply to have a shape defined by the ply shape model, and then generating the set of fiducial markers at the set of reference locations on the composite ply using the automated manufacturing equipment.

[0028] Preferably, in the method, generating a set of generated fiducial markers at a set of reference locations on the composite ply using automated manufacturing equipment includes generating, using the automated manufacturing equipment, the set of fiducial markers at the set of reference locations on the composite ply before cutting, using the automated manufacturing equipment, the composite ply to have a shape defined by the ply shape model.

[0029] Preferably, in the method, generating the set of generated fiducial markers at the set of reference locations on the composite ply using automated manufacturing equipment includes generating the set of fiducial markers directly on the composite ply at the set of reference locations using automated manufacturing equipment.

[0030] Preferably, in the method, generating the set of generated fiducial markers at the set of reference locations on the composite ply using automated manufacturing equipment includes generating the set of fiducial markers directly on the backing for the composite ply at the set of reference locations using automated manufacturing equipment.

[0031] According to yet another aspect of the present disclosure, a composite manufacturing system includes manufacturing equipment and a manufacturing controller within a computer system, the manufacturing controller performing steps of: identifying a set of reference locations for a set of reference markers on a composite ply from a ply shape model for the composite part; generating a set of reference markers at the set of reference locations on the composite ply; and cutting the composite ply to have a shape defined by the ply shape model. The manufacturing equipment is controlled to perform the above.

[0032] Advantageously, in the composite manufacturing system, the manufacturing controller uses the sensor system to identify a current position of the shaped composite ply using a set of fiducial markers, and generates instructions to a placement device to move the shaped composite ply from its current position to a desired position. The manufacturing equipment is controlled to perform the above.

[0033] Preferably, in the composite manufacturing system, when generating instructions for the placement device to move the shaped composite ply from a current position to a desired position, the manufacturing controller controls the manufacturing equipment to generate instructions for the placement device to perform a picking operation to pick up the composite ply from its current position and place the composite ply at the desired position.

[0034] Preferably, in the composite manufacturing system, when generating instructions to a placement device to move a shaped composite ply from a current position to a desired position, the manufacturing controller controls manufacturing equipment to generate instructions to the placement device to place the composite ply in the desired position over other composite plies as part of forming a composite charge.

[0035] Preferably, in the composite manufacturing system, when generating instructions for a placement device to move a shaped composite ply from a current position to a desired position, the manufacturing controller controls the manufacturing equipment to generate instructions for the placement device to place the composite ply on the layup tool.

[0036] Preferably, in the composite manufacturing system, when cutting the composite ply to have a shape defined by the ply shape model, the manufacturing controller controls manufacturing equipment to use a tool to cut the composite ply to have a shape defined by the ply shape model, and when generating a set of reference markers at the set of reference locations on the composite ply, the manufacturing controller controls manufacturing equipment to use a tool to generate the set of reference markers at the set of reference locations on the composite ply.

[0037] Preferably, in the composite manufacturing system, when generating the set of reference markers at the set of reference locations on the composite ply, the manufacturing controller controls the manufacturing equipment to generate the set of reference markers at the set of reference locations on the composite ply after cutting the composite ply to have a shape defined by the ply shape model.

[0038] Preferably, in the composite manufacturing system, when generating the set of reference markers at the set of reference locations on the composite ply, the manufacturing controller controls the manufacturing equipment to generate the set of reference markers at the set of reference locations on the composite ply before cutting the composite ply to have a shape defined by the ply shape model.

[0039] Preferably, in the composite manufacturing system, when generating a set of fiducial markers at a set of reference locations on the composite ply, the manufacturing controller controls manufacturing equipment to generate the set of fiducial markers directly on the composite ply at the set of reference locations.

[0040] Preferably, in the composite manufacturing system, when generating the set of fiducial markers at the set of reference locations on the composite ply, the manufacturing controller controls the manufacturing equipment to generate the set of fiducial markers directly on the backing for the composite ply at the set of reference locations.

[0041] Preferably, in the composite manufacturing system, the set of fiducial markers comprises at least one of ink, reflective ink, magnetic ink, stickers, paint, or liquid chalk.

[0042] Preferably, in the composite manufacturing system, the composite plies are processed to form composite parts for a platform selected from the group including a mobile platform, a fixed platform, a land structure, an aquatic structure, a space-based structure, an aircraft, a commercial aircraft, a rotorcraft, a tilt rotor aircraft, a tilt wing aircraft, a vertical take-off and landing aircraft, a powered vertical take-off and landing aircraft, a personal air vehicle, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, and a building.

[0043] According to yet another aspect of the present disclosure, a composite manufacturing system includes manufacturing equipment and a manufacturing controller in a computer system, where the manufacturing controller controls the manufacturing equipment to cut the composite plies to have a shape defined by a ply shape model for the composite part and to generate a set of fiducial markers at a set of reference locations on the composite plies.

[0044] Advantageously, in the composite manufacturing system, the manufacturing controller controls to identify, from the ply shape model, a set of reference locations for a set of fiducial markers on the composite ply.

[0045] Preferably, in the composite manufacturing system, the manufacturing controller uses the sensor system to identify a current position of the shaped composite ply using a set of reference markers, and generates instructions to a placement device to move the shaped composite ply from the current position to a desired position. The manufacturing equipment is controlled to perform the above.

[0046] Preferably, in the composite manufacturing system, when generating the set of reference markers at the set of reference locations on the composite ply, the manufacturing controller controls the manufacturing equipment to generate the set of reference markers at the set of reference locations on the composite ply after cutting the composite ply to have a shape defined by the ply shape model.

[0047] Preferably, in the composite manufacturing system, when generating the set of reference markers at the set of reference locations on the composite ply, the manufacturing controller controls the manufacturing equipment to generate the set of reference markers at the set of reference locations on the composite ply before cutting the composite ply to have a shape defined by the ply shape model.

[0048] Preferably, in the composite manufacturing system, when generating a set of fiducial markers at a set of reference locations on the composite ply, the manufacturing controller controls manufacturing equipment to generate the set of fiducial markers directly on the composite ply at the set of reference locations.

[0049] Preferably, in the composite manufacturing system, when generating the set of fiducial markers at the set of reference locations on the composite ply, the manufacturing controller controls the manufacturing equipment to generate the set of fiducial markers directly on the backing for the composite ply at the set of reference locations.

[0050] These features and functions can be realized independently in various embodiments of the present disclosure or can be combined in yet further embodiments, further details of which can be seen in conjunction with the following specification description and drawings.

[0051] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments, as well as the preferred mode of use, further objects and features thereof, will best be understood by reading the following detailed description of illustrative embodiments of the present disclosure when read in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0052] [Figure 1] FIG. 1 is an illustration of a composite manufacturing system in accordance with an illustrative embodiment. [Figure 2] FIG. 1 is a diagram of an automatic cutting and marking machine according to an illustrative embodiment. [Figure 3] 3 is a diagram of a cutter in the multi-function tool of FIG. 2 according to an exemplary embodiment. [Figure 4] 3 is a diagram of a marker in the multi-function tool of FIG. 2 according to an exemplary embodiment. [Figure 5] FIG. 1 is a diagram of an automatic cutting and marking machine according to an illustrative embodiment. [Figure 6] FIG. 1 is an illustration of a composite ply with fiducial markers in accordance with an illustrative embodiment; [Figure 7] FIG. 1 is an illustration of a fiducial marker according to an exemplary embodiment; [Figure 8] FIG. 1 is an illustration of a fiducial marker according to an exemplary embodiment; [Figure 9] FIG. 10 is another view of a fiducial marker according to an example embodiment. [Figure 10] FIG. 1 is a flow diagram of a process for manufacturing a composite part in accordance with an illustrative embodiment. [Figure 11] FIG. 1 is a process flow diagram for performing a manufacturing process in accordance with an illustrative embodiment. [Figure 12] FIG. 10 is a flow diagram of a process for generating a set of fiducial markers according to an illustrative embodiment. [Figure 13] FIG. 10 is another flow diagram of a process for generating a set of fiducial markers according to an illustrative embodiment. [Figure 14] FIG. 10 is a flow diagram of a process for generating a set of fiducial markers according to an illustrative embodiment. [Figure 15] FIG. 10 is a flow diagram of a process for generating a set of fiducial markers according to an illustrative embodiment. [Figure 16] FIG. 1 is a process flow diagram for performing a manufacturing process in accordance with an illustrative embodiment. [Figure 17] FIG. 1 is a process flow diagram for performing a manufacturing process in accordance with an illustrative embodiment. [Figure 18] FIG. 1 is a block diagram of a composite part manufacturing environment in accordance with an illustrative embodiment. [Figure 19] FIG. 1 is a block diagram of a data processing system in accordance with an illustrative embodiment; [Figure 20] FIG. 1 is an illustration of an aircraft manufacturing and service method in accordance with an illustrative embodiment. [Figure 21] FIG. 1 is a block diagram of an aircraft in which an illustrative embodiment may be implemented; [Figure 22] FIG. 1 is a block diagram of a product management system in accordance with an illustrative embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0053] The illustrative embodiments recognize and take into account one or more of a variety of concerns. For example, the illustrative embodiments recognize and take into account that currently used automated systems or composite ply handling can have cumulative errors at various steps that can cause the final placement to be outside of tolerances. The illustrative embodiments recognize and take into account that these errors can be errors in positioning the ply cutter, errors in cutting the composite material, robot calibration errors, errors in aligning the robot with the pick-up area, and positioning errors in other processes involving moving or handling the composite plies. For example, the illustrative embodiments recognize and take into account that positioning errors can occur during movement of storage units, during movement of plies to pick-up zones on the belt, and during other types of processes that move or position composite plies.

[0054] The illustrative embodiments recognize and take into account that even small errors made during the various steps of moving the plies or ply layups can add up and result in the final positioning being out of tolerance.

[0055] The illustrative embodiments recognize and take into account that automated ply processing includes cutting composite sheets to generate ply shapes, moving plies to storage using a robot, placing plies in storage, picking up stored plies, placing plies on tools, and other operations. The illustrative embodiments recognize and take into account that these and other operations performed to manufacture a composite part can result in accumulated errors that make it very difficult to maintain required positional tolerances.

[0056] The illustrative embodiments recognize and take into account that one way that errors may be reduced includes scanning or identifying the ply boundaries of the composite ply after the picking operation while the composite ply is secured to the robot and end effector. The illustrative embodiments recognize and take into account that scanning the boundaries of the composite ply can be used to determine the position at which to pick up the composite ply.

[0057] The illustrative embodiments recognize and take into account that while scanning the ply boundaries can eliminate positional errors from previous processes, errors from cut quality, cutter calibration, and new position calculations often do not provide a level of accuracy that meets tolerances for manufacturing composite parts.

[0058] Thus, the illustrative embodiments recognize and take into account that creating one or more fiducial markers on the composite ply before the composite ply is aligned relative to the pick-up area can improve accuracy in positioning the composite ply during processes performed to manufacture the composite part. The illustrative embodiments recognize and take into account that the set of additional markers can have a design that can include a shape or pattern that allows a camera to resolve the location and orientation of the set of fiducial markers. The illustrative embodiments recognize and take into account that automated movement of the ply can be accompanied by inspection using a camera prior to movement to measure the set of fiducial markers relative to an end effector or other tool that can move or position the composite ply.

[0059] The illustrative embodiments recognize and take into account that the use of a set of fiducial markers can avoid additional errors when the relative positions of the composite plies are recalculated before each action that moves the composite plies, such as a pinching action.

[0060] The illustrative embodiments also recognize and take into account that generating the set of fiducial markers as early as possible may reduce the amount of error. For example, the illustrative embodiments recognize and take into account generating the set of fiducial markers immediately before or immediately after cutting the composite ply to have the shape that will be used in forming the composite part. The illustrative embodiments also recognize and take into account that generating the set of fiducial markers immediately before or immediately after cutting the composite ply can bleed air from aligning the cutter belt with the pick-up position.

[0061] Thus, the illustrative embodiments recognize and take into account that the final position of the composite ply is a combination of the accuracy in marking the fiducial markers on the composite ply, the final robot accuracy, and the tolerance of the composite ply boundary formed from cutting the composite ply.

[0062] Referring now to the figures, and in particular to FIG. 1 , a diagram of a composite manufacturing system is depicted in accordance with an illustrative embodiment. Composite manufacturing system 100 can operate cells 102 to manufacture composite parts 104. In this example, composite parts 104 may take any number of different forms. For example, composite parts 104 may be selected from at least one of a skin panel, a stringer, a door, a nacelle, or any other suitable type of composite part.

[0063] As used herein, the phrase "at least one of" when used in conjunction with a list of items means that various combinations of one or more of the listed items may be used, and furthermore, that only one of each listed item may be required. In other words, "at least one of" means that any combination of items, and that some items from the list may be used, but not all of the listed items are required. An item may be a specific object, article, or category.

[0064] For example, without limitation, "at least one of item A, item B, and 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 also be present. In some exemplary embodiments, "at least one of" may be, by way of example and not limitation, "two item A, one item B, and ten item C," "four item B, and seven item C," or other suitable combinations.

[0065] As shown, composite manufacturing system 100 includes several different cells that operate to manufacture composite parts 104. As shown, cells 102 within composite manufacturing system 100 may include, for example, cutting and weaving tools 106, automated charge layup cells 108, charge-to-tool transfer and forming cells 110, cleaning cells 112, and cleaning cells 113.

[0066] As shown, cutting and weaving tool 106 is a cell within composite manufacturing system 100 that operates to create composite plies 114 used in manufacturing composite part 104. In this example, cutting and weaving tool 106 performs the cutting process automatically using automated cutting and marking machine 116 and automated cutting and marking machine 118. As shown, automated cutting and marking machine 116 and automated cutting and marking machine 118 may be a cutting table, an automated flatbed cutting system, a conveyor cutting table, or other suitable type of automated cutting and marking machine. In this example, the marking function combined with the cutting function through the use of a multi-function tool in the cutting machine allows the cutting machine to be modified to function as both a cutting and marking machine. The cutting and marking machine may be, for example, a computer numerical control (CNC) machine.

[0067] In this embodiment, the automated cutting and marking machine 116 includes a multi-function tool 120, and the automated cutting and marking machine 118 includes a multi-function tool 122. In this embodiment, the multi-function tool 120 and the multi-function tool 122 are integrated tools, where each of the tools includes a cutter (not shown) and a marker (not shown). The cutter can take several different forms. For example, the cutter can be an electric vibration knife, a drag knife, an ultrasonic knife, a laser cutter, or some other suitable type of device capable of cutting the composite material to form the composite ply 114 with a shape for manufacturing the composite part 104. The marker can be an inkjet printer, a pen, a sticker applicator, or some other suitable device capable of marking the composite ply 114.

[0068] As shown, the multi-function tool 120 is capable of moving along a gantry 126 in the direction of arrow 124. The multi-function tool 122 is also capable of moving on a gantry 128 in the direction of arrow 124. In addition, the gantry 126 is capable of moving a flatbed 132 of the automatic cutting and marking machine 116 in the direction of arrow 130. Similarly, the gantry 128 is capable of moving a flatbed 134 of the automatic cutting and marking machine 118 in the direction of arrow 130. In this embodiment, the flatbeds 132 and 134 may be beds equipped with moving conveyor belts.

[0069] In addition to cutting composite ply 114 , multi-function tool 120 and multi-function tool 122 are also capable of marking composite ply 114 to create fiducial markers 136 on composite ply 114 .

[0070] As shown, a pick-and-place robot 138 can move composite plies 114 with fiducial markers 136 from the automated cutting and marking machine 116 and the automated cutting and marking machine 118 to storage 140 to form kits 142. In this example, the pick-and-place robot 138 can detect the fiducial markers 136 on the composite plies 114 when picking up the composite plies 114 from the flatbeds 132 and 134 and placing the composite plies 114 on storage 140. The pick-and-place robot 138 can include a camera system (not shown) for detecting the fiducial markers 136 on the composite plies 114.

[0071] As shown, kit 142 includes composite plies 114 with the necessary shapes to form composite components in composite part 104. In this example, storage 140 may be a cart or other mobile platform that can be moved automatically or by workers. Storage 140 allows composite plies 114 to be moved to other cells for additional processing to produce composite part 104.

[0072] As shown, storage 140 is capable of transferring composite plies 114 to charge layup cell 108 for further processing. In this example, a pick-and-place robot 144 picks composite plies 146 from storage 148 and places composite plies 146 on preform table 150. In this example, pick-and-place robot 144 may include a camera 152 that detects fiducial markers 151 on composite plies 146 for use in picking composite plies 146 from storage 148 and placing composite plies 146 on preform table 150.

[0073] Through the use of fiducial markers 151, composite plies 146 can be positioned with a desired level of tolerance on preform table 150. In this embodiment, preform table 150 is a carrier for the composite plies and can take the form of a grid of metal strips joined together in a grid pattern.

[0074] The pick and place robot 138 may also use the fiducial markers 136 to move the composite ply 114 with a desired level of tolerance, although this type of placement may be optional with the use of the pick and place robot 144 within the charge layup cell 108. In other words, the fiducial markers 151 for placing the composite ply 146 on the preform table 150 may be used to reduce or eliminate other positional errors that arise from other movements of the composite ply 146 on the flatbed 132, on the storage 148, and other movements of the composite ply by the pick and place robot 138.

[0075] In this example, charge layup cell 108 is an example of a cell that can reduce or eliminate errors from a previous move. In the illustrated example, fiducial marker 151 can be used to reduce or eliminate errors in placing composite ply 146 on preform table 150.

[0076] A layup of composite plies may be performed to form a charge, such as charge 156 on preform table 158. Preform table 158 may be moved to charge-to-tool transfer and forming cell 110.

[0077] As shown, a charge 160 is transferred onto a tool 162 from a preform table 164. In this embodiment, resin can be impregnated into the charge 160 from a resin reservoir 166. When prepreg is used, the addition of resin can be optional.

[0078] The tool 162, together with the resin-impregnated charge 160, may be transferred to an autoclave 168 in the cleaning cell 112. After this, the composite part 104 may be removed from the tool 170 by a robotic arm 172 in the cleaning cell 113. In this cell, steps such as bagging and cleaning of the tool 170 may be performed, allowing the tool 170 to be cleaned for further use.

[0079] In this example, computer 174 may execute program 176 to control the various cells within composite manufacturing system 100 and automatically execute processes for manufacturing composite part 104. As shown, computer 174 may communicate with computers or other controllers (not shown) for manufacturing equipment within cell 102 using communication link 178. Communication link 178 may be at least one of a physical connection or a wireless connection.

[0080] Thus, in an embodiment, fiducial markers 136 may be created directly on composite ply 114 before composite ply 114 is aligned within cutting and weaving tool 106 for movement by a pick-and-place robot, such as pick-and-place robot 138 and pick-and-place robot 144. From the time fiducial markers 136 are created on composite ply 114, subsequent movement of composite ply 114 may be performed using a camera on the pick-and-place robot to resolve the position of composite ply 114 relative to an end effector on the pick-and-place robot. In this manner, the positioning of the end effector relative to fiducial markers 136 may be determined with a desired level of accuracy using fiducial markers 136.

[0081] Because the relative position of the composite ply 114 can be determined before each operation of moving the composite ply 114, subsequent steps of moving the composite ply 114 do not introduce additional error.

[0082] 2, an automatic cutting and marking machine is shown in accordance with an exemplary embodiment. As shown, automatic cutting and marking machine 200 is an example of one implementation of automatic cutting and marking machine 116 and automatic cutting and marking machine 118 in FIG.

[0083] In this embodiment, the automatic cutting and marking machine 200 includes a flatbed 202, a gantry 204, and a multi-function tool 206. As shown, the multi-function tool 206 is movably mounted to the gantry 204. The gantry 204 is movably mounted to the flatbed 202.

[0084] In this example, gantry 204 is a bridge-like overhead structure that supports multi-function tool 206. As shown, gantry 204 may move along flatbed 202 in the direction of arrow 208. In this example, multi-function tool 206 may move along gantry 204 in the direction of arrow 210. As a result, multi-function tool 206 is capable of moving over surface 212 of flatbed 202 in two dimensions, represented by arrows 208 and 210.

[0085] In this embodiment, the multi-function tool 206 may include two components: a cutter 214 and a marker 216. As shown, the cutter 214 and the marker 216 are mounted within a housing 218 of the multi-function tool 206. The housing 218 of the multi-function tool 206 is movably connected to the gantry 204.

[0086] As shown, automated cutting and marking machine 200 can be programmed to cut composite ply 222 into shape 224 and generate fiducial markers, such as fiducial marker 226, fiducial marker 228, and fiducial marker 230, on surface 232 of composite ply 222. These fiducial markers are one example of an implementation of fiducial marker 136 and fiducial marker 151 in FIG.

[0087] In this example, cutter 214 has cut composite ply 222 to have shape 224. As shown, composite ply 222 is cut to have shape 224 prior to the creation of fiducial markers. In this example, fiducial marker 226 and fiducial marker 228 have been created on surface 232 by marker 216. In this example, marker 216 has not yet completed the creation of fiducial marker 230 on surface 232 of composite ply 222.

[0088] Referring to Figure 3, a diagram of a cutter in the multi-function tool of Figure 2 is shown in accordance with an exemplary embodiment. In this example, cutter 214 takes the form of a drag blade 300. The illustration of cutter 214 as a drag blade 300 is provided as an example of an implementation of cutter 214. This example does not limit the type of cutter that may be used in other examples. For example, cutter 214 may be implemented using an electric vibrating knife, an ultrasonic knife, a laser cutter, a kit cutting machine, a driven rotary blade, or any other suitable type of cutter.

[0089] 4, an illustration of a marker within the multi-function tool of FIG. 2 is shown in accordance with an illustrative embodiment. As shown, the marker 216 takes the form of an ink pen 400.

[0090] The illustration of marker 216 as ink pen 400 is provided as one example of an implementation of marker 216. This embodiment is not intended to limit the types of markers that may be used in other embodiments. For example, marker 216 may be implemented using an inkjet printer, a sticker applicator, or some other device capable of marking on surface 232 of composite ply 222.

[0091] 5, a diagram of an automatic cutting and marking machine is shown in accordance with one illustrative embodiment. As shown, automatic cutting and marking machine 500 is an example of other types of automatic cutting and marking machines that may be used in place of automatic cutting and marking machine 116 and automatic cutting and marking machine 118 shown in FIG. 1.

[0092] In this example, the automated cutting and marking machine 500 includes a platform 502, a robotic arm 504, and an end effector 506. In this example, the robotic arm 504 is capable of moving the end effector 506 in three dimensions, including a plane defined by an x-axis 508 and a y-axis 510.

[0093] A composite ply 512 rests on a surface 514 of the platform 502. In this example, the end effector 506 is a multi-function tool that includes a cutter 516 and a marker 518, which are shown visibly within a housing 520 of the end effector 506.

[0094] As shown, robotic arm 504 can move end effector 506 and use marker 518 to generate fiducial marker 522, fiducial marker 524, and fiducial marker 526 on surface 528 of composite ply 512. These fiducial markers are one example of an implementation of fiducial marker 136 and fiducial marker 151 of FIG.

[0095] As shown, composite ply 512 is not cut by cutter 516 in end effector 506. As can be seen in this example, fiducial markers are created prior to cutting composite ply 512.

[0096] 6, an illustration of a composite ply including fiducial markers is depicted in accordance with an illustrative embodiment. As shown, composite ply 600 is constructed from carbon fiber and can be cut to shape 602.

[0097] In this example, fiducial marker 606 , fiducial marker 608 , and fiducial marker 610 are generated on surface 612 of composite ply 600 .

[0098] In this example, fiducial marker 606 is generated at fiducial position 614 , fiducial marker 608 is generated at fiducial position 616 , and fiducial marker 610 is generated at fiducial position 618 .

[0099] These reference locations may be identified from a computer-aided design (CAD) model 620 of composite ply 600. In this example, computer-aided design model 620 defines a contour 622 for a shape 624 of composite ply 600. Contour 622 may be used to cut composite ply 600 to have shape 602 of the desired dimensions.

[0100] Computer-aided design model 620 may also include a reference location 626 for contour 622. Reference location 626 may be used to generate fiducial marker 606 at reference location 614, fiducial marker 608 at reference location 616, and fiducial marker 610 at reference location 618 on composite ply 600.

[0101] Referring to Figure 7, a diagram of a fiducial marker is shown in accordance with an example embodiment. Fiducial marker 700 is an example of one implementation of fiducial markers 136 and 151 in Figure 1, and fiducial markers 606, 608, and 610 in Figure 6. As shown, fiducial marker 700 has a symmetrical shape.

[0102] Referring to Figure 8, a diagram of a fiducial marker is shown in accordance with an example embodiment. Fiducial marker 800 is an example of one implementation of fiducial markers 136 and 151 in Figure 1, and fiducial markers 606, 608, and 610 in Figure 6. As shown, fiducial marker 800 has a symmetrical shape.

[0103] 9, another view of a fiducial marker is shown in accordance with an example embodiment. Fiducial marker 900 is an example of one implementation of fiducial markers 136 and 151 in FIG. 1 and fiducial markers 606, 608, and 610 in FIG. 6. As shown, fiducial marker 900 has an asymmetrical shape.

[0104] The illustrations of fiducial markers 700 in FIG. 7 , 800 in FIG. 8 , and 900 in FIG. 9 are provided as non-limiting examples of fiducial markers that can be used in various embodiments. The presentation of the fiducial markers above does not limit the manner in which other fiducial markers may be implemented in other embodiments. For example, in some embodiments, the fiducial marker may have multiple colors. In still other embodiments, the fiducial marker may have other shapes or sizes in addition to or instead of those shown in this embodiment. The particular shape and size of the fiducial marker may be selected to improve the ability of the sensor to detect the fiducial marker and its orientation.

[0105] Referring now to Figure 10, a flow diagram of a method for manufacturing a composite part is shown, in accordance with an illustrative embodiment. The process of Figure 10 may be implemented in hardware, software, or both. When implemented in software, the process may take the form of program code executed by one or more processor units located in one or more hardware devices in one or more computer systems. For example, the process may be implemented in program 176 executing on computer 174 of Figure 1.

[0106] The process begins by identifying a set of reference locations for a set of fiducial markers on the composite plies from a ply geometry model for the composite part (step 1000). The process generates a set of fiducial markers at the set of reference locations on the composite plies (step 1002).

[0107] The process cuts the composite plies to have the shape defined by the ply shape model (operation 1004), after which the process ends.

[0108] In this example, steps 1002 and 1004 may be performed using the same tool. In other words, cutting the composite ply and generating a set of fiducial markers at a set of fiducial locations on the composite ply may be performed using a single tool. For example, there may be an end effector of a robotic arm that has both a cutter and markers. In another example, the tool may be a multi-function tool head that moves along one axis on a gantry, where the gantry moves along another axis.

[0109] Referring to Figure 11, a process flow diagram is shown for performing a manufacturing process according to an exemplary embodiment. The process shown in Figure 11 is an example of additional steps that can be performed in conjunction with the steps shown in the flow diagram of Figure 10.

[0110] The process uses a sensor system to identify the current position of the shaped composite ply using a set of fiducial markers (step 1100). The process generates instructions to a placement machine to move the shaped composite ply from the current position to a desired position (step 1102). The process then ends.

[0111] 12, a flow diagram of a process for generating a set of fiducial markers is shown in accordance with an example embodiment. The steps shown in FIG. 12 are an example of an implementation of step 1002 of FIG. 10.

[0112] After cutting the composite ply to have a shape defined by the ply shape model, the process generates a set of fiducial markers at a set of fiducial locations on the composite ply (step 1200), after which the process ends.

[0113] 13, another flow diagram of a process for generating a set of fiducial markers is shown in accordance with an example embodiment. The steps shown in FIG. 13 are an example of an implementation of step 1002 of FIG. 10.

[0114] The process generates a set of fiducial markers at a set of fiducial locations on the composite ply before cutting the composite ply to have a shape defined by the ply shape model (step 1300), after which the process ends.

[0115] 14, a flow diagram of a process for generating a set of fiducial markers is shown in accordance with an illustrative embodiment. The steps shown in FIG. 14 are an example of an implementation of step 1002 of FIG. 10.

[0116] The process generates a set of fiducial markers directly on the composite plies at a set of fiducial locations (step 1400), after which the process ends.

[0117] 15, a flow diagram of a process for generating a set of fiducial markers is shown in accordance with an exemplary embodiment. The steps shown in FIG. 15 are an example of an implementation of step 1002 of FIG. 10.

[0118] The process generates a set of fiducial markers directly on the backing for the composite ply at a set of fiducial locations (step 1500), after which the process ends.

[0119] 16, a process flow diagram for performing a set of manufacturing steps in accordance with an illustrative embodiment is shown. The steps shown in FIG. 16 are an example implementation of step 1102 of FIG. 11.

[0120] The process generates instructions for a placement device to perform a picking operation to pick up a composite ply from its current position and place the composite ply in a desired position (operation 1600). The process generates instructions for a placement device to place the composite ply in a desired position on another composite ply as part of forming a composite charge (operation 1602).

[0121] The process generates instructions for a placement device to place the composite ply on the layup tool (operation 1604), after which the process ends.

[0122] Referring to Figure 17, a process flow diagram for performing a set of manufacturing steps according to an exemplary embodiment is shown. The process shown in Figure 17 is an example of additional steps that can be performed in conjunction with the steps shown in the flow diagram of Figure 10.

[0123] The process begins by selecting a composite ply having a set of fiducial markers (step 1700). The process picks up the composite ply (step 1702). The process uses the set of fiducial markers to place the composite ply on other composite plies to form a composite ply layup (step 1704). In step 1704, the set of fiducial markers can be used to place the composite ply on the other composite plies to form a desired position for the composite ply layup.

[0124] A determination is made as to whether another composite ply is needed (step 1706). If another composite ply is needed, the process returns to step 1700 to select another composite ply for composite ply layup. Otherwise, the process ends.

[0125] 17 can be used to lay up composite plies, stacks of composite plies, charges, composite preforms, or other structures using composite plies or other composite materials. Using composite plies with a set of fiducial markers allows for a desired level of precision in the placement of each composite ply relative to previously placed composite plies. Such precision can reduce the need for rework or scrap of composite parts made from composite plies laid up using fiducial markers.

[0126] The flow diagrams and block diagrams in the various illustrated embodiments illustrate the architecture, functionality, and operations of some possible implementations of apparatuses and methods in example embodiments. In this regard, each block in a flow diagram or block diagram may represent at least one of a module, a segment, a function, or a portion of an operation or step. For example, one or more blocks may be implemented as program code, hardware, or a combination of program code and hardware. When implemented in hardware, the hardware may take the form of, for example, an integrated circuit that is manufactured or configured to perform one or more operations of the flow diagrams or block diagrams. When implemented as a combination of program code and hardware, the implementation may take the form of firmware. Each block in a flow diagram or block diagram may be implemented using a special-purpose hardware system that performs various operations, or a combination of special-purpose hardware and program code executed by the special-purpose hardware.

[0127] In some alternative implementations of exemplary embodiments, the functions described in the blocks may be performed out of the order described in the figures. For example, in some cases, two blocks shown in succession may be performed substantially simultaneously, or the blocks may sometimes be performed in reverse order according to the functionality involved. Furthermore, other blocks may be added in addition to the blocks shown in the flow diagrams or block diagrams. For example, although generating an additional set of markers in step 1002 is shown as occurring before cutting the composite ply in step 1004 in FIG. 10, these steps may be performed in the reverse order. As another example, various steps shown in FIG. 16 may be performed in a different order than shown in the flow diagram of FIG. 17. Additionally, two or more of these steps may be performed in parallel with each other.

[0128] With reference now to Figure 18, an illustration of a block diagram of a composite part manufacturing environment is depicted in accordance with an illustrative embodiment. The various components and processes shown and described in Figures 1-17 may be implemented in composite part manufacturing environment 1800.

[0129] In this example, composite manufacturing system 1802 may operate to manufacture composite parts 1804 for platform 1806. As shown, composite manufacturing system 100 of FIG. 1 is one implementation of manufacturing equipment 1808 within composite manufacturing system 1802.

[0130] In this example, platform 1806 may be any number of platforms. For example, platform 1806 may be selected from the group including a mobile platform, a fixed platform, a land-based structure, an aquatic structure, a space-based structure, an aircraft, a commercial aircraft, a rotorcraft, a tilt rotor aircraft, a tilt wing aircraft, a vertical take-off and landing aircraft, a powered vertical take-off and landing aircraft, a personal air vehicle, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, a building, and other suitable types of platforms.

[0131] Composite components 1804 for platform 1806 may also take any number of different forms. For example, composite components 1804 may be selected from at least one of skin panels, stringers, wings, wing boxes, nacelles, fuselage sections, doors, panels, control surfaces, vertical stabilizers, horizontal stabilizers, rudder, elevators, ailerons, vehicle hoods, wall panels, panels, composite sandwich panels, and other suitable types of composite components used within platform 1806.

[0132] In this example, composite manufacturing system 1802 includes several different components. As shown, composite manufacturing system 1802 includes manufacturing equipment 1808, a computer system 1810, and a manufacturing controller 1812.

[0133] Manufacturing equipment 1808 is physical equipment and may include physical machines or devices that can be used to perform processes in manufacturing composite part 1804. In this example, manufacturing equipment 1808 may include automated manufacturing equipment 1814. Automated manufacturing equipment 1814 is a hardware system and may include software. Automated manufacturing equipment is capable of performing tasks without requiring input or instructions from an operator. Automated manufacturing equipment 1814 may include circuitry, such as a processor unit, an application specific integrated circuit (ASIC), or other hardware configured or designed to enable the performance of the tasks. The hardware may be programmable and may be, for example, a computer numerical control (CNC) machine.

[0134] For example, the automated manufacturing equipment 1814 can be a machine that cuts the composite plies 1816. For example, the automated manufacturing equipment 1814 can be a cutting machine that utilizes a cutter such as an electric oscillating knife, an ultrasonic knife, a laser cutter, a kit cutting machine, a drag knife, a driven rotary blade, or any other suitable type of machine that can be automated to cut the composite plies 1816.

[0135] As another example, the automated manufacturing equipment 1814 may still be an automated fiber placement (AFP) machine, such as a pick-and-place robot that operates to move or place the composite plies 1816. In other embodiments, the automated manufacturing equipment 1814 may be an inkjet printer or inkjet robot that is capable of printing on the composite plies 1816.

[0136] In yet another embodiment, the automated manufacturing equipment 1814 can be a multi-function machine. For example, the automated manufacturing equipment 1814 can perform cutting and marking operations. For example, the automated manufacturing equipment 1814 can include a flatbed with a gantry having a multi-function tool with a cutter and a marker.

[0137] In this example, composite ply 1816 may be comprised of fibers that can be impregnated with resin and cured to form composite part 1804. In this example, composite ply 1816 is already impregnated with resin, such that composite ply 1816 may be a layer of prepreg.

[0138] The fibers may be, for example, carbon fibers. These fibers may also be used in addition to or in place of carbon fibers, such as fiberglass, para-aramid fibers, aramid fibers, or other suitable fibers that may be used to form the composite plies 1816. In embodiments, multiple layers of composite plies 1816 may be laid up in various orientations and cured into various shapes to form the composite part 1804. The composite plies 1816 may be laid up by themselves or with other plies to form face sheets with a core material between the two face sheets to form a composite sandwich for the composite part 1804.

[0139] In this example illustration, manufacturing equipment 1808 may also include charge layup systems, conveyors, autoclaves, ovens, lathes, paint application systems, or other suitable equipment operable to manufacture composite parts 1804. These other types of manufacturing equipment 1808 may or may not be automated.

[0140] As shown, manufacturing controller 1812 is located within computer system 1810. Manufacturing controller 1812 may be implemented in software, hardware, firmware, or a combination thereof. When software is used, the operations performed by manufacturing controller 1812 may be implemented in program code configured to run on hardware, such as a processor unit. When firmware is used, the operations performed by manufacturing controller 1812 may be implemented in program code and data, stored in persistent memory, and executed on a processor unit. When hardware is utilized, the hardware may include circuitry that operates to perform the operations within manufacturing controller 1812.

[0141] In this example, the hardware may take the form of at least one of a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or any other suitable type of hardware configured to perform certain operations. When a programmable logic device is used, the device may be configured to perform certain operations. The device may be later reconfigured or may be permanently set to perform certain 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, processes may be implemented in organic components incorporated into inorganic components, and may be entirely composed of non-human organic components. For example, processes may be implemented as circuits in organic semiconductors.

[0142] As used herein, "a number of" when used in reference to an item means one or more items. For example, "a number of steps" are one or more carriers.

[0143] Computer system 1810 is a physical hardware system and includes one or more data processing systems. When more than one data processing system is present in computer system 1810, the 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 a computer, a server computer, a tablet computer, or any other suitable data processing system. Computer system 1810 may be configured to perform at least one of the steps, processes, or actions described in the various illustrative embodiments using software, hardware, firmware, or a combination thereof.

[0144] In this embodiment, when the manufacturing controller 1812 takes the form of software, the program 1838 may be an example of an implementation of the manufacturing controller 1812 .

[0145] In this embodiment, manufacturing controller 1812 may perform one or more of the various steps illustrated in the flow diagrams of FIGS.

[0146] As shown, manufacturing controller 1812 can control manufacturing equipment 1808 to use automated manufacturing equipment 1814 to cut composite plies 1816 having a shape 1818 defined by a ply shape model 1820 for composite part 1804. In this example, ply shape model 1820 is information readable by manufacturing controller 1812. Ply shape model 1820 can be, for example, a computer-aided design (CAD) model that defines the shape 1818 for composite ply 1816.

[0147] Additionally, the ply shape model 1820 may also identify a set of reference locations 1824 on the composite ply 1816. As used herein, "a set of" when used with respect to an item means one or more items. For example, a set of reference locations is one or more reference locations.

[0148] Thus, with the above information, ply shape model 1820 contains information that can be used to cut composite ply 1816, to generate a set of fiducial markers 1822 on composite ply 1816, or to both cut composite ply 1816 and generate a set of fiducial markers on composite ply 1816.

[0149] Manufacturing controller 1812 controls manufacturing equipment 1808 to generate a set of fiducial markers 1822 at a set of fiducial locations 1824 on composite plies 1816 using automated manufacturing equipment 1814. In this example, manufacturing controller 1812 may identify a set of fiducial locations 1824 for the set of fiducial markers 1822 on composite plies 1816 from ply shape model 1820 for composite part 1804.

[0150] In an example, composite ply 1816 can be cut to a shape 1818 defined by ply shape model 1820 using tool 1826 in automated manufacturing equipment 1814, and a set of fiducial markers 1822 can be generated at a set of fiducial locations 1824 using tool 1826. For example, tool 1826 can be a cutter 1871 controlled by manufacturing controller 1812, and cutter 1871 can be a laser cutter and inkjet printer head in a multi-function tool in automated manufacturing equipment 1814, where the tool can move in an x-axis on a bridge or gantry, and the bridge or gantry can move along an x-axis.

[0151] In other embodiments, tool 1826 may be a marker 1873 controlled by manufacturing controller 1812 to generate the set of fiducial markers 1822. Tool 1826 may be, for example, an ink pen, an inkjet printer, a sticker applicator, or any other device capable of generating the set of fiducial markers 1822. In one embodiment, tool 1826 may be a hybrid tool that includes both a cutter and a marker.

[0152] In other embodiments, the cutting tool 1826 can be the end effector 1851. In one embodiment, the end effector 1851 can include an ultrasonic knife on a robotic arm in the automated manufacturing equipment 1814 and an ink pen.

[0153] In embodiments, the set of fiducial markers 1822 may be generated in several different ways. For example, generating the set of fiducial markers 1822 at the set of fiducial locations 1824 on the composite ply 1816 may include: This is performed by a manufacturing controller 1812 that controls manufacturing equipment 1808 to generate a set of fiducial markers 1822 at a set of reference locations 1824 on the composite plies 1816 after cutting the composite plies 1816 to have the shape 1818 defined by the ply shape model 1820. In other embodiments, manufacturing controller 1812 can control manufacturing equipment 1808 to generate a set of fiducial markers 1822 at a set of reference locations 1824 on the composite plies 1816 before cutting the composite plies 1816 to have the shape 1818 defined by the ply shape model 1820.

[0154] In generating the set of fiducial markers 1822 at the set of reference locations 1824 on the composite ply 1816, the manufacturing controller 1812 can control the manufacturing equipment 1808 to generate the set of fiducial markers 1822 directly on the composite ply 1816 at the set of reference locations 1824. In another embodiment, the manufacturing controller 1812 can control the manufacturing equipment 1808 to generate the set of fiducial markers 1822 directly on a backing 1828 for the composite ply 1816 at the set of reference locations 1824. In this case, the set of fiducial markers 1822 is applied indirectly on the composite ply 1816.

[0155] In this embodiment, the set of fiducial markers 1822 may take several different forms, for example, the set of fiducial markers 1822 may be composed of at least one of ink, reflective ink, magnetic ink, stickers, paint, or liquid chalk, or any other suitable marking mechanism.

[0156] In an embodiment, after cutting composite ply 1816 and generating a set of fiducial markers 1822 at a set of sets of reference locations 1824, manufacturing controller 1812 can control manufacturing equipment 1808 to perform a set of manufacturing processes 1830 using composite ply 1816 having shape 1818 using the set of fiducial markers 1822 at the set of reference locations 1824 on composite ply 1816.

[0157] For example, manufacturing controller 1812 may control manufacturing equipment 1808 to perform a set of manufacturing operations 1830. In performing the set of manufacturing operations 1830, manufacturing controller 1812 may control a placement tool 1841 in manufacturing equipment 1808 to perform a picking operation 1831 that uses a set of fiducial markers 1822 to pick up a composite ply 1816 from a current position 1835 and place the composite ply 1816 at a desired position 1832. In this example, desired position 1832 may be a location in three-dimensional space. For example, desired position 1832 may be described using a Cartesian coordinate system. Additionally, desired position 1832 may be specified in terms of an orientation of composite ply 1816.

[0158] In another example, the manufacturing controller 1812 can use the sensor system 1840 to determine a current position 1835 of the set of fiducial markers 1822 on the composite ply 1816. The manufacturing controller 1812 can generate instructions 1833 to the placement device 1841 to move an end effector on the placement device 1841 from the current position 1835 to a desired position 1832 relative to the set of fiducial markers 1822, where the end effector can pick up the composite ply 1816 on which the set of fiducial markers 1822 is located.

[0159] In this embodiment, manufacturing controller 1812 can generate instructions 1833, which can be generated to perform certain manufacturing processes 1830. Instructions 1833 include at least one of code, commands, or data usable by automated manufacturing equipment 1814 to perform manufacturing processes 1830.

[0160] For example, the manufacturing controller 1812 may generate instructions 1833 for the placement device 1841 to move a composite ply 1816 having a shape 1818 from a current position 1835 to a desired position 1832. In another example, the manufacturing controller 1812 may generate instructions 1833 for the placement device 1841 to perform a pick action 1831 to pick up the composite ply 1816 from the current position 1835 and place the composite ply 1816 in the desired position 1832 on another composite ply 1837 as part of forming a composite charge 1834.

[0161] In yet another example, manufacturing controller 1812 may generate instructions 1833 to placement device 1841 to place composite ply 1816 on layup tool 1836. In this example, layup tool 1836 may be a component within manufacturing equipment 1808, such as a charge layup tool, a mandrel, a curing mandrel, or any other tool usable to process composite ply 1816 to form composite part 1804.

[0162] In this example, manufacturing controller 1812 may utilize programs 1838 to control the operation of manufacturing equipment 1808, including automated manufacturing equipment 1814. Programs 1838 may be, for example, computer numerical control (CNC) programs or any other suitable program code that may be used to control the operation of manufacturing equipment 1808, including automated manufacturing equipment 1814.

[0163] As shown, sensor system 1840 is a physical hardware system that detects information about manufacturing equipment 1808, including automated manufacturing equipment 1814, the environment surrounding manufacturing equipment 1808, including automated manufacturing equipment 1814, or both, to generate sensor data 1842. Sensor system 1840 may be comprised of at least one of a camera system, a laser sensor, an ultrasonic sensor, a light detection and ranging (LIDAR) scanner, an encoder, a rotary encoder, a temperature sensor, a pressure sensor, an accelerometer, or any other suitable type of sensor.

[0164] The sensor system 1840 may generate sensor data 1842 about the operation of the manufacturing equipment 1808, including the automated manufacturing equipment 1814. The sensor data 1842 may be used by the manufacturing controller 1812 to control the operation of the manufacturing equipment 1808, including the automated manufacturing equipment 1814. In this example, some or all of the sensor system 1840 may be associated with or connected to the automated manufacturing equipment 1814, such as the placement machine 1841.

[0165] For example, sensor system 1840 may include a camera located in end effector 1851 of placement device 1841. According to this exemplary implementation, end effector 1851 is moved by manufacturing controller 1812 sending instructions 1833 to placement device 1841 until a set of fiducial markers 1822 is within a selected position within the field of view of the camera in sensor system 1840.

[0166] For example, a set of fiducial markers 1822 may be centered within an image in sensor data 1842 generated by a camera on sensor system 1840. In the example shown, the position of the set of fiducial markers 1822 may be identified within ply shape model 1820. When the set of fiducial markers 1822 is in the correct position within the image, the coordinates of the set of fiducial markers 1822 may be determined relative to a camera coordinate system of a camera in sensor system 1840. A transform may be used to convert coordinates in the camera coordinate system to coordinates in a base coordinate system of the base of the robot arm. Other transforms exist to convert coordinates from the base coordinate system to coordinates for the end effector coordinate system.

[0167] In yet another embodiment, the camera in the sensor system 1840 can be located at a location other than within the end effector 1851. In this embodiment, the camera can be positioned to generate an image of the desired position 1832 of the end effector 1851, the set of fiducial markers 1822, the layup tool 1836, etc. In this embodiment, the image can be of the composite ply 1816 in a position within the camera coordinate system. A transformation can be performed to convert the coordinates to the coordinate system for the end effector 1851.

[0168] In this way, the plies on the effector line can be determined in three dimensions. With this information, the end effector 1851 can be moved to pick up the ply 1816 from its current position 1835. A similar process can be used to move the composite ply 1816 from its current position 1835 to a desired position 1832, such as on a layup tool 1836 or on another composite ply 1837.

[0169] The illustration of composite part manufacturing environment 1800 in FIG. 18 is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the illustrated components may be used. Some components may be unnecessary. Moreover, blocks are presented to illustrate some functional components. One or more of the blocks may be combined, divided, or combined and divided into different blocks when implemented in an illustrative embodiment.

[0170] For example, the set of manufacturing steps 1830 can take other forms in addition to the set of manufacturing steps 1830 described in various embodiments. For example, the set of manufacturing steps 1830 can include laying up the composite ply 1816 with other composite plies to form a charge or composite preform. As another example, the set of manufacturing steps 1830 can include impregnating the composite ply 1816 with a resin.

[0171] Referring now to Figure 19, a block diagram of a data processing system is shown in accordance with an illustrative embodiment. Data processing system 1900 may be used to implement computer 174 in Figure 1 and computer system 1810 in Figure 18. In this example, data processing system 1900 includes a communications framework 1902 that provides communications between a processor unit 1904, a memory 1906, persistent storage 1908, communications units 1910, input / output (I / O) units 1912, and a display 1914. In this example, communications framework 1902 takes the form of a bus system.

[0172] The processor unit 1904 is responsible for executing instructions for software that may be loaded into the memory 1906. The processor unit 1904 includes one or more processors. For example, the processor unit 1904 may be selected from at least one of a central processing unit (CPU), a graphics processing unit (GPU), a physics processing unit (PPU), a digital signal processor (DSP), a network processor, or any other suitable type of processor. The processor unit 1904 may be implemented using one or more heterogeneous processor systems in which a main processor and a secondary processor coexist on a single chip. As another example, the processor unit 1904 may be a symmetric multiprocessor system that includes multiple processors of the same type.

[0173] Memory 1906 and persistent storage 1908 are examples of storage device 1916. A storage device is any hardware capable of temporarily, permanently, or both temporarily and permanently storing information, such as, but not limited to, data, program code in a functional form, or other suitable information. Storage device 1916 may also be referred to as a computer-readable storage device in this illustrative example. In this example, memory 1906 may be, for example, a random access memory or any other suitable volatile or non-volatile storage device. Persistent storage 1908 may take various forms depending on the particular embodiment.

[0174] For example, persistent storage 1908 may comprise one or more components or devices. For example, persistent storage 1908 may be a hard drive, a solid-state drive (SSD), a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The medium used by persistent storage 1908 may be removable. For example, a removable hard drive may be used for persistent storage 1908.

[0175] In this embodiment, communication unit 1910 provides for communication with other data processing systems or devices. In this embodiment, communication unit 1910 is a network interface card.

[0176] Input / output unit 1912 allows for the input and output of data to and from other devices that may be connected to data processing system 1900. For example, input / output unit 1912 may provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, input / output unit 1912 may send output to a printer. Display 1914 provides a mechanism for displaying information to a user.

[0177] Instructions for at least one of the operating system, applications, or programs may reside in storage devices 1916, which are in communication with processor unit 1904 through communications framework 1902. The processes of the different embodiments may be performed by processor unit 1904 using computer-executable instructions, which may reside in a memory, such as memory 1906.

[0178] These instructions, which may also be referred to as program code, computer-usable program code, or computer-readable program code, may be read and executed by a processor in processor unit 1904. In different embodiments, the program code may be embodied on different physical or computer-readable storage media, such as memory 1906 or persistent storage 1908.

[0179] Program code 1918 is present in a functional form on computer readable media 1920 that is selectively removable and may be loaded onto or transferred to data processing system 1900 for execution by processor unit 1904. In this example, program code 1918 and computer readable media 1920 form computer program product 1922. In an exemplary example, computer readable media 1920 is computer readable storage medium 1924.

[0180] Computer readable storage medium 1924 is a physical or tangible storage device used to store program code 1918, rather than a medium that carries or transmits program code 1918. As used herein, computer readable storage medium 1920 should not be interpreted as being a transitory signal, such as an electric wave or other freely propagating electromagnetic wave, an electromagnetic wave propagating through a waveguide or other transmission medium (such as a light pulse passing through a fiber optic cable), or an electrical signal transmitted through a wire.

[0181] Alternatively, program code 1918 may be transferred to data processing system 1900 using a computer readable signal medium. The computer readable signal medium may be, for example, a propagated data signal containing program code 1918. For example, the computer readable signal medium may be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. The signals may be transmitted over a connection, such as a wireless connection, an optical fiber cable, a coaxial cable, an electrical wire, or any other suitable type of connection.

[0182] Additionally, as used herein, "computer-readable medium 1920" may refer to either singular or plural. For example, program code 1918 may be located in computer-readable medium 1920 in the form of a single storage device or system. In other examples, program code 1918 may be located in computer-readable medium 1920 distributed across multiple data processing systems. In other words, some instructions in program code 1918 may be located in one data processing system, and other instructions in program code 1918 may be located in another data processing system. For example, part of program code 1918 may be located in computer-readable medium 1920 in a server computer, while other parts of program code 1918 may be located in computer-readable medium 1920 located in a set of client computers.

[0183] The different components illustrated for data processing system 1900 are not meant to provide architectural limitations to the manner in which different embodiments may be implemented. In some examples, one or more of the components may be integrated into or otherwise form a part of other components. For example, in some examples, memory 1906, or portions thereof, may be integrated into processor unit 1904. Various illustrative embodiments may be implemented in a data processing system including components in addition to or in place of the components illustrated for data processing system 1900. Other components illustrated in FIG. 19 may differ from the illustrated examples. Various embodiments may be implemented using any hardware device or system capable of executing program code 1918.

[0184] An exemplary embodiment of the present disclosure may be described with reference to aircraft manufacturing and service method 2000 shown in Figure 20 and aircraft 2100 shown in Figure 21. Referring initially to Figure 20, an aircraft manufacturing and service method is illustrated in accordance with an exemplary embodiment. During pre-production, aircraft manufacturing and service method 2000 may include specification and design 2002 of aircraft 2100 in Figure 21 and material procurement 2004.

[0185] During production, component and subassembly manufacturing 2006 and system integration 2008 of the aircraft 2100 of Figure 21 occurs. The aircraft 2100 of Figure 21 then undergoes certification and delivery 2010 and is placed into service 2012. While in customer service 2012, the aircraft 2100 of Figure 21 is scheduled for routine maintenance and service 2014, which may include modifications, reconfigurations, refurbishments, and other maintenance or upkeep.

[0186] Each process of aircraft manufacturing and service method 2000 may be performed or carried out by a system integrator, a third party, an entity, or some combination. In these examples, the entity may be a customer. As used herein, 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 entity may be an airline, a leasing company, a military organization, a service organization, etc.

[0187] Referring now to Figure 21 , a block diagram of an aircraft is shown in which an illustrative embodiment may be implemented. In this example, aircraft 2100 is produced by aircraft manufacturing and service method 2000 of Figure 20 and may include an airframe 2102 having a number of systems 2104 and an interior 2106. Example systems 2104 include one or more of a propulsion system 2108, an electrical system 2110, a hydraulic system 2112, and an environmental system 2114. Any number of other systems may also be included. While an aerospace example is shown, various illustrative embodiments may be applied to other industries, such as the automotive industry.

[0188] Apparatus and methods embodied herein may be used during at least one stage of aircraft manufacturing and service method 2000 in Figure 20 .

[0189] In one illustrative example, the components or subassemblies produced in component and subassembly production 2006 of Figure 20 may be fabricated or manufactured in a manner similar to the components or subassemblies produced while aircraft 2100 is in service 2012 of Figure 20. In yet another example, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during production stages such as component and subassembly production 2006 of Figure 20 and system integration 2008. One or more apparatus embodiments, method embodiments, or a combination thereof may be utilized while aircraft 2100 is in service 2012 of Figure 20, during maintenance and service 2014, or both. Utilization of some various illustrative embodiments may significantly increase the efficiency of assembly of aircraft 2100, reduce the cost of aircraft 2100, or both increase the efficiency of assembly of aircraft 2100 and reduce the cost of aircraft 2100.

[0190] For example, composite manufacturing system 100 of FIG. 1 and composite manufacturing system 1802 of FIG. 18 may be used during component and subassembly manufacturing 2006 to produce composite parts. The use of additional markers may reduce the amount of rework or scrap of composite parts or charges or preforms for composite parts. As another example, composite manufacturing system 100 of FIG. 1 and composite manufacturing system 1802 of FIG. 18 may be used during maintenance and service 2014 to produce composite parts for various maintenance and service operations, which may include refurbishment, reconfiguration, strengthening, and other maintenance or service.

[0191] 22, an illustration of a block diagram of a product management system is shown in accordance with an illustrative embodiment. Product management system 2200 is a physical hardware system. In this illustrative example, product management system 2200 includes at least one of a manufacturing system 2202 or a maintenance system 2204.

[0192] Manufacturing system 2202 is configured to manufacture products, such as aircraft 2100 in Figure 21. As shown, manufacturing system 2202 includes manufacturing equipment 2206. Manufacturing equipment 2206 includes at least one of processing equipment 2208 or assembly equipment 2210.

[0193] Processing equipment 2208 is equipment used to manufacture components for parts used to form aircraft 2100 in FIG. 21 . For example, processing equipment 2208 may include machines and tools. These machines and tools may be at least one of a drill, a hydraulic press, a furnace, a mold, a composite tape layer, a vacuum system, a lathe, or other suitable type of equipment. Processing equipment 2208 may be used to manufacture at least one of a metal part, a composite part, a semiconductor, a circuit, a fastener, a rib, a skin, a spar, an antenna, or other suitable type of part.

[0194] Assembly equipment 2210 is equipment used to assemble parts that form aircraft 2100 of FIG. 21 . Specifically, assembly equipment 2210 is used to assemble components and parts that form aircraft 2100 of FIG. 21 . Assembly equipment 2210 may also include machines and tools. Such machines and tools may be at least one of a robotic arm, a crawler, a fastener installation system, a rail-based drilling system, or a robot. Assembly equipment 2210 may be used to assemble parts such as seats, horizontal stabilizers, wings, engines, engine housings, landing gear systems, and other parts for aircraft 2100 of FIG. 21 .

[0195] In this illustrative example, maintenance system 2204 may include maintenance equipment 2212. Maintenance equipment 2212 may include any equipment necessary to perform maintenance on aircraft 2100 in Figure 21. Maintenance equipment 2212 may include tools for performing various operations on parts of aircraft 2100 in Figure 21. The operations may include at least one of disassembling the part, refurbishing the part, inspecting the part, reworking the part, manufacturing a replacement part, or other operations for performing maintenance on aircraft 2100 in Figure 21. These operations may be routine maintenance, inspections, upgrades, modifications, or other types of maintenance operations.

[0196] In example embodiments, maintenance equipment 2212 may include ultrasonic inspection devices, x-ray imaging systems, vision systems, drills, crawlers, and other suitable devices. In some cases, maintenance equipment 2212 may include processing equipment 2208, assembly equipment 2210, or both, to produce and assemble parts needed for maintenance.

[0197] Product management system 2200 also includes a control system 2214. Control system 2214 is a hardware system and may also include software or other types of components. Control system 2214 is configured to control operations of at least one of manufacturing system 2202 or maintenance system 2204. Specifically, control system 2214 may control operations of at least one of processing equipment 2208, assembly equipment 2210, or maintenance equipment 2212.

[0198] The hardware in control system 2214 may be implemented using hardware that may include computers, circuits, networks, and other types of devices. The control may take the form of direct control of manufacturing equipment 2206. For example, robots, computer-controlled machines, and other equipment may be controlled by control system 2214. In other illustrative examples, control system 2214 may manage the processes performed by personnel 2216 in the manufacture or maintenance of aircraft 2100. For example, control system 2214 may assign tasks, provide instructions, display models, or perform other processes to manage the work performed by personnel 2216. In such illustrative examples, program 176 in FIG. 1 and manufacturing controller 1812 in FIG. 18 are implemented in control system 2214 to manage at least one of the manufacture or maintenance of aircraft 2100 in FIG. 21. For example, at least one of program 176 in FIG. 1 or manufacturing controller 1812 in FIG. 18 is operable to control the manufacture of composite parts using processing equipment 2208 in manufacturing equipment 2206.

[0199] In various illustrative examples, operations personnel 2216 may operate or interact with at least one of production equipment 2206, maintenance equipment 2212, or control system 2214. This interaction may occur to produce aircraft 2100 in Figure 21 .

[0200] Of course, product management system 2200 may be configured to manage other products besides aircraft 2100 of Figure 21. Although product management system 2200 is described with reference to manufacturing in the aerospace industry, product management system 2200 may be configured to manage products in other industries. For example, product management system 2200 may be configured to manufacture products in the automotive industry, and any other suitable industry.

[0201] Some features of the embodiments are described in the following clauses. These clauses are examples of features and are not intended to limit other embodiments.

[0202] Clause 1. A method for manufacturing a composite part (1804), comprising: identifying (1000) a set of reference locations (1824) for a set of fiducial markers (1822) on a composite ply (1816) from a ply shape model (1820) for a composite part (1804); generating (1002) a set of fiducial markers (1822) at a set of fiducial locations (1824) on a composite ply (1816); Cutting (1004) a composite ply (1816) to have a shape (1818) defined by a ply shape model (1820); A method comprising:

[0203] Clause 2. Using a sensor system (1840), determining a current position (1835) of said composite ply (1816) having a shape (1818) using a set of fiducial markers (1822); generating instructions (1833) to a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1832); 2. The method of clause 1, further comprising:

[0204] Clause 3. The method of clause 2, wherein generating instructions (1833) for a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1832) includes generating instructions (1833) for the placement device (1841) to perform a picking operation (1831) to pick up the composite ply (1816) from the current position (1835) and place the composite ply (1816) into the desired position (1832).

[0205] Clause 4. The method of clause 2 or 3, wherein generating instructions (1833) to a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1832) includes generating instructions (1833) to the placement device (1841) to place the composite ply (1816) in the desired position (1832) on another composite ply (1837) as part of forming a composite charge (1834).

[0206] Clause 5. The method of any one of clauses 2 to 4, wherein generating instructions (1833) for a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1832) includes generating instructions (1833) for the placement device (1841) to place the composite ply (1816) on a layup tool (1836).

[0207] Clause 6. Using a sensor system (1840), determining the current positions (1835) of a set of fiducial markers (1822) on the composite ply (1816); generating commands (1833) for the placement device (1841) to move an end effector on the placement device (1841) from a current position (1835) to a desired position (1835) relative to a set of fiducial markers (1822); 6. The method of any one of clauses 1 to 5, further comprising:

[0208] Clause 7. Cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820) includes cutting (1004) the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820) using a tool (1826); 7. The method of any one of clauses 1 to 6, wherein generating (1002) a set of reference markers (1822) at a set of reference locations (1824) on the composite ply (1816) includes generating (1002) a set of reference markers (1822) at the set of reference locations (1824) on the composite ply (1816) using a tool (1826).

[0209] Clause 8. The method of any one of clauses 1 to 7, wherein generating (1002) a set of reference markers (1822) at a set of reference locations (1824) on the composite ply (1816) includes generating (1200) a set of reference markers (1822) at a set of reference locations (1824) on the composite ply (1816) after cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820).

[0210] Clause 9. The method of any one of clauses 1 to 8, wherein generating (1002) a set of reference markers (1822) at a set of reference locations (1824) on the composite ply (1816) includes generating (1300) a set of reference markers (1822) at the set of reference locations (1824) on the composite ply (1816) before cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820).

[0211] Clause 10. The method of any one of clauses 1 to 9, wherein generating (1002) a set of fiducial markers (1822) at a set of reference locations (1824) on the composite ply (1816) includes generating (1400) a set of fiducial markers (1822) directly on the composite ply (1816) at the set of reference locations (1824).

[0212] Clause 11. The method of any one of clauses 1 to 10, wherein generating (1002) a set of fiducial markers (1822) at a set of reference locations (1824) on the composite ply (1816) includes generating (1500) a set of fiducial markers (1822) directly on a backing (1828) for the composite ply (1816) at the set of reference locations (1824).

[0213] Clause 12. The method of any one of clauses 1 to 11, wherein the set of reference markers (1822) is comprised of at least one of ink, reflective ink, magnetic ink, sticker, paint, or liquid chalk.

[0214] Clause 13. The method of any one of clauses 1 to 12, wherein the composite ply (1816) is processed to form a composite part (1804) for a platform (1806) selected from the group including a mobile platform, a fixed platform, a land-based structure, an aquatic structure, a space-based structure, an aircraft, a commercial aircraft, a rotorcraft, a tilt rotor aircraft, a tilt wing aircraft, a vertical take-off and landing aircraft, a powered vertical take-off and landing aircraft, a personal air vehicle, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, and a building.

[0215] Clause 14. A method for manufacturing a composite part (1804), comprising: cutting (1004) a composite ply (1816) using automated manufacturing equipment (1814) to have a shape (1818) defined by a ply shape model (1820) for the composite part (1804); generating (1002) a set of fiducial markers (1822) at a set of fiducial locations (1824) on a composite ply (1816) using automated manufacturing equipment (1814); A method comprising:

[0216] Clause 15. The method of clause 14, further comprising identifying (1000) a set of reference locations (1824) for a set of reference markers (1822) on the composite ply (1816) from the ply shape model (1820).

[0217] Clause 16. Using a sensor system (1840), determining a current position (1835) of a composite ply (1816) having a shape (1818) using a set of fiducial markers (1822); generating instructions (1833) to a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1832); 16. The method of clause 14 or 15, further comprising:

[0218] Clause 17. The method of any one of clauses 14 to 16, wherein generating (1002) a set of fiducial markers (1822) at a set of reference locations (1824) on a composite ply (1816) using an automated manufacturing device (1814) includes: using the automated manufacturing device (1814) to cut the composite ply (1816) to have a shape (1818) defined by a ply shape model (1820), and then generating (1200) a set of fiducial markers (1822) at the set of reference locations (1824) on the composite ply (1816).

[0219] Clause 18. The method of any one of clauses 14 to 17, wherein using automated manufacturing equipment (1814) to generate a set of fiducial markers (1822) at a set of reference locations (1824) on the composite ply (1816) includes using the automated manufacturing equipment (1814) to generate a set of fiducial markers (1822) at the set of reference locations (1824) on the composite ply (1816) before using the automated manufacturing equipment (1814) to cut the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820).

[0220] Clause 19. The method of any one of clauses 14 to 18, wherein generating a set of fiducial markers (1822) at a set of reference locations (1824) on the composite ply (1816) using automated manufacturing equipment (1814) includes generating the set of fiducial markers (1822) directly on the composite ply (1816) at the reference locations (1824) using automated manufacturing equipment (1814).

[0221] Clause 20. The method of any one of clauses 14 to 19, wherein generating a set of fiducial markers (1822) at a set of reference locations (1824) on a composite ply (1816) using automated manufacturing equipment (1814) includes generating a set of fiducial markers (1822) directly on a backing (1828) for the composite ply (1816) at the set of reference locations (1824) using automated manufacturing equipment (1814).

[0222] Clause 21. A composite manufacturing system (1802), comprising: Manufacturing equipment (1808, 2208) and a manufacturing controller (1812) in a computer system (1810); Equipped with The manufacturing controller (1812) identifying a set of fiducial locations (1824) for a set of fiducial markers (1822) on the composite plies (1816) from a ply shape model (1820) for the composite part (1804); generating a set of fiducial markers (1822) at a set of fiducial locations (1824) on the composite ply (1816); Cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820). A method for controlling manufacturing equipment (1808, 2208) to perform the above.

[0223] Article 22. The Manufacturing Controller (1812) generating instructions (1833) to a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1832); generating instructions (1833) to a placement device (1841) to perform a picking action (1831) to pick up the composite ply (1816) from its current position (1835) and place the composite ply (1816) into a desired position (1832); 22. The composite manufacturing system (1802) of claim 21, wherein the manufacturing equipment (1808, 2208) is controlled to perform the steps.

[0224] Clause 23. The composite manufacturing system (1802) described in clause 22, wherein when generating instructions (1833) for a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1808, 1832), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to generate instructions (1833) for the placement device (1841) to perform a picking operation (1831) to pick up the composite ply (1816) from the current position (1835) and place the composite ply (1816) into the desired position (1832).

[0225] Clause 24. A composite manufacturing system (1802) as described in clause 22 or 23, wherein, when generating instructions (1833) to a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1808, 1832), the manufacturing controller (1812) controls manufacturing equipment (1808, 2208) to generate instructions to the placement device (1841) to place the composite ply (1816) in the desired position (1832) on another composite ply (1837) as part of forming a composite charge (1834).

[0226] Clause 25. A composite manufacturing system (1802) as described in any one of clauses 22 to 24, wherein when generating instructions (1833) for a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1808, 1832), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to generate instructions (1833) for the placement device (1841) to place the composite ply (1816) on the layup tool (1836).

[0227] Clause 26. When cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to use the tool (1826) to cut the composite ply (1816) to have the shape (1818) defined by the ply shape model (1820); A composite manufacturing system (1802) as described in any one of clauses 21 to 25, wherein when generating a set of reference markers (1822) at a set of reference positions (1824) on the composite ply (1816), the manufacturing controller (1812) controls manufacturing equipment (1808, 2208) to generate the set of reference markers (1822) at the set of reference positions (1824) on the composite ply (1816) using a tool (1826).

[0228] Clause 27. A composite manufacturing system (1802) as described in any one of clauses 21 to 26, wherein when generating a set of reference markers (1822) at a set of reference locations (1824) on a composite ply (1816), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to generate a set of reference markers (1822) at the set of reference locations (1824) on the composite ply (1816) after cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820).

[0229] Clause 28. A composite manufacturing system (1802) as described in any one of clauses 21 to 27, wherein when generating a set of reference markers (1822) at a set of reference locations (1824) on the composite ply (1816), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to generate a set of reference markers (1822) at the set of reference locations (1824) on the composite ply (1816) before cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820).

[0230] Clause 29. A composite manufacturing system (1802) described in any one of clauses 21 to 28, wherein when generating a set of reference markers (1822) at a set of reference locations (1824) on the composite ply (1816), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to generate the set of reference markers (1822) directly on the composite ply (1816) at the reference locations (1824).

[0231] Clause 30. A composite manufacturing system (1802) as described in any one of clauses 21 to 29, wherein when generating a set of reference markers (1822) at a set of reference locations (1824) on a composite ply (1816), the manufacturing controller (1812) controls manufacturing equipment (1808, 2208) to generate the set of reference markers (1822) directly on a backing (1828) for the composite ply (1816) at the set of reference locations (1824).

[0232] Clause 31. A composite manufacturing system (1802) according to any one of clauses 21 to 30, wherein the set of fiducial markers (1822) is comprised of at least one of ink, reflective ink, magnetic ink, sticker, paint, or liquid chalk.

[0233] Clause 32. The composite manufacturing system (1802) of any one of clauses 21 to 31, wherein the composite ply (1816) is processed to form a composite part (1804) for a platform (1806) selected from the group including a mobile platform, a fixed platform, a land structure, an aquatic structure, a space-based structure, an aircraft, a commercial aircraft, a rotorcraft, a tilt rotor aircraft, a tilt wing aircraft, a vertical take-off and landing aircraft, a powered vertical take-off and landing aircraft, a personal air vehicle, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, and a building.

[0234] Clause 33. A composite manufacturing system (1802), comprising: Manufacturing equipment (1808, 2208) and a manufacturing controller (1812) in a computer system (1810); Equipped with The manufacturing controller (1812) cutting a composite ply (1816) to have a shape (1818) defined by a ply shape model (1820) for the composite section (1804); generating a set of fiducial markers (1822) at a set of fiducial locations (1824) on the composite ply (1816); A composite manufacturing system (1802) that controls manufacturing equipment (1808, 2208) to perform the above.

[0235] Clause 34. A composite manufacturing system (1802) as described in clause 33, wherein the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to identify a set of reference locations (1824) for a set of reference markers (1822) on the composite ply (1816) from the ply shape model.

[0236] Article 35. The Manufacturing Controller (1812) using a sensor system (1840) to identify a current position (1835) of a composite ply (1816) having a shape (1818) using a set of fiducial markers (1822); generating instructions (1833) to a placement device (1841) to move a composite ply (1816) having a shape (1818) from a current position (1835) to a desired position (1832); 35. The composite manufacturing system (1802) of claim 33 or 34, which controls manufacturing equipment (1808, 2208) to perform the steps.

[0237] Clause 36. A composite manufacturing system (1802) as described in any one of clauses 33 to 35, wherein when generating a set of reference markers (1822) at a set of reference locations (1824) on a composite ply (1816), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to generate a set of reference markers (1822) at the set of reference locations (1824) on the composite ply (1816) after cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820).

[0238] Clause 37. A composite manufacturing system (1802) as described in any one of clauses 33 to 36, wherein when generating a set of reference markers (1822) at a set of reference locations (1824) on the composite ply (1816), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to generate a set of reference markers (1822) at the set of reference locations (1824) on the composite ply (1816) before cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820).

[0239] Clause 38. A composite manufacturing system (1802) as described in any one of clauses 33 to 37, wherein when generating a set of reference markers (1822) at a set of reference locations (1824) on the composite ply (1816), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to generate the set of reference markers (1822) directly on the composite ply (1816) at the reference locations (1824).

[0240] Clause 39. A composite manufacturing system (1802) as described in any one of clauses 33 to 38, wherein when generating a set of fiducial markers (1822) at a set of reference locations (1824) on a composite ply (1816), the manufacturing controller (1812) controls manufacturing equipment (1808, 2208) to generate the set of fiducial markers (1822) directly on a backing (1828) for the composite ply (1816) at the set of reference locations (1824).

[0241] Thus, in one or more embodiments, the final position of the composite ply can be a combination of the accuracy of generating the fiducial markers on the composite ply, the final robot accuracy, and the boundary tolerance. In various embodiments, the fiducial markers are easier to implement and more accurate than other approaches, such as using boundaries to determine component movement. In such embodiments, the composite ply can be cut to a desired shape, and fiducial markers on the composite ply having the desired shape can be generated in the same location, such as on the same cutting machine in the same cell. Furthermore, because composite ply boundaries can be frayed or frayed, determining position using fiducial markers is easier than extracting boundaries.

[0242] Furthermore, using the additional markers allows the camera field of view to be much smaller when only the portion of the composite ply with the fiducial markers needs to be inspected compared to using the entire composite ply boundary. Consequently, the use of the fiducial markers allows for better pixel / mm resolution compared to current boundary-based techniques. In other words, the pixel density can be higher in an image that includes the fiducial markers compared to an image that uses the ply boundary.

[0243] The description of various exemplary embodiments is presented for purposes of illustration and description and is not intended to be exhaustive or to be limited to the disclosed forms of embodiments. Components that perform actions or operations are described by various examples. In the exemplary examples, the components may be configured to perform the described actions or operations. For example, the components may have a configuration or design for the structure that provides the components with the ability to perform the actions or operations described as being performed by the components in the exemplary examples. Furthermore, to the extent that the terms "includes," "including," "has," "contains," and variations thereof are used herein, such terms are intended to be inclusive in the same manner as the term "comprises" as an open transitional phrase, without excluding any additional or other elements.

[0244] Numerous modifications and variations will be apparent to those skilled in the art. Furthermore, various exemplary embodiments may provide different features as compared to other preferred embodiments. The selected embodiments have been chosen and described in order to best explain the principles and practical applications of the embodiments and to facilitate others skilled in the art in understanding the disclosure of the various embodiments and various modifications suitable for the particular use contemplated.

Claims

1. A method of manufacturing a composite part (1804), comprising: identifying (1000) a set of reference locations (1824) for a set of fiducial markers (1822) on a composite ply (1816) from a ply shape model (1820) for the composite part (1804); generating (1002) the set of fiducial markers (1822) at the set of fiducial locations (1824) on the composite ply (1816); cutting (1004) the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820); A method comprising:

2. using a sensor system (1840) to identify a current position (1835) of the composite ply (1816) having the shape (1818) using the set of fiducial markers (1822); generating instructions (1833) for a placement device (1841) to move the composite ply (1816) having the shape (1818) from the current position (1835) to a desired position (1832); The method of claim 1 further comprising:

3. 3. The method of claim 2, wherein generating instructions to the placement device to move the composite ply having the shape from the current position to the desired position comprises generating instructions to the placement device to perform a picking operation to pick the composite ply from the current position and place the composite ply into the desired position.

4. 4. The method of claim 2 or 3, wherein generating the instructions to the placement device to move the composite ply having the shape from the current position to the desired position comprises generating the instructions to the placement device to place the composite ply in the desired position on another composite ply as part of forming a composite charge.

5. using a sensor system (1840) to determine the current positions (1835) of the set of fiducial markers (1822) on the composite ply (1816); generating instructions (1833) for a placement device (1841) to move an end effector on the placement device (1841) from the current position (1835) to a desired position (1835) relative to the set of reference markers (1822); The method of claim 1 further comprising:

6. 2. The method of claim 1, wherein generating (1002) the set of fiducial markers (1822) at the set of reference locations (1824) on the composite ply (1816) comprises generating (1200) the set of fiducial markers (1822) at the set of reference locations (1824) on the composite ply (1816) after cutting the composite ply (1816) to have the shape (1818) defined by the ply shape model (1820).

7. 2. The method of claim 1, wherein generating the set of fiducial markers at the set of reference locations on the composite ply comprises generating the set of fiducial markers at the set of reference locations on the composite ply before cutting the composite ply to have the shape defined by the ply shape model.

8. 2. The method of claim 1, wherein generating (1002) the set of fiducial markers (1822) at the set of reference locations (1824) on the composite ply (1816) comprises generating (1400) the set of fiducial markers (1822) directly on the composite ply (1816) at the set of reference locations (1824).

9. A composite manufacturing system (1802), comprising: Manufacturing equipment (1808, 2208); a manufacturing controller (1812) in a computer system (1810); Equipped with The manufacturing controller (1812) identifying a set of reference locations (1824) for a set of fiducial markers (1822) on a composite ply (1816) from a ply shape model (1820) for the composite part (1804); generating the set of fiducial markers (1822) at the set of fiducial locations (1824) on the composite ply (1816); Cutting the composite ply (1816) to have a shape (1818) defined by the ply shape model (1820). controlling the manufacturing equipment (1808, 2208) to perform Composite manufacturing systems.

10. The manufacturing controller (1812) generating instructions (1833) to a placement device (1841) to move the composite ply (1816) having the shape (1818) from a current position (1835) to a desired position (1832); generating instructions (1833) to the placement device (1841) to perform a picking action (1831) to pick up the composite ply (1816) from the current position (1835) and place the composite ply (1816) into the desired position (1832); 10. The composite manufacturing system of claim 9, further comprising:

11. generating the instructions (1833) to the placement device (1841) to move the composite ply (1816) having the shape (1818) from the current position (1835) to the desired position (1808, 1832); The manufacturing controller (1812) controlling the manufacturing equipment (1808, 2208) to generate the instructions (1833) to the placement device (1841) to perform a picking action (1831) to pick the composite ply (1816) from the current position (1835) and place the composite ply (1816) into the desired position (1832); 11. The composite manufacturing system (1802) of claim 10.

12. 12. The composite manufacturing system of claim 10 or 11, wherein, when generating the instructions to the placement device to move the composite ply having the shape from the current position to the desired position, the manufacturing controller controls the manufacturing equipment to generate the instructions to the placement device to place the composite ply in the desired position on another composite ply as part of forming a composite charge.

13. 11. The composite manufacturing system (1802) of claim 10, wherein when generating the instructions (1833) for the placement device (1841) to move the composite ply (1816) having the shape (1818) from the current position (1835) to the desired position (1832), the manufacturing controller (1812) controls the manufacturing equipment (1808, 2208) to generate the instructions (1833) for the placement device (1841) to place the composite ply (1816) on a layup tool (1836).

14. 10. The composite manufacturing system of claim 9, wherein when generating the set of fiducial markers at the set of reference locations on the composite ply, the manufacturing controller controls the manufacturing equipment to generate the set of fiducial markers at the set of reference locations on the composite ply after cutting the composite ply to have the shape defined by the ply shape model.

15. 10. The composite manufacturing system of claim 9, wherein when generating the set of fiducial markers at the set of reference locations on the composite ply, the manufacturing controller controls the manufacturing equipment to generate the set of fiducial markers at the set of reference locations on the composite ply before cutting the composite ply to have the shape defined by the ply shape model.

Images