Multi-head automated fiber placement system and method

Abstract

To provide a system and method for producing composite layups at a high rate.SOLUTION: A manufacturing system includes a plurality of rails 118, a plurality of head manipulating mechanisms 200 respectively coupled to the rails, and a plurality of automated fiber placement (AFP) heads 220 respectively coupled to the head manipulating mechanisms. The rails are arranged around a barrel-shaped layup tool 150, and each rail is parallel to a tool axis. Each head manipulating mechanism moves along a rail. The head manipulating mechanisms position the AFP heads in circumferential relation to each other about a tool surface of the layup tool. A total quantity of AFP heads comprises the maximum number of AFP heads that can be circumferentially arranged in longitudinal alignment with each other on the layup tool without interfering with each other while applying layup material over the tool when the layup tool is stationary and during rotation about the tool axis, to thereby fabricate a green state layup having a barrel shape.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure generally relates to the manufacture of composite materials, and more particularly to systems and methods for fabricating composite material structures having a barrel shape.

Background Art

[0002] Composite materials are used in a wide range of applications such as aircraft manufacturing due to their inherent high strength, inherent high stiffness, and high corrosion resistance. In addition, composite materials result in an extended service life for various structures of an aircraft. In this regard, composite materials are increasingly being used to form aircraft wings, tail section components, and fuselages.

[0003] The manufacture of a composite fuselage may involve separately fabricating a plurality of composite fuselage barrel segments and joining the ends of the barrel segments together. The manufacture of each barrel segment includes laying up multiple plies of composite material one by one on a layup tool to produce a green state layup, which is then cured. Composite materials are typically fibrous materials (e.g., prepregs) in which the resin is pre-impregnated. For example, the composite material can be an epoxy-impregnated carbon fiber prepreg.

[0004] An automated fiber placement head can increase the speed at which a layup is produced. The fiber placement head supplies a course of composite material when the fiber placement head automatically moves over the layup tool. The composite material is typically in a form in which fiber bundles are juxtaposed. Multiple courses are laid up adjacent to and continuously with each other to form a composite ply. The process of laying up each composite ply is repeated until all plies are laid up in the desired ply stacking sequence.

[0005] While fiber placement heads increase the speed at which composite materials can be laid, conventional layup systems are still relatively slow and do not meet the needs of future manufacturing programs. Furthermore, layup tools are relatively expensive to assemble, making it desirable to minimize the total number of layup tools required to lay up each individual composite component in a manufacturing program. The desire to limit the total number of layup tools reflects the need to minimize the total amount of time spent using each layup tool while laying up composite components.

[0006] As described above, there is a need in this field for systems and methods for the high-speed production of composite material layups. [Overview of the project]

[0007] To address the aforementioned needs related to the manufacture of composite material layups, this disclosure provides a manufacturing system comprising multiple rails arranged parallel to each other around a barrel-shaped layup tool. Each rail is oriented substantially parallel to the tool axis of the layup tool. The manufacturing system also comprises multiple head operating mechanisms, each coupled to a dedicated rail among the rails, and movable along the longitudinal direction of the corresponding rail. In addition, the manufacturing system comprises multiple automated fiber placement (AFP) heads, each coupled to a dedicated head operating mechanism among the head operating mechanisms. The head operating mechanisms are configured to arrange the AFP heads around the tool surface of the layup tool at circumferential spacing relative to each other. The total number of AFP heads is such that the AFP heads lay a course of layup material on the tool surface or a previously laid layup material, thereby creating a barrel-shaped green layup, both when the layup tool is fixed and while the layup tool is rotating around its tool axis. This includes the maximum number of AFP heads that can be positioned circumferentially at the point of the largest circumference on the layup tool, while being longitudinally aligned with each other and without interfering with one another.

[0008] A method for manufacturing a barrel-shaped composite layup is also disclosed. This method involves moving a plurality of head operating mechanisms along a plurality of rails arranged in a parallel relationship around a barrel-shaped layup tool having a tool surface and a tool axis. Each rail is oriented substantially parallel to the tool axis, and each head operating mechanism supports an automatic fiber placement (AFP) head. This method involves using AFP heads to lay a course of layup material on the tool surface or a previously laid layup material while the layup tool is fixed and while it is rotating around the tool axis, thereby creating a green layup. This method also involves using the head operating mechanisms to maintain the AFP heads around the tool surface in a circumferentially spaced relationship with respect to each other while the AFP heads lay a course of layup material on the layup tool. The total number of AFP heads includes the maximum number of AFP heads that can be circumferentially positioned longitudinally with respect to each other without interfering with each other at the point of the largest circumference on the layup tool while laying a course of layup material on the layup tool.

[0009] According to one aspect of the present disclosure, a manufacturing system comprises a plurality of rails arranged parallel to each other around a barrel-shaped layup tool, each rail oriented substantially parallel to the tool axis of the layup tool; a plurality of head operating mechanisms, each coupled to a dedicated rail among the rails, the head operating mechanisms being movable along the longitudinal direction of the corresponding rail; and a plurality of automatic fiber placement (AFP) heads, each coupled to a dedicated head operating mechanism among the head operating mechanisms, wherein the head operating mechanisms are configured to arrange the AFP heads around the tool surface of the layup tool at circumferential spacing from each other, and the total number of AFP heads includes the maximum number of AFP heads that can be arranged circumferentially in a longitudinally aligned manner at the point of maximum circumference on the layup tool without interfering with each other while the plurality of AFP heads lay a course of layup material on the tool surface or a previously laid layup material, thereby producing a barrel-shaped green layup, when the layup tool is fixed and while the layup tool is rotating around the tool axis.

[0010] Advantageously, the manufacturing system is configured to adjust the head speed of at least some of the AFP heads so that the head operating mechanism offsets the AFP heads longitudinally from one another to avoid interference between them as they move along the tapered section of the layup tool.

[0011] Preferably, the manufacturing system is configured such that the head operating mechanism maintains multiple AFP heads longitudinally aligned with one another while the layup tool moves along its length.

[0012] Preferably, the manufacturing system includes a plurality of AFP heads comprising n AFP heads, and a plurality of head operating mechanisms configured to space the plurality of AFP heads circumferentially from each other by approximately 360 degrees / n.

[0013] Preferably, in the manufacturing system, each head operating mechanism is a six-axis arm that allows each AFP head to move around six axes.

[0014] Preferably, the manufacturing system further includes a head change station located at one of the ends of the layup tool and supporting one or more alternate AFP heads, each alternate AFP head supported on a head stand, and each head operating mechanism is configured to release an AFP head onto an empty head stand and engage with an alternate AFP head supported by another head stand.

[0015] Preferably, the manufacturing system further comprises: a plurality of fiber bundle sensors, each attached to a plurality of AFP heads, wherein the fiber bundle sensor on each AFP head is configured to capture layup data relating to the layup material immediately after it has been laid by the AFP head; and a processor configured to receive layup data along with the location where the layup data was captured; to detect anomalies in the green state layup by comparing the layup data with reference data including examples of various anomalies that may potentially occur in the green state layup; to identify the anomaly type of each anomaly in the layup data based on the comparison, and to determine the location of each anomaly in the green state layup based on the location where the layup data was captured, in order to enable the physical localization of each anomaly for possible rework.

[0016] Preferably, the manufacturing system is configured such that the processor constructs a green state digital model of the green state layup, the green state digital model includes anomalies identified in the layup data, and determines whether each anomaly in the green state digital model is acceptable or unacceptable by comparing the characteristics of each anomaly with a database of design criteria that define maximum and / or minimum values ​​for each anomaly characteristic for each anomaly type.

[0017] Preferably, in the manufacturing system, the processor receives inspection measurements obtained from non-destructive testing of the green state layup, compares the inspection measurements with the values ​​of the reference layup, thereby detecting anomalies in the green state layup. To construct a non-destructive inspection (NDI) digital model of the green state layup, including anomalies detected via inspection measurements; to verify the green state digital model by comparing it with the NDI digital model; and to identify any differences between the green state digital model and the NDI digital model. It is configured to perform the following actions.

[0018] Preferably, the manufacturing system is configured such that the processor records one or more processing parameters associated with manufacturing a green layup, wherein the processing parameters include at least one of the following: an instrument parameter associated with an AFP head, and a material parameter associated with the layup material supplied by the AFP head; the processor correlates the processing parameters with the completion time required to manufacture the green layup, and at least one of the anomalies in the green layup; and the processor adjusts one or more processing parameters for each subsequently manufactured green layup to obtain at least one of the following: a reduction in completion time and a reduction in the amount of anomalies.

[0019] According to one aspect of the present disclosure, a composite material layup system comprises a layup tool having a barrel shape, a tool surface, and a tool axis around which the layup tool can rotate; a plurality of rails arranged parallel to each other around the layup tool, each rail oriented substantially parallel to the tool axis; a plurality of head operating mechanisms, each coupled to a dedicated rail among the rails, the head operating mechanisms being movable along the longitudinal direction of the corresponding rail; and a plurality of automatic fiber placement (AFP) heads, each coupled to a dedicated head operating mechanism among the head operating mechanisms, and a head operating machine The configuration is such that AFP heads are arranged around the tool surface of the layup tool at circumferential spacing from one another, and the total number of AFP heads includes the maximum number of AFP heads that can be arranged circumferentially in a longitudinally aligned manner at the point of the largest circumference on the layup tool without interfering with each other, while the layup tool is fixed and while the layup tool is rotating around its tool axis, laying a course of layup material on the tool surface or previously laid layup material, thereby creating a barrel-shaped green layup.

[0020] Advantageously, in the manufacturing system, layup tools are shaped and configured to create the fuselage barrel section.

[0021] According to one aspect of this disclosure, a method for manufacturing a barrel-shaped composite layup is: The method involves moving a plurality of head operating mechanisms along a plurality of rails arranged in a parallel relationship around a barrel-shaped layup tool having a tool surface and a tool axis, each rail being oriented substantially parallel to the tool axis, and each head operating mechanism supporting an automatic fiber placement (AFP) head; using AFP heads to lay a course of layup material on the tool surface or a previously laid layup material when the layup tool is fixed and while it is rotating around the tool axis, thereby creating a green layup; and using the head operating mechanisms to maintain the AFP heads around the tool surface in a circumferentially spaced relationship with respect to each other while the AFP heads lay a course of layup material on the layup tool, the total number of AFP heads being the maximum number of AFP heads that can be circumferentially positioned aligning longitudinally with respect to each other without interfering with each other at the point of the largest circumference on the layup tool while laying a course of layup material on the layup tool.

[0022] Advantageously, the method further includes using a head maneuvering mechanism to adjust the head speed of one or more AFP heads so as they move along the tapered section of the layup tool, they are offset longitudinally in an alternating manner to prevent interference between the AFP heads.

[0023] Preferably, the method further includes using a head operating mechanism to maintain the AFP heads longitudinally aligned with each other while the layup tool is moving along its longitudinal direction.

[0024] Preferably, the method further includes using at least one head operating mechanism to replace an AFP head currently attached to a head operating mechanism with an alternative AFP head supported on a head stand of a head change station located at one of the ends of the layup tool.

[0025] Preferably, the method includes using a fiber bundle sensor attached on each AFP head among the AFP heads to capture layup data of the layup material immediately after being laid by the AFP head, receiving the layup data at a processor together with the capture position of the layup data, using the processor to compare the layup data with reference data including examples of various abnormalities potentially occurring in the green state layup to detect abnormalities in the green state layup, using the processor to identify the abnormality type of each abnormality in the layup data based on the comparison and determine the position of each abnormality on the green state layup based on the capture position of the layup data in order to physically locate each abnormality for possible rework.

[0026] Preferably, the method further includes using a processor to construct a green state digital model of the green state layup, the green state digital model including the abnormalities identified in the layup data, and comparing the characteristics of each abnormality with a database of design criteria defining the maximum and / or minimum values for each abnormality characteristic for each abnormality type to determine whether each abnormality in the green state digital model is acceptable or unacceptable.

[0027] Preferably, the method further includes using a processor to receive inspection measurement values obtained from a non-destructive inspection of the green state layup, compare the inspection measurement values with the values of a reference layup, thereby detecting abnormalities in the green state layup, construct a non-destructive inspection (NDI) digital model of the green state layup including the abnormalities detected via the inspection measurement values, and compare the green state digital model with the NDI digital model to verify the green state digital model and identify any differences between the green state digital model and the NDI digital model.

[0028] Preferably, the method involves using a processor to record one or more process parameters associated with, i.e., manufacturing a green state layup, where the process parameters include at least one of equipment parameters associated with the AFP head and material parameters associated with the layup material supplied by the AFP head, recording one or more process parameters, correlating the process parameters with the completion time required to manufacture the green state layup and at least one of the abnormalities in the green state layup, and adjusting one or more process parameters so that for each subsequent manufactured green state layup, a reduction in the completion time and a reduction in the amount and / or type of abnormalities are obtained.

[0029] The above features, functions, and advantages can be realized alone in various versions of the present disclosure or may be combined in yet another version where further details can be understood by referring to the description in the following specification and the drawings.

[0030] The present disclosure can be better understood by referring to the following detailed description in relation to the accompanying drawings, which show preferred exemplary versions but are not necessarily drawn to scale. The drawings are examples and are not intended to limit the description in this specification or the scope of the claims.

Brief Description of the Drawings

[0031] [Figure 1] FIG. 1 is a perspective view of an example of a manufacturing system for producing a green state layup on a rotatable layup tool, the manufacturing system including a plurality of automated fiber placement (AFP) heads each supported on a dedicated head operating mechanism, the head operating mechanisms each being coupled to a dedicated rail, and each rail being attached to a frame assembly. [Figure 2] FIG. 2 is a side view of the manufacturing system of FIG. 1. [Figure 3]Figure 1 is an end view of the manufacturing system, showing AFP heads spaced circumferentially around the layup tool. [Figure 4] This is a perspective view of an example of an aircraft having a fuselage consisting of composite fuselage barrel sections that can be manufactured using the manufacturing systems and methods disclosed herein. [Figure 5] Figure 4 is an enlarged view of a part of the aircraft indicated by reference numeral 5, showing an example of a fuselage barrel section manufactured using the manufacturing system disclosed herein. [Figure 6] This is an example of an AFP head coupled to a head operating mechanism, which has been shown to be configured as a 6-axis robotic arm. [Figure 7] This is a front perspective view of a further example of a manufacturing system having a head change station located at one end of a layup tool. [Figure 8] Figure 7 is a front view of the manufacturing system. [Figure 9] Figure 7 is a side view of the manufacturing system showing the head change station. [Figure 10] Figure 7 is a rear perspective view of the manufacturing system showing the head change station. [Figure 11] Figure 10 is a perspective view of a part of the manufacturing system indicated by reference numeral 11, showing one of the head operating mechanisms that moves the AFP head toward an empty head stand of the head change station. [Figure 12] This shows the head operating mechanism that releases the AFP head onto an empty head stand. [Figure 13] This shows a head operating mechanism that rotates toward other head stands, including an alternative AFP head. [Figure 14] This shows the engagement between the alternative AFP head and the head operating mechanism. [Figure 15] Figure 7 is a side view of the manufacturing system with the frame assembly removed, showing the head operating mechanism that moves the AFP heads longitudinally aligned with each other while laying 0-degree ply composite material on a fixed section of the layup tool. [Figure 16] Figure 15 is a side view of the manufacturing system, showing a head operating mechanism that adjusts the head speed of alternating AFP heads so that the AFP heads are offset from each other longitudinally to avoid interference between AFP heads as they move along the tapered section of the layup tool. [Figure 17] This is a perspective view of the layup tool after laying the 0-degree ply. [Figure 18] Figure 7 is a side view of the manufacturing system, showing a head operating mechanism that moves the AFP heads while aligning them longitudinally with each other while laying 45-degree composite material on the layup tool. [Figure 19] This is a perspective view of the layup tool after laying 45-degree plies. [Figure 20] Figure 7 is a side view of the manufacturing system, showing the head operating mechanism that moves the AFP heads in a offset position while laying the composite material at a 90-degree angle on the layup tool. [Figure 21] This is a perspective view of the layup tool after laying 90-degree plies. [Figure 22] This is a side view of an example of an AFP head during the laying of a course of layup material on a tool surface, showing a fiber bundle sensor attached to the AFP head, which captures layup data of the layup material downstream of a compression roller for compressing the layup material on the tool surface, and the tool surface is heated by a heating device located downstream of the compression roller. [Figure 23] Figure 22 is a perspective view along line 23, showing a fiber bundle sensor configured as an infrared camera that captures a series of infrared images of juxtaposed fiber bundles of composite material laid on the tool surface by an AFP head. [Figure 24] An example of a layup image captured by an infrared camera is shown, illustrating various types of anomalies that can potentially occur in the fiber bundle during laying by an AFP head. [Figure 25]This is a perspective view of the AFP head, showing a fiber bundle sensor configured as a surface shape measuring device for recording the surface shape of fiber bundles laid on the tool surface by the AFP head. [Figure 26] This is a schematic diagram of the profile recorded by a surface shape measuring device, and represents the gaps between adjacent fiber bundles, as shown in the schematic diagram of fiber bundles located on the layup profile. [Figure 27] This is a schematic diagram of a profile that shows the overlap of adjacent fiber bundles, as shown in the schematic diagram of fiber bundles located on the layup profile. [Figure 28] This is a schematic diagram of a profile representing a fiber bundle defect, as shown in the schematic diagram of the fiber bundle located on top of the layup profile. [Figure 29] This is a schematic diagram of a profile representing the folds in a fiber bundle, as shown in the schematic diagram of the fiber bundle located on top of the layup profile. [Figure 30] This example shows a computer that includes a processor for detecting and identifying anomalies based on layup data captured by a fiber bundle sensor while laying the layup material onto the layup tool via an AFP head. [Figure 31] Figure 30 shows a computer screen displaying a green state digital model generated by the processor, which includes anomalies identified by the processor during the analysis of layup data from fiber bundle sensors. [Figure 32] Figure 31 is a magnified view of a portion of the green state digital model on the screen, showing labels indicating the location and type of several anomalies detected in the green state layup. [Figure 33] This is a block diagram of a processor showing examples of inputs and outputs used to detect and identify anomalies in a green state layup. [Figure 34] This is a flowchart of the steps involved in manufacturing a barrel-shaped composite layup.

[0032] The figures presented in this disclosure represent various aspects of the presented version, and only the differences are described in detail. [Modes for carrying out the invention]

[0033] This specification will now provide a more comprehensive description of embodiments of the disclosure with reference to the accompanying drawings, which show only some, and not all, of the versions disclosed. In practice, several different versions may be provided, and these should not be construed as limiting the versions described herein. Rather, these versions are provided to make this disclosure comprehensive and to ensure that the scope of this disclosure is fully conveyed to those skilled in the art.

[0034] This specification includes references to “one version” or “a version.” Examples of the expressions “one version” or “a version” do not necessarily refer to the same version. Similarly, this specification includes references to “one example” or “a example.” Examples of the expressions “one example” or “a example” do not necessarily refer to the same example. Certain features, structures, or characteristics can be combined in any appropriate way that conforms to this disclosure.

[0035] In this specification, “comprising” is an open-ended term and, when used in a claim, does not exclude additional structures or steps.

[0036] In this specification, "configured to" means that various parts or components may be described or claimed to be "configured to" perform a particular task. In this context, "configured to" is used to imply a structure by indicating that the part or component contains a structure that performs a particular task during the process. Thus, a part or component can be said to be configured to perform its task even when a particular part or component is not currently operating (e.g., powered off).

[0037] In this specification, an element or process described in the singular and followed by the term "one ("a" or "an")" should be understood not to necessarily exclude multiple elements or processes.

[0038] In this specification, the expression "at least one of" used with a list of items means that any combination of one or more of the enumerated items may be used, and only one of each item in the list may be required. In other words, "at least one of" means that any combination and any number of items from the enumerated list may be used, but not all of the enumerated items are required. An item can be a specific object, thing, or category.

[0039] Referring here to the drawings illustrating various examples of the present disclosure, Figures 1 to 3 show an example of a manufacturing system 100 for producing a single barrel-shaped composite layup, referred to herein as a green-state layup 264. The green-state layup 264 is an uncured composite layup having one or more plies 254 (Figure 22) of the composite material. Figures 1 to 3 show the manufacturing system 100 located within a manufacturing cell of a manufacturing facility. The manufacturing system 100 includes a barrel-shaped layup tool 150. The layup tool 150 has a tool surface 154 and a tool axis 152 around which the layup tool 150 can rotate completely (i.e., 360 degrees).

[0040] As described below, the layup tool 150 may include a constant section 160, where the width of the cross-section is substantially constant along a longitudinal section of the layup tool 150. The layup tool 150 may also include a tapered section 158, which can be described as a section of the layup tool 150 where the width of the cross-section of the layup tool 150 decreases or where the width of the cross-section of the layup tool 150 is smaller than that of the section with the maximum cross-sectional width. In the example shown, the layup tool 150 is molded and configured for laying up the fuselage barrel section 390 of an aircraft 392. However, the manufacturing system 100 can be implemented on a layup tool 150 of any size, shape, or configuration, and is not limited to use on a layup tool 150 similar to that shown in the drawings.

[0041] As shown in Figures 1 to 3, the layup tool 150 is supported by a headstock 162 and a tailstock 166 located at both ends of the layup tool 150, respectively. The layup tool 150 is rotatable via one or more tool drive motors (not shown) which may be included in the headstock 162. The headstock 162 and tailstock 166 are supported on the factory floor 102 of the manufacturing cell. The layup tool 150 is supported such that the tool axis 152 is approximately horizontal (e.g., + / - 10 degrees).

[0042] In the example shown, the headstock 162 is movable along a headstock path 164 mounted to or incorporated into the factory floor 102, and the headstock 162 can be moved laterally to move the layup tool 150 longitudinally into and out of the manufacturing system 100, after which the headstock 162 is moved back to its original position and the layup tool 150 is coupled to the headstock 162 and tailstock 166. The tailstock 166 may optionally include a path system (not shown) to facilitate the movement of the layup tool 150 into and out of the tailstock 166 end of the manufacturing system 100.

[0043] Referring further to Figures 1 to 3, the manufacturing system 100 includes a plurality of rails 118 arranged parallel to each other around the layup tool 150. Each rail 118 is linear (e.g., straight) and oriented substantially parallel to the tool axis 152 (e.g., within a range of 10 degrees). In addition, the rails 118 are shown oriented parallel to each other. The rails 118 are fixedly coupled to a frame assembly 110, which is shown supported on the factory floor 102 and may include beam members 112 and columns 116 that roughly surround the layup tool 150. The frame assembly 110 includes horizontal beams 114 configured to provide relatively rigid or distortion-free support for the rails 118.

[0044] The manufacturing system 100 also includes a plurality of multi-axis head operating mechanisms 200. Each head operating mechanism 200 supports an automated fiber placement (AFP) head 220, and each head operating mechanism 200 is configured to move along a dedicated rail 118. The head operating mechanisms 200 are controlled by one or more controllers 360. Each head operating mechanism 200 is configured to provide the full range of motion of the AFP head 220 to which it is mounted. For example, each head operating mechanism 200 is configured to translate along three mutually orthogonal axes and rotate the AFP head 220 around those axes.

[0045] As detailed below, the head operating mechanism 200 is shown as a robotic arm 202 (e.g., Figure 6), each robotic arm 202 having an arm base 204 coupled to a rail 118. In addition, each robotic arm 202 includes a plurality of arm segments 206 interconnected by arm joints 208. However, the head operating mechanism 200 may be provided by alternative configurations and is not limited to a robotic arm 202. In this regard, the head operating mechanism 200 may be provided in any configuration that enables multi-axis movement of the AFP heads 220 over their full range of motion to maintain each AFP head 220 approximately aligned with the tool surface 154 (i.e., locally perpendicular to the tool surface 154).

[0046] As previously mentioned, the manufacturing system 100 includes a plurality of AFP heads 220, each supported by a head operating mechanism 200. Each AFP head 220 is configured to lay lay-up material 252 on the tool surface 154 (Figure 22) or on previously laid lay-up material 252 while the AFP head 220 moves toward the tool surface 154 along a pre-programmed tool path (Figures 22-23). ​​The AFP heads 220 are configured to lay lay-up material 252 on the tool when the lay-up tool 150 is fixed (i.e., not rotating) and when the lay-up tool 150 is rotating around the tool axis 152.

[0047] Referring briefly to Figures 22-23, an example of an AFP head 220 for laying composite material 254 on a tool surface 154 is shown. The AFP head 220 has a plurality of material rolls 226, each material roll 226 containing a continuous winding of fiber bundles 256 of composite material 254. In one example, the composite material 254 is a prepreg consisting of unidirectional reinforcing fibers pre-impregnated with resin. The reinforcing fibers can be made of any material from a variety of materials such as plastic, glass, ceramic, carbon, metal, or any combination thereof. The resin is a thermosetting resin or a thermoplastic resin and can be made of any material from a variety of organic or inorganic materials.

[0048] The AFP head 220 collects fiber bundles 256 from the material roll 226, places the fiber bundles 256 parallel to each other in a juxtaposed relationship, and arranges the juxtaposed fiber bundles 256 as a course 250 on the tool surface 154 or on a course 250 of previously laid fiber bundles 256. The AFP head 220 has a compression device or compression roller 228 for compressing the fiber bundles 256 onto the substrate 156 (e.g., the tool surface 154 or a previously laid fiber bundle 256). In addition, the AFP head 220 has a heating device 230 (e.g., an infrared heater) located upstream of the compression roller 228 for heating the substrate 156 to increase the degree of adhesion or bonding between the fiber bundles 256 and the substrate 156. As will be described in more detail below, the heat 232 applied to the substrate 156 by the heating device 230 facilitates the detection of anomalies 300 in the fiber bundle 256 during laydown using a fiber bundle sensor 234 (e.g., an infrared camera) located downstream of the compression roller 228.

[0049] Each fiber bundle 256 is relatively narrow in width, which allows it to conform to the local curvature or shape of the layup tool 150. In one example, each AFP head 220 may be configured to lay up an 8-inch wide strip of 1 / 2-inch wide fiber bundles 256 onto a very uneven layup tool 150. In another example, the AFP head 220 may be configured to lay up a 16-inch wide strip of 1 / 2-inch wide fiber bundles 256 for use with a relatively large-diameter layup tool 150. However, the fiber bundles 256 may be supplied in any width, such as 1 / 4-inch or other widths. In yet another example not shown, each AFP head 220 may be configured to lay up a single-width composite tape having a width of 3 inches or more.

[0050] However, the AFP head 220 is not limited to laying up composite material 254 and may be configured to supply alternative types of layup material 252. For example, the AFP head 220 may be configured to supply metal foil or wire mesh as one of the plies of the green state layup 264 (for example, for protection from electromagnetic effects). In yet another example, the AFP head 220 may be configured to supply one or more processing layers to facilitate the layup or processing of the green state layup 264. Such processing layers may include release films, adhesive films, breather layers, bleeder layers, release layers, or any of various other layers, films, or adhesives, which may be laid up before or during the creation of the green state layup 264. Such processing layers may facilitate the layup, degassing, molding (to a desired shape), and / or curing of the green state layup 264.

[0051] Returning to Figures 1-3, each head operating mechanism 200 is movable along the length of the rail 118 to which it is mounted. Each rail 118 has a length that allows the head operating mechanism 200 to position the AFP head 220 along the entire length of the tool surface 154. While the AFP head 220 lays a course 250 of layup material 252 on the tool surface 154 or on previously laid layup material 252, both when the layup tool 150 is stationary and while it is rotating around the tool axis 152 (Figures 22-23), the head operating mechanism 200 is configured to maintain the AFP heads 220 separately around the tool surface 154, spaced circumferentially apart from each other. The circumferential spacing 120 between the AFP heads 220 (Figure 8) is preferably maintained when the AFP heads 220 are moving along the length of the layup tool 150 at the same head speed or when the AFP heads 220 are fixed (i.e., not moving along the length). In some examples shown in Figures 16 and 20 and described in more detail below, the head operating mechanism 200 is configured to adjust the head speed of one or more AFP heads 220 (i.e., in a direction parallel to the tool axis 152) so as necessary to prevent interference between the AFP heads 220 and the layup material 252 in a particular area of ​​the layup tool 150 (e.g., along a tapered section 158), by offsetting at least some of the AFP heads 220 longitudinally and alternately with respect to the remaining AFP heads 220.

[0052] The manufacturing system 100 has as many AFP heads 220 as possible, such that all AFP heads 220 are aligned longitudinally with each other (224) (i.e., in a line (Figures 9, 15, and 18)), and the AFP heads 220 are arranged circumferentially so that no two AFP heads 220 come into contact with each other when positioned at a point on the layup tool 150 where the circumference is maximum, and such that there is a nominal amount of spacing between adjacent AFP heads 220 to accommodate local changes in the contour of the tool surface 154 and to allow individual AFP heads 220 to rotate to accommodate the changed movement of individual AFP heads 220. The manufacturing system 100 includes a relatively large number (e.g., three or more) of AFP heads 220 that lay the layup material 252 onto the layup tool 150 simultaneously without interfering with each other, thereby significantly improving the material laydown rate compared to the material laydown rate of conventional composite layup systems. For example, in the above case where the layup tool 150 is configured to lay up the fuselage barrel section 390 (Figure 5) of a civilian aircraft 392 (Figure 4), the manufacturing system 100 disclosed herein increases the material laydown rate by up to eight times compared to conventional composite layup systems. Advantageously, such a high material laydown rate enables high-speed production of composite parts at a relatively low cost.

[0053] Referring to Figure 6, an example of a head operating mechanism 200 is shown, configured as a six-axis robotic arm 202 supporting one of the AFP heads 220 that lay the layup material 252. As previously mentioned, the robotic arm 202 includes an arm base 204 coupled to a rail 118. The robotic arm 202 also includes a plurality of arm segments 206 interconnected by arm joints 208. The robotic arm 202 allows the movement of the AFP heads 220 along and / or around six rotational axes 210. The rail 118 provides a linear axis 212 for the movement of the AFP heads 220. Although not shown, each head operating mechanism 200 may also include a linear feed axis.

[0054] Although a 6-axis robotic arm 202 is shown in the figure, the head operating mechanism 200 may be provided in any configuration of various alternative configurations that allow the AFP head 220 to follow a pre-programmed tool path along the layup tool 150 (including following the tool path along a tapered section 158 (Figure 2)) while continuously orienting the AFP head 220 according to the local contour of the tool surface 154 (for example, perpendicular to the contour). The motion of each AFP head 220 includes rotation around an axis (not shown) perpendicular to the tool axis 152 to ensure the laydown direction of the AFP head 220. In addition, the motion of each AFP head 220 includes translation of the AFP head 220 along an axis perpendicular to the tool axis 152 to alternately move the AFP head 220 onto and away from the layup tool 150 at the beginning and end of each course 250.

[0055] Referring to Figures 7 to 14, other examples of the manufacturing system 100 for producing a green layup 264 are shown. The manufacturing system 100 in Figures 7 to 14 is similar to the manufacturing system 100 described earlier in Figures 1 to 3, except for the head change station 130 in Figures 7 to 14, which will be described in more detail below. The manufacturing system 100 shown in Figures 7 to 14 includes the rail 118 described above, supported by a frame assembly 110. In addition, the manufacturing system 100 includes a plurality of AFP heads 220, each coupled to a dedicated head operating mechanism 200 (e.g., a robotic arm). As described above, the head operating mechanism 200 maintains the AFP heads 220 circumferentially spaced apart from each other around the tool surface 154 of the layup tool 150 while the AFP heads 220 lay the layup material 252 on the tool surface 154 or on previously laid layup material 252 (Figure 22). As previously described and further described below, the head operating mechanism 200 is configured to adjust the head speed of one or more AFP heads 220 as necessary in order to offset at least some of the AFP heads 220 longitudinally in an alternating manner relative to the remaining AFP heads 220 in order to prevent interference between the AFP heads 220 while laying the layup material 252 in a particular section of the layup tool 150.

[0056] In the examples shown in Figures 7 to 14, the layup tool 150 has a fixed section 160 (e.g., a cylindrical section) and a tapered section 158 (Figure 9). The manufacturing system 100 includes eight AFP heads 220, each coupled to eight head operating mechanisms 200. The eight head operating mechanisms 200 are each coupled to eight rails 118. The AFP heads 220 are spaced circumferentially around the layup tool 150. In some examples, when the AFP heads 220 are aligned longitudinally with each other (i.e., in a line) as shown in Figure 9 (224), the AFP heads 220 are spaced circumferentially from each other by an amount that allows each AFP head 220 to move (e.g., rotate) smoothly (e.g., via the head operating mechanisms) without interfering with the AFP heads 220 on either side. The ability of each AFP head 220 to rotate smoothly (i.e., without contacting the adjacent AFP heads 220 on either side) makes it possible to adjust the orientation of each AFP head 220 as needed to continuously maintain the AFP head 220 perpendicular to the local contour of the tool surface 154.

[0057] In any of the examples disclosed herein, the plurality of AFP heads 220 comprises n AFP heads 220, and the plurality of head operating mechanisms 200 are configured to space the AFP heads 220 from each other circumferentially (i.e., equally spaced circumferentially) by approximately 360 degrees / n. When determining the circumferential spacing 120 (Figure 8), the central tool point (not shown) of each AFP head 220 may be located in the center of its circumferential reach.

[0058] Figures 1-3 and 7-14 show eight AFP heads 220, but the total number of AFP heads 220 in a given manufacturing system 100 is determined by the size of the layup tool 150. More specifically, the total number of AFP heads 220 depends on the cross-sectional width and / or maximum circumference of the layup tool 150, and is based on the fact that the AFP heads 220 are aligned with each other longitudinally (224) (e.g., Figure 9) and have gaps between adjacent AFP heads 220. In this regard, a layup tool 150 with a relatively large circumference or cross-sectional width allows for a correspondingly larger number of AFP heads 220 (e.g., up to 12 AFP heads 220), while a layup tool 150 with a smaller circumference or cross-sectional width will result in a smaller number of AFP heads 220. The total number of AFP heads 220 is selected to reduce or minimize the total number of passes or courses required for the AFP heads 220 to produce a green-condition layup 264. Preferably, the manufacturing system 100 includes as many AFP heads 220 as possible to maximize the material laydown rate, and the head operating mechanism 200 is configured to move the AFP heads 220 at an optimal head speed so as to avoid interference with one another.

[0059] As shown in Figures 9 to 14, the manufacturing system 100 includes a head change station 130 located at one of the ends of the layup tool 150. The head change station 130 consists of a beam member 112 coupled to the frame assembly 110. The beam member 112 supports a plurality of head stands 132. Each head stand 132 is configured to support an AFP head 220. In the example shown, the head change station 130 is configured to provide at least one alternative AFP head 134 at the end of each rail 118. The head change station 130 is configured to avoid restricting the movement of any head operating mechanism 200 and to avoid restricting the movement of any AFP head 220. In addition, the head change station 130 is preferably configured to provide an option to replace all AFP heads 220 simultaneously.

[0060] In Figures 9 to 14, each AFP replacement head is supported on a head stand 132. In the examples shown, each replacement head is supported by a head stand 132 located near an available head stand 132. However, in other examples not shown, the head change station 130 may be configured such that each head stand 132 can be translated and / or rotated to present an alternative AFP head 134 to the head operating mechanism 200, thereby minimizing the motion requirements of the head operating mechanism 200 and reducing the amount of downtime for each AFP head 220 during the production of the green state layup 264. The AFP head 220 may require replacement due to mechanical failure, periodic maintenance, to accommodate a change in the type of layup material 252 required in a particular area or ply of the green state layup 264, and / or in anticipation of running out of layup material 252 carried on the material roll 226 of the AFP head 220.

[0061] In a series of Figures 11 to 14, to replace the AFP head 220, the head operating mechanism 200 can move to the end of its rail 118 at the position of the head change station 130. The head operating mechanism 200 can extend the currently loaded AFP head 220 toward an empty head stand 132 on the head change station 130, as shown in Figure 11. Once the currently loaded AFP head 220 is aligned with an empty head stand 132 (for example, positioned directly above an empty head stand 132), the head operating mechanism 200 slowly lowers and releases the AFP head 220 toward the empty head stand 132, as shown in Figure 12. Although not shown, each head operating mechanism 200 may have a quick-release mechanism (not shown) configured to release and engage with the AFP head 220.

[0062] After the AFP head 220 is released (e.g., Figure 12), the head operating mechanism 200 prepares to engage with the alternate AFP head 134. In the example in Figure 13, the head operating mechanism 200 moves (e.g., rotates) toward the head stand 132 containing the alternate AFP head 134. In other examples not shown, the head stand 132 may be movable to present the alternate AFP head 134 to the head operating mechanism 200, as previously mentioned. Whether the head stand 132 is fixed (e.g., Figures 11-14) or movable (not shown), the head operating mechanism 200 engages with the alternate AFP head 134 as shown in Figure 14. The head operating mechanism 200 then returns the alternate AFP head 134 to operation with the other AFP head 220, which continues to produce a green layup 264 during the head change operation.

[0063] Advantageously, the head change station 130 provides means to minimize the downtime of the AFP head 220 during the production of the green state layup 264, and / or to minimize or prevent the need for rework of the green state layup 264 due to any of the various fiber bundle anomalies 300 (Figure 24), as detailed below. The manufacturing system 100 can also be configured to proactively replace the AFP head 220 before a situation arises that necessitates an unplanned head change. For example, for each AFP head 220, the manufacturing system 100 may be configured to perform a predetermined number of head changes before the AFP head 220 reaches its previously set fiber bundle defect rate. A fiber bundle defect can be defined as a defect in the AFP head 220 laying up the fiber bundle 256 (i.e., composite material 254) along its predetermined length according to the design intent. A defect in the fiber bundle may involve an error associated with the addition of the fiber bundle 256 to the green layup 264 at the beginning of a given fiber bundle, or an error associated with the cutting of the fiber bundle 256 at the end of a given fiber bundle.

[0064] To illustrate the advantages of proactive head replacement, when producing a green layup 264 requiring 120,000 individual fiber bundles 256 using eight AFP heads 220, each AFP head 220 needs to lay approximately 15,000 fiber bundles 256. If the previously established fiber bundle defect rate for each AFP head 220 is 1 in 10,000, the manufacturing system 100 can be configured to proactively replace each AFP head 220 when the defect rate reaches half (for example, with 5,000 fiber bundles), thus potentially eliminating the need to rework the green layup 264 because there are no anomalies 300. A defect rate of 1 in 5,000 would require three head replacements per AFP head 220. Assuming that each head replacement takes approximately 5 minutes, and that all AFP heads 220 are replaced simultaneously, the total head downtime during the creation of the green layup 264 is approximately 15 minutes, which is far less than the time required to rework the green layup 264 due to anomalies 300 caused by fiber bundle defects.

[0065] Referring here to Figures 15 to 21, examples of the relative positioning of the AFP heads 220 (e.g., offset vs. aligned) when laying the layup material 252 on the layup tool 150 in various orientations are shown. For example, Figures 15 to 16 show the AFP heads 220 laying up a 0-degree ply 258 of the composite material 254. When laying up the 0-degree ply 258, the layup tool 150 is generally fixed (i.e., not rotating) while the AFP heads 220 are moved along the length of the layup tool 150, but the layup tool 150 may rotate when the AFP heads 220 are within the tapered section 158. Figure 17 shows an example of the layup tool 150 after the 0-degree ply 258 has been laid.

[0066] As mentioned earlier, in the illustrated example of the layup tool 150, there is a constant section 160 in which the cross-sectional width of the layup tool 150 is constant, and a tapered section 158 in which the cross-sectional width of the layup tool 150 decreases. Figure 15 shows a head operating mechanism 200 that moves along the rail 118 while maintaining the AFP heads 220 aligned longitudinally with each other (224) as each AFP head 220 lays the composite material 254 on the layup tool 150.

[0067] Figure 16 shows how the AFP head 220 moves along the tapered section 158 of the layup tool 150. The head operating mechanism 200 temporarily adjusts the head speed of the AFP heads 220 so that they are offset longitudinally from one another (222) to avoid interference between them. The head speed of the AFP heads 220 is determined by the speed of the head operating mechanism 200 along the rail 118. The head operating mechanism 200 can adjust the relative longitudinal position of the AFP heads 220 by temporarily reducing the head speed of every other AFP head 220 (for example, every other AFP head 220 when viewed from the end (Figure 8)) while the remaining AFP heads 220 continue to move at the same head speed. Alternatively, the head speed of every other AFP head 220 can be increased while the remaining AFP heads 220 continue to move at the same head speed. In yet another example, the relative longitudinal position of the AFP heads 220 can be adjusted by combining the reduction in head speed of every other AFP head 220 with the increase in head speed of the remaining AFP heads 220.

[0068] The head speeds are adjusted so that the AFP heads 220 differ from each other in the longitudinal direction by an amount that prevents interference between the AFP heads 220 (222). Otherwise, interference between the AFP heads 220 will occur because the circumferential gap between adjacent AFP heads 220 gradually decreases as the AFP heads 220 gradually move radially inward while following the surface shape of the tapered section 158. When the AFP heads 220 return to a position on the layup tool 150 where alternating longitudinal offsets (222) are no longer necessary, the AFP heads 220 can be gradually moved to a longitudinally aligned (224) state (for example, Figure 15) by reversing one of the above examples of alternating longitudinal offsets.

[0069] In the layup tool 150 shapes shown in Figures 15-16, it is required that every other AFP head 220 be staggered in the longitudinal direction. However, it is necessary to stagger the AFP head 220 in the longitudinal direction on one side of the layup tool 150, and not on the opposite side of the layup tool 150. Layup tools 150 can be provided in other shapes. For example, in the layup tool 150 shapes shown in Figures 1-3, when multiple AFP heads 220 move into the tapered section 158 of the layup tool 150, which is the right-hand side of the layup tool 150 in Figure 2, it is necessary to stagger two of the AFP heads 220 in the longitudinal direction.

[0070] The movement of the head operating mechanism 200 and the AFP head 220, and the rotation of the tool can be controlled by one or more controllers 360 (Figure 3). In one example, the manufacturing system 100 includes a master controller (not shown) working in cooperation with one or more slave controllers (not shown). As the AFP heads 220 move radially inward while laying the composite material 254 on the tapered section 158, the one or more controllers 360 move along the rails 118 so that the AFP heads 220 are offset longitudinally from one another, thereby instructing the head operating mechanism 200 to avoid interference between adjacent AFP heads 220. As previously mentioned, the total amount of time required to produce the green layup 264 is determined primarily by the head speed of the AFP heads 220. The ability to move each AFP head 220 at its optimal head speed results in the shortest completion time and the minimum number of anomalies 300 in the green layup 264. By minimizing the amount by which the AFP head 220 is shifted alternately in the longitudinal direction, maximum efficiency is achieved, thereby eliminating the need for additional time in the layup process.

[0071] Referring to Figures 18 and 19, Figure 18 shows the AFP head 220 laying up a 45-degree ply 260 of the composite material 254. Figure 19 shows the layup tool 150 after the 45-degree ply 260 is completed. When laying up the 45-degree ply 260, the layup tool 150 is rotated around the tool axis 152 while the AFP head 220 moves longitudinally in a coordinated manner along the length of the layup tool 150. When the manufacturing system 100 is in operation, the control structure may be such that the tool axis 152 is the master axis, and the movement of the head operating mechanism 200 and the AFP head 220 (e.g., adding and cutting fiber bundles) follows the rotation of the layup tool 150 around the tool axis 152.

[0072] Figure 18 shows a head operating mechanism 200 that moves along a rail 118 while maintaining the AFP heads 220 in a longitudinal alignment (224) with each other as they lay a course 250 of composite material 254 in a fixed section 160 of the layup tool 150. Although not shown, when an AFP head 220 moves into a tapered section 158 of the layup tool 150, the head operating mechanism 200 adjusts the head speed of every other AFP head 220 in the same manner as the process shown in Figure 16, shifting them alternately in the longitudinal direction to prevent interference between adjacent AFP heads 220 (222).

[0073] Referring to Figures 20 and 21, Figure 20 shows the AFP head 220 laying up a 90-degree ply 262 of the composite material 254. Figure 21 shows the layup tool 150 after the 90-degree ply 262 has been completed. When laying up the 90-degree ply 262, the layup tool 150 is rotated around the tool axis 152, while the AFP head 220 remains mostly fixed longitudinally and does not move longitudinally except for any longitudinal movement that may be necessary to allow the AFP head 220 to follow its respective pre-programmed tool path and remain locally perpendicular to the tool surface 154 with its complex contour. In general, each AFP head 220 is maintained in a fixed relationship with the others offset longitudinally by an amount equal to the width of the course 250 of the composite material 254 being laid by the AFP head 220 (for example, a strip of fiber bundles 256 arranged side by side (Figure 23)). After each rotation is completed, the rotation of the layup tool 150 can be temporarily stopped, allowing the head operating mechanism 200 to shift the multiple AFP heads 220 longitudinally by a certain amount, so that the subsequent course 250 to be laid is in contact with the previously laid course 250. As the AFP heads 220 move into the tapered section 158 of the layup tool 150, the head speeds of some of the AFP heads 220 are adjusted so that the AFP heads 220 are offset longitudinally (222) to prevent interference between adjacent AFP heads 220.

[0074] Another method for laying up plies oriented at approximately 90 degrees involves programming a spiral tool path for the AFP heads 220 and simultaneously starting the AFP heads 220 at one end of the layup tool 150 to lay adjacent (i.e., adjacent) courses of composite material 254 spirally along the length of the layup tool 150. In this method, a fiber angle deviation equal to the number of AFP heads 220 multiplied by the course width and divided by the local circumference of the layup tool 150 is introduced. However, for layup tools 150 with relatively large cross-sectional widths, the fiber angle deviation can be relatively small. For example, in a manufacturing system with eight AFP heads 220, each laying an 8-inch wide course of composite material 254 on a 14-foot diameter layup tool 150, the fiber angle deviation from 90 degrees is 7 degrees, which may be considered acceptable considering that this method is faster than the method described above in Figure 20.

[0075] Referring now to Figures 22 and 23, Figure 23 shows an example of an AFP head 220 laying layup material 252 on a tool surface 154. As previously mentioned and shown in Figure 22, each AFP head 220 has a compression roller 228 for compressing the course 250 of the layup material 252 on a substrate 156. The substrate 156 includes the tool surface 154 or the previously laid layup material 252. Each AFP head 220 has a heating device 230 for improving the degree of adhesion (e.g., bonding) between the course 250 and the substrate 156. The heat 232 applied to the substrate 156 by the heating device 230 reduces the viscosity of the resin in the previously laid composite material 254, thereby increasing the degree of adhesion between the course 250 and the substrate 156. In addition, the application of heat 232 to the substrate 156 causes the viscosity of the resin in the course 250 to decrease due to the transfer of heat 232 from the substrate 156 into the course 250, as shown in Figure 22. The heating device 230 may be provided as an infrared heater, a laser heater, a xenon flash lamp, or any of the various alternative heating device configurations.

[0076] Each AFP head 220 includes at least one fiber bundle sensor 234 configured to capture layup data 270 (Figure 33) for each course 250 of the layup material 252 after laying onto the substrate 156. In the example shown, the fiber bundle sensor 234 is located downstream of the compression roller 228. Each fiber bundle sensor 234 is configured to capture layup data 270 while the AFP head 220 moves against the tool surface 154. As described below, the layup data 270 is used to measure the quality of each course 250 of the layup material 252 after laying onto the substrate 156. The layup data 270 is received by a processor 362 (Figure 33), which analyzes the layup data 270 to detect anomalies 300 in the green state layup 264.

[0077] In the example in Figure 23, the layup material 252 includes fiber bundles 256 of juxtaposed composite material 254. However, as previously shown, the layup material 252 may include non-composite materials, such as films, adhesives, or layers, that can facilitate the layup or processing of the green state layup 264. Fiber bundle sensors 234 on the AFP head 220 are configured to capture layup data 270 (Figure 33) continuously or at periodic intervals. For example, depending on the head speed of the AFP head 220, the fiber bundle sensors 234 can capture layup data 270 every 0.1 seconds or every few inches the AFP head 220 moves relative to the tool surface 154 to ensure that layup data 270 for the entire length of each course 250 is captured.

[0078] In Figure 23, the fiber bundle sensor 234 is an imaging device 236. The imaging device 236 is configured to capture a series of layup images 272 (Figure 24) of the layup material 252 (e.g., fiber bundles 256 of a composite material) immediately after laying on the tool surface 154 or on a previously laid layup material 252. In one example, the imaging device 236 may be a visible light camera (not shown) configured to capture a series of visible light images of the layup material 252 immediately after laying on the substrate 156. In the example in Figure 23, the imaging device 236 is an infrared camera 238 configured to capture a series of infrared images 274 (Figure 24) of the layup material 252. The infrared camera 238 is mounted and oriented so that its field of view extends across the entire width of the course 250. The field of view of the infrared camera 238 may additionally capture smaller sections of the substrate on both sides of the course 250. Figure 23 shows one infrared camera 238 mounted on an AFP head 220, but in other examples not shown, each AFP head 220 may include two or more infrared cameras 238, each mounted to image different areas of the course 250 immediately after laying on the substrate 156.

[0079] Figure 24 shows an example of an infrared image 274 captured by an infrared camera 238 (Figure 23) as a result of heat 232 (Figure 22) being transferred from the substrate 156 (Figure 22) into the recently laid layup material 252 (Figure 22). The fiber bundles 256 (Figure 23) of course 250 are preferably laid on the substrate 156 in a non-overlapping, gap-free manner as shown in Figure 23, however anomalies 300 (e.g., fiber bundle defects) may occur in course 250. As shown in Figure 24, any one or more of the various types of anomalies 300 may occur in the fiber bundles 256 during laying by the AFP head 220. Each fiber bundle 256 is assigned a fiber bundle identification number 276, which may facilitate the physical localization of the anomalies 300 in the green layup 264 for manual inspection and possible rework. In the infrared image 274 of Figure 24, abnormality types include twists 302, folds 304, gaps 306, overlaps 308, bridging (not shown), folds 310, wrinkles 312, loss of fiber bundles 256, poor quality adhesive 316, resin balls 320, lint balls 322, or fragments of foreign matter 318.

[0080] The twist 302 is a position along the length of the fiber bundle 256, where the composite material 254 is spirally wound (for example, 180 degrees) around itself when laid down on the substrate 156 by the AFP head 220. The fold 304 is a position along the length of the fiber bundle 256, where the composite material 254 is folded in half or folded on top of itself when laid down on the AFP head 220. The fiber bundle defect 324 is a fiber bundle 256 that was initially laid on the substrate 156 but was unintentionally cut by the AFP head 220, or a result of the material running out from the material roll 226 on the AFP head 220. The gap 306 is a state where the side ends of adjacent fiber bundles 256 on the same composite material ply are separated from each other over a certain section of their length.

[0081] Overlap 308 can be described as a state in which adjacent fiber bundles 256 on the same composite ply overlap each other over a certain section of their length. Bridging (not shown) is a state in which fiber bundles 256 extend over valleys (e.g., concave curves) on the surface of the substrate 156 and can occur at the interior angles on the tool surface 154 of the layup tool 150. Folds 310 can be described as regions of composite material 254 that are locally raised along the side edges of fiber bundles 256 and can occur in fiber bundles 256 that are manipulated in the in-plane direction (not shown). Wrinkles 312 are similar to folds 310 and can be described as out-of-plane distortion within the internal region between the side edges of fiber bundles 256. Low-quality adhesion 316 can be described as a low level of adhesion between the coarse 250 and the substrate 156. Although not shown in the illustration, voids or holes are a type of anomaly 300 that may occur in a green state layup 264 as a result of enclosed air or volatile matter.

[0082] The foreign matter fragments 318 can be any kind of foreign matter unintentionally introduced during the green state layup 264 and may include small pieces of backing paper or backing film, plastic or metal particles, liquids such as water or oil, or any other kind of foreign matter. Other examples of foreign matter fragments 318 include, but are not limited to, resin balls 320 and lint balls 322. Resin balls 320 can be described as small spheres of resin that can accumulate on the components of the AFP head 220, eventually falling onto the substrate 156. Lint balls 322 can be described as loose bundles of filament fibers that form along the side ends of the fiber bundle 256 as they pass through the AFP head 220 and may fall onto the substrate 156 or onto the course 250 being laid on the substrate 156 by the AFP head 220.

[0083] Referring to Figure 25, an example of an AFP head 220 in which the fiber bundle sensor 234 is a shape measuring device 240 is shown. The surface shape measuring device 240 is configured to image a series of layup profiles 278 of the courses 250 of the layup material 252 immediately after laying on the substrate 156 (Figures 26-29). The surface shape measuring device 240 may be a laser surface shape measuring device configured to emit one or more laser beams within the scanning plane 242. For example, the laser surface shape measuring device may emit a single laser beam configured to scan back and forth within the scanning angle range of the scanning plane 242. Alternatively, the laser surface shape measuring device may emit multiple laser beams (not shown) within the range of the scanning plane 242. The laser beams emitted by the laser surface shape measuring device strike the surface of the courses 250 of the layup material 252 during scanning, resulting in the layup profiles 278. Although described as an imaging device 236 or a surface shape measuring device 240, the fiber bundle sensor 234 can be provided in any configuration from a variety of alternative configurations that can measure the quality of the layup material 252 after it has been laid on the substrate 156.

[0084] Figures 26 to 29 show several examples of layup profiles 278 generated by the laser surface geometry analyzer shown in Figure 25. Each layup profile 278 represents a different type of anomaly in a green state layup 264. For example, Figure 26 shows a layup profile 278 representing a gap 306 between adjacent fiber bundles 256, as shown in the schematic diagram of the fiber bundles 256 located on top of the layup profile 278. Figure 27 shows a layup profile 278 representing an overlap 308 of adjacent fiber bundles 256, as shown in the schematic diagram on top of the layup profile 278. Figure 28 shows a layup profile 278 representing a fiber bundle defect 314, as shown in the fiber bundle 256 illustrated on top of the layup profile 278. Figure 29 shows a layup profile 278 representing a fold 304 on a fiber bundle 256, as shown in the schematic diagram of the fiber bundle 256 located on top of the layup profile 278.

[0085] The processor 362 (Figures 30 and 33) is configured to continuously or periodically receive layup data 270 (e.g., layup images 272, layup profiles 278, etc.) from the fiber bundle sensor 234. In addition, the processor 362 receives the layup data 270 along with the capture location of the layup data 270. The capture location identifies the position where the layup data 270 was captured relative to the layup tool 150. In the example where the fiber bundle sensor 234 (Figure 23) is an imaging device 236 (Figure 23), each layup image 272 (Figure 24) is provided to the processor 362 along with the capture location of the layup image 272. In the example where the fiber bundle sensor 234 (Figure 25) is a surface shape measuring device 240 (Figure 25), each layup profile 278 (Figures 26 to 29) is provided to the processor 362 along with the capture location of the layup profile 278.

[0086] The capture position of each layup image 272 may be based on the mechanical tool path of the AFP head 220 from which the layup image 272 was generated. For example, the capture position of each layup image 272 may be determined by correlating its acquisition time with the mechanical tool path of the AFP head 220. The capture position of the layup data 270 may be provided in terms of Cartesian coordinates, cylindrical coordinates, or other reference systems. The layup data 270 provided to the processor 362 optionally includes a formation identification (ID) number assigned to the green state layup 264. Although not shown, the manufacturing system 100 may include a separate (e.g., mounted in the manufacturing cell) laser positioning system for verifying the mechanical tool path of each AFP head 220 via a laser tracker (not shown) mounted on each AFP head 220.

[0087] Referring to Figure 33, upon receiving layup data 270, the processor 362 is configured to detect anomalies 300 in the green state layup 264 by comparing the layup data 270 with a database of reference data 380 containing examples of various anomalies 300 that may potentially occur in the green state layup 264. For example, if the layup data 270 includes layup images 272 generated by the imaging device 236, the processor 362 can detect anomalies 300 in the green state layup 264 by comparing each layup image 272 with a database of reference images containing examples of various anomalies 300 that may potentially occur in the green state layup 264. For example, if the layup data 270 includes layup profiles 278 generated by the surface shape measuring device 240, the processor 362 can detect anomalies 300 by comparing each layup profile 278 with a database of reference profiles. Before initiating the process of creating a green state layup, a database of reference images and / or reference profiles can be generated by analyzing a reference layup (not shown) laid up in a controlled environment, where the reference layup includes intentionally introduced anomalies 300.

[0088] The processor 362 is configured to identify the anomaly type of each anomaly 300 in the layup data 270 (if any) based on comparison, and to determine the anomaly location of each anomaly 300 identified in the green state layup 264 based on the capture location in the layup data 270. For example, assuming there is a series of layup images 272 or a series of layup profiles 278, the processor 362 is configured to determine the spatial location (e.g., on-part coordinates) of each anomaly 300 identified in each of the layup images 272 or layup profiles 278. The spatial location of each anomaly 300 is provided in terms of coordinates relative to the part origin 342 (Figure 32) of the layup tool 150 or the green state layup 264. As described below, the spatial location may include the ply number in the ply stacking sequence and may also include the fiber bundle identification number 276 associated with each anomaly 300, enabling quality assurance (QA) personnel to physically locate each anomaly 300 on the green state layup 264. As described below, the detection and identification of anomalies 300 in the green layup 264 allows for manual inspection and / or rework of the green layup 264 before curing.

[0089] Referring to Figures 30 to 32, the processor 362 is configured to construct a green state digital model 340 (e.g., a three-dimensional model) of the green state layup 264 based on the layup data 270. An example of the green state digital model 340 is shown on the screen 366 of the computer 364. In the example shown, the green state digital model 340 includes the anomalies 300 identified in the layup data 270. As shown in Figure 32, the green state digital model 340 may be displayed with labels 326 that identify the anomaly type and location of each anomaly 300 in the green state layup 264.

[0090] Referring to Figures 30 to 33, the processor 362 can determine whether the green state layup 264 meets the design intent by analyzing each anomaly 300 in the green state digital model 340 and determining whether the anomaly 300 is acceptable or unacceptable. In one example, the processor 362 compares the characteristics of each anomaly 300 with a database of design criteria 382 that defines minimum and / or maximum values ​​(e.g., tolerances) for each anomaly (300) characteristic for each anomaly type. For example, the processor 362 can determine whether the anomaly 300 is acceptable by determining whether the magnitude of the anomaly is greater than the maximum magnitude defined in the design criteria 382. In another example, the processor 362 can determine whether the anomaly 300 is acceptable by analyzing the anomaly location relative to other features of the green state layup 264. For example, the processor 362 can determine whether an anomaly 300 is acceptable by determining its location within the ply stack of the green state layup 264, or by determining the distance of the anomaly 300 from the edge of the green state layup 264, or the distance of the anomaly 300 from a subsequently formed cutout. As can be seen from the above, the database of design criteria 382 can specify minimum and / or maximum values ​​for a wide range of anomaly 300 characteristics. After analyzing each anomaly 300, the processor 362 can create a nonconformity report 384 that includes a list of all anomalies 300 in the green state layup 264 and indicates whether each anomaly 300 is acceptable or unacceptable. The nonconformity report 384 allows QA personnel to physically inspect the anomalies 300 in the green state layup 264 for processing, such as anticipated rework of unacceptable anomalies 300.

[0091] Non-destructive testing may be performed on the green-state layup 264 after the layup process is complete and while the green-state layup 264 is supported on the layup tool 150. Non-destructive testing may be performed using a robotic device (not shown) that moves an inspection probe (e.g., ultrasonic, infrared thermography, not shown) over the surface of the green-state layup 264 to generate inspection measurements 348 (e.g., thickness measurements) of the green-state layup 264.

[0092] Referring to Figure 33, the processor 362 receives an inspection measurement 348 from a non-destructive inspection of the green state layup 264 and compares the inspection measurement 348 with a value of a reference layup (not shown). The reference layup may be a digital representation of the green state layup 264 that is known to be defect-free and of normal thickness. Comparing the inspection measurement 348 with the value of the reference layup facilitates the detection of anomalies 300 in the green state layup 264, such as foreign matter fragments 318, voids, holes, low-compression areas, or fiber bundle defects. In addition, comparing the inspection measurement 348 with the value of the reference layup facilitates the determination of whether the thickness measurement of the green state layup 264 is within the thickness tolerance range.

[0093] The processor 362 constructs a non-destructive testing (NDI) digital model 344 (i.e., a three-dimensional model) of the green state layup 264 based on the inspection measurement 348. The NDI digital model 344 includes the anomalies 300 detected via the inspection measurement 348. The NDI digital model 344 is constructed for the non-destructive testing thickness measurement. The processor 362 verifies the green state digital model 340 by comparing it with the NDI digital model 344 and creates the aforementioned non-conformity report 384, which identifies the difference between the anomalies 300 in the green state digital model 340 and the anomalies 300 in the NDI digital model 344.

[0094] Nonconformity report 384 may include a list of all anomalies 300, including an indication of the anomaly type and location of each anomaly 300. In addition, nonconformity report 384 can verify whether each anomaly 300 in the green state digital model 340 is present in the NDI digital model 344, and whether each anomaly 300 in the NDI digital model 344 is present in the green state digital model 340. Anomalies 300 present in the green state digital model 340 but not in the NDI digital model 344 may prompt manual verification of the layup data 270 (e.g., layup image 272 or layup profile 278) containing the missing anomalies 300 to determine whether the anomalies 300 were misidentified. Anomalies 300 present in the NDI digital model 344 but not in the green state digital model 340 may prompt manual verification of the test measurement 348 to determine whether the anomalies 300 were misidentified. Advantageously, the capabilities of the aforementioned processor 362 eliminate the time-consuming and costly inspection of each composite ply of the green layup 264 by QA personnel, replacing this inspection with an automated process that rapidly detects anomalies 300, identifying the location and type of the anomaly.

[0095] Referring to Figure 33, in some examples, the processor 362 is configured to perform machine learning to improve the layup process for subsequent green-state layups 264 to be manufactured. In this regard, the processor 362 can continuously record processing parameters associated with manufacturing each green-state layup 264. An example of processing parameters is instrument parameters associated with the operation of the AFP head 220. Instrument parameters may be automatically recorded for each AFP head 220 during the manufacturing of each green-state layup 264. Examples of instrument parameters include, but are not limited to, the position of fiber bundle addition and cutting, fiber bundle tension, thermal output of the heating device 230 for heating the substrate 156, head speed, fiber bundle temperature, substrate temperature, compressive force applied to the layup material 252 by the compression roller 228, relative positions of the AFP heads 220, and other parameters. Examples of processing parameters also include material parameters associated with the layup material 252. Material parameters include, but are not limited to, the type of layup material 252 supplied by the AFP head 220, the material lot number, the material composition (e.g., resin composition), the degree of adhesion of the composite material 254, the output time of the composite material 254, and other parameters.

[0096] The processor 362 correlates processing parameters with the completion time required to produce a green layup 264 (e.g., from the start to the end of the layup process), and / or correlates processing parameters with the occurrence of anomalies 300 in the green layup 264 detected by the processor 362. Based on the above correlation, the processor 362 can repeatedly adjust one or more processing parameters for each subsequent green layup 264 to be produced, so as to shorten the completion time of the subsequent green layup 264, and / or reduce the amount and / or type of anomalies 300 in the subsequent green layup 264. In this way, the processor 362 can improve the reliability of the AFP head 220 when performing a particular task, thereby improving the quality of the final product.

[0097] The processor 362 can also verify any anomalies 300 identified in the green state digital model 340 by comparing the green state digital model 340 with the digital model 346 of the green state layup 264 as designed. In this regard, the processor 362 can verify that the anomalies 300 detected by the processor 362 in the green state digital model 340 are indeed anomalies 300 and are not part of the intended design of the green state layup 264, for example, not a component that was intentionally added (e.g., an embedded sensor). The processor 362 can also verify the thickness measurements from non-destructive testing of the green state layup 264 by confirming that the thickness measurements fall within the thickness tolerances specified for the green state layup 264.

[0098] As previously mentioned, the processor 362 may adjust or optimize one or more processing parameters so as to reduce the completion time or the number of anomalies 300 in the green-state layup 264 currently being laid up and / or subsequent green-state layups 264 being manufactured. Examples of the types of adjustments that can be made include adjustments to any one or more of the previously mentioned equipment parameters, e.g., the position of fiber bundle addition and cutting, the tension of the fiber bundles, the thermal output of the heating device 230, the head speed of the AFP heads 220 at various positions on the green-state layup 264, the fiber bundle temperature, the substrate temperature, the compression force applied by the compression rollers 228, the relative positions of the AFP heads 220, and other parameters. Examples of adjustments to material parameters, but not limited to, include the type of layup material 252 (e.g., composition), the degree of adhesion of the composite material 254, the output time of the composite material 254, and other material parameters.

[0099] Another example of adjusting processing parameters that can be done to reduce completion time and / or anomalies 300 includes reallocating or energizing AFP heads 220 to perform a particular task. The reallocating or energizing can be done by an optimization algorithm, which is driven periodically by the processor 362 (for example, each time anomalies 300 of the green state layup 264 are checked) and reallocates tasks based on the AFP head 220 that completes the task in the minimum amount of time and has the fewest anomalies 300. Reallocating or reallocating AFP heads 220 can also be done in real time if the optimal performance of one of the AFP heads 220 is not achieved. Reallocating AFP heads 220 may be based on a variety of factors, namely, but not limited to, the amount of layup material 252 remaining on each AFP head 220, the position of the head, and / or the head travel time of each AFP head 220 to the required position on the green state layup 264, and other factors. The processor 362 can also proactively schedule maintenance for the AFP head 220 to avoid unplanned downtime due to head malfunction, thereby improving machine reliability. The AFP head 220 can be removed and repositioned using the head change station 130 described earlier.

[0100] Referring to Figure 34, a flowchart of the steps included in method 400 for manufacturing a barrel-shaped composite layup is shown. Method 400 includes step 402 of moving a plurality of head operating mechanisms 200 along a plurality of rails 118 arranged parallel to each other around a barrel-shaped layup tool 150 (for example, under the control of a controller 360). As previously mentioned, each rail 118 is oriented substantially parallel to the tool axis 152, and each head operating mechanism 200 is movable along the longitudinal direction of the rail 118 to which it is mounted. Each head operating mechanism 200 supports an AFP head 220.

[0101] The method 400 also includes the step of laying a course 250 of laying material 252 on the tool surface 154 or a previously laid laying material 252 while the laying tool 150 is fixed and rotating around the tool axis 152 (404), by moving the head operating mechanism 200 along the rail 118, thereby creating a green layup 264. The AFP head 220 lays the laying material 252 simultaneously in a coordinated manner under the control of the controller 360.

[0102] In addition, the method 400 also includes step 406 of using a head operating mechanism 200 to maintain the AFP heads 220 circumferentially spaced apart from one another around the tool surface 154 while the AFP heads 220 lay a course 250 of layup material 252 on the layup tool 150. As previously described, the total number of AFP heads 220 includes the maximum number of AFP heads 220 that can be positioned circumferentially at the point of the largest circumference on the layup tool 150 while laying a course 250 of layup material 252 on the layup tool 150, while being longitudinally aligned with one another. The total number of AFP heads 220 is maximized as a means to reduce the total number of passes required by the AFP heads 220 to produce a green layup 264. In some examples, step 406, which maintains the AFP heads 220 circumferentially spaced apart from one another, includes using the head operating mechanism 200 to circumferentially space the AFP heads 220 by approximately 360 degrees / n minutes relative to each other. In this way, the AFP heads 220 are spaced equally apart from each other.

[0103] As part of the process of laying up a green state layup 264, the method includes using each head operating mechanism 200 to rotate the corresponding AFP head 220 about an axis perpendicular to the tool axis 152 in order to reverse the laydown direction of the AFP head 220. As part of the laydown process, the method also includes using each head operating mechanism 200 to translate the corresponding AFP head 220 along an axis perpendicular to the tool axis 152, alternately at the beginning and end of each course 250, in order to move the AFP head 220 either onto or away from the layup tool 150 (i.e., the tool surface 154 or the previously laid composite material 254).

[0104] As previously described, the method further includes adjusting the head speed of one or more AFP heads 220 using the head operating mechanism 200 to offset the AFP heads 220 longitudinally in an alternating manner to prevent interference between the AFP heads 220 during movement along the tapered section 158 of the layup tool 150. In one example, the adjustment of the head speed includes temporarily increasing or decreasing the head speed of every other AFP head 220 to result in the AFP heads 220 being offset longitudinally from one another, as shown in the example in Figure 16. In the example shown, the AFP heads 220 move at a reduced head speed every other time, and the AFP heads 220 are ultimately offset longitudinally by an amount that prevents interference between the AFP heads 220 (222).

[0105] The method further includes using the head operating mechanism 200 to maintain the AFP heads 220 in a longitudinally aligned position relative to each other while the layup tool 150 moves along its length. Figures 15 and 18 illustrate the longitudinal alignment of the AFP heads 220, as previously described. Maintaining a constant head speed for the AFP heads 220 ensures that no additional time is added to the total time required to produce a green layup 264. As described above, when laying a 0-degree ply 258, the layup tool 150 remains fixed (i.e., does not rotate) while the AFP heads 220 move longitudinally along the length of the layup tool 150. When laying a 45-degree ply 260, the layup tool 150 rotates around the tool axis 152 while the AFP heads 220 move along the length of the layup tool 150. When laying up 90-degree plies 262, the layup tool 150 rotates around the tool axis 152, while the AFP head 220 remains fixed longitudinally as it lays each course 250 of the layup material 252.

[0106] The process of laying a course 250 of the layup material 252 onto the layup tool 150 involves using an AFP head 220 to supply the layup material 252 as juxtaposed fiber bundles 256 of the composite material 254. As previously mentioned, each AFP head 220 is typically configured to supply a strip of juxtaposed fiber bundles 256. For example, each AFP head 220 can supply an 8-inch wide strip consisting of 1 / 2-inch fiber bundles 256. The width of the strip may increase for layup tools 150 with larger diameters. The width of the individual fiber bundles 256 may decrease for layup tools 150 with more precise contours.

[0107] While laying the layup material 252, the method includes using a head operating mechanism 200 to move the corresponding AFP head 220 around multiple axes to maintain the AFP head 220 approximately perpendicular to the contour of the tool surface 154. To this end, the method includes rotating each AFP head 220 around at least one of six axes (e.g., six rotation axes 210) to continuously maintain the AFP head 220 being perpendicular when laying the course 250 of the layup material 252 onto the tool surface 154. In addition, when reversing the laydown direction of the AFP head 220, the AFP head 220 is rotated around an axis perpendicular to the tool axis 152. At the beginning and end of each course 250, when moving the AFP head 220 onto and away from the layup tool 150, the AFP head 220 is translated along an axis perpendicular to the tool axis 152.

[0108] Referring to Figures 11-14 described earlier, the method further includes using the head operating mechanism 200 to replace the AFP head 220 currently mounted on the head operating mechanism 200 with an alternative head supported on a head stand 132 of a head change station 130 located at one of the ends of the layup tool 150. As previously described, each AFP includes a quick-release mechanism (not shown) for releasing the AFP head 220 (e.g., if it is malfunctioning or the material roll 226 has been used up) onto an empty head stand 132 and then engaging it with an alternative AFP head 134 supported by another head stand 132.

[0109] Referring to Figures 22 to 32 described earlier, some examples of this method include capturing layup data 270 for courses 250 of the layup material 252 using one or more fiber bundle sensors 234 on each AFP head 220 immediately after the AFP head 220 is laid. As previously mentioned, each fiber bundle sensor 234 may be an imaging device 236, such as an infrared camera 238 or a visible light camera, configured to capture a series of layup images 272 of each course 250 during laying. Alternatively or additionally, the fiber bundle sensor 234 may be a surface topographic device 240 configured to record a series of layup profiles 278 of each course 250 during the laying of the layup tool 150.

[0110] The method includes the processor 362 continuously or periodically receiving the layup data 270 (e.g., layup images 272 and / or layup profiles 278) along with the capture location of the layup data 270. In addition, the method includes using the processor 362 to detect anomalies 300 in the green state layup 264 by comparing the layup data 270 with reference data 380 which collectively contains examples of various anomalies 300 that may potentially occur in the green state layup 264. As previously mentioned, the comparison may include comparing each layup image 272 with a database of reference images and / or comparing each layup profile 278 with a database of reference profiles.

[0111] In addition, the method includes using a processor 362 to identify the type of anomaly 300 in the layup data 270 based on comparison, and determining the location of each anomaly 300 in the green state layup 264 based on the capture location in the layup data 270. The location of each anomaly 300 in the green state layup 264 may include the ply number and fiber bundle identification number 276 associated with each anomaly 300. As previously described, the detection and identification of anomalies 300 in the green state layup 264 allows for manual inspection and / or rework of the green state layup 264.

[0112] Referring to Figures 30 to 32, the method also includes using a processor 362 to construct a green state digital model 340 of the green state layup 264. As previously described, the green state digital model 340 includes the anomalies 300 identified in the layup data 270. As shown in Figure 32, the green state digital model 340 may include labels 326 that identify the anomaly type and location of each anomaly 300.

[0113] In some examples, the method may include determining whether each anomaly 300 in the green condition digital model 340 is acceptable or unacceptable by comparing the characteristics of each anomaly 300 with a database of design criteria 382 that define minimum and / or maximum values ​​(e.g., tolerances) for each anomaly (300) characteristic for each anomaly type. The method may also include listing the anomalies 300 in a nonconformity report 384 to facilitate the physical location and inspection of the anomalies 300 on the green condition layup 264.

[0114] To validate the green state model, the method includes performing non-destructive testing of the green state layup 264 after the completion of the layup process. Although not shown, the non-destructive testing can be performed using an NDI system (not shown), which may include using a robotic device to move one or more inspection probes over the surface of the green state layup 264. As previously mentioned, the inspection probes may be provided in one of various forms, but are not limited to ultrasonic testing or infrared thermography. The non-destructive testing of the green state layup 264 results in an inspection measurement 348, such as a measurement of the thickness of the green state layup 264.

[0115] This method involves receiving inspection measurement values ​​348 from non-destructive testing of a green-state layup 264 and comparing the inspection measurement values ​​348 (e.g., thickness measurements) with a reference layup value, where the reference layup value may be a digital model of a green-state layup 264 known to be defect-free and of normal thickness. The comparison of the inspection measurement values ​​348 with the reference layup reveals anomalies 300 in the green-state layup 264, such as FOD, fiber bundle defects, or other defects. In addition, the above comparison can identify areas of the green-state layup 264 where the thickness measurement values ​​fall outside the defined tolerance range for the green-state layup 264.

[0116] Based on the above comparison, the method includes constructing a non-destructive inspection (NDI) digital model 344 of the green state layup 264, where the NDI digital model 344 includes anomalies 300 detected via inspection measurements 348. The method further includes comparing the green state digital model 340 with the NDI digital model 344 to verify the green state digital model 340 and identify any differences between the green state digital model 340 and the NDI digital model 344. The method includes generating a non-conformity report 384 listing all anomalies 300, including listing the anomaly type and location, to identify the differences between the anomalies 300 in the green state digital model 340 and those in the NDI digital model 344, as described above, thereby verifying the green state digital model 340.

[0117] In some examples, the method may further include recording processing parameters associated with the production of the green layup 264. As previously described, such processing parameters may include equipment parameters associated with the AFP head 220 and / or material parameters associated with the layup material 252. The method includes correlating the processing parameters with the completion time required to produce the green layup 264 from the start to the end of the layup process. In addition, the method includes correlating the processing parameters with the occurrence of anomalies 300 in the green layup 264 detected by the processor 362. The method may further include repeating for each subsequent green layup 264 produced to adjust one or more processing parameters so that the completion time of the subsequent green layup 264 is consequently reduced and / or the number of anomalies 300 in the subsequent green layup 264 is consequently reduced.

[0118] Referring to Figure 34, the method may further include verifying the anomaly 300 identified in the green state digital model 340 by comparing the green state digital model 340 with the digital model 346 of the green state layup 264 as designed, and confirming that the anomaly 300 detected in the green state digital model 340 by the processor 362 is indeed an anomaly 300 and is not part of the intended design of the green state layup 264. In addition, the thickness measurement from non-destructive testing of the green state layup 264 is verified by comparing the green state digital model 340 with the digital model 346 as designed. In this regard, the above comparison confirms that the thickness measurement of the green state layup 264 falls within the range of a predetermined thickness tolerance.

[0119] The method further includes using the processor 362 to adjust or optimize processing parameters so as to minimize the completion time and the number of anomalies 300 in the subsequent green layup 264. Adjusting processing parameters may include adjusting equipment parameters, adjusting material parameters, reallocating the AFP heads 220, and / or scheduling proactive maintenance for the AFP heads 220. Adjusting equipment parameters may include adjusting the position of fiber bundle addition and cutting, fiber bundle tension, heat output of the heating device 230, head speed of the AFP heads 220, fiber bundle temperature, substrate temperature, compressive force applied to the layup material 252 by the compression rollers 228, the relative positions of the AFP heads 220, and / or other parameters. Adjusting material parameters may include selecting layup materials 252 having different material compositions (e.g., resin compositions), selecting composite materials 254 with different tackiness, changing the maximum output time of the composite material 254, and any of the various other adjustments.

[0120] The processor 362 may reallocate the AFP heads 220 to lay up in different areas of a subsequently manufactured green state layup 264 in order to reduce or prevent the repetition of one or more anomalies 300 in one or more previously manufactured green state layups 264. As previously stated, the processor 362 may also proactively schedule maintenance for the AFP heads 220 to avoid unplanned downtime due to head failure. Reallocation of the AFP heads 220 may be based on the amount of layup material 252 remaining on each AFP head 220, the reliability of each head performing a specific task without anomalies 300, the head position of each AFP head 220 and / or the head travel time of each AFP head 220 to the required position on the green state layup 264, and other factors.

[0121] This disclosure includes exemplary embodiments in accordance with the following clauses.

[0122] Clause 1. Manufacturing system 100, A plurality of rails 118 are arranged around a barrel-shaped layup tool 150 in a relationship parallel to each other, wherein each rail 118 is oriented substantially parallel to the tool axis 152 of the layup tool, Multiple head operating mechanisms 200, each connected to a dedicated rail among the rails 118, wherein the multiple head operating mechanisms 200 are movable along the longitudinal direction of the corresponding rail, Multiple automatic fiber placement (AFP) heads, each coupled to a dedicated head operating mechanism 200 within the head operating mechanism 200, Equipped with, The manufacturing system 100 includes a head operating mechanism 200 configured to position AFP heads 220 around the tool surface 154 of the layup tool 150 at circumferential spacing from one another, wherein the total number of AFP heads 220 includes the maximum number of AFP heads 220 that can be positioned circumferentially on the layup tool 150 while the AFP heads 220 lay a course 250 of layup material 252 on the tool surface 154 or a previously laid layup material 252, thereby creating a barrel-shaped green layup 264, without interfering with each other at the point of the maximum circumference on the layup tool 150, while the layup tool 150 is fixed and while the layup tool 150 is rotating around the tool axis 152, and while the layup tool 150 lays a course 250 of layup material 252 on the tool surface 154 or a previously laid layup material 252, thereby creating a barrel-shaped green layup 264.

[0123] Article 2. To avoid interference between the AFP heads 220 during movement of the layup tool 150 along the tapered section 158, the manufacturing system 100 according to Clause 1 is configured to adjust the head speed of at least some of the AFP heads 220 so that they are staggered longitudinally relative to one another.

[0124] Article 3. The manufacturing system 100 according to Clause 1 or 2, wherein the head operating mechanism 200 is configured to maintain a plurality of AFP heads 220 in a longitudinally aligned state with respect to one another while the layup tool 150 moves along its longitudinal direction.

[0125] Article 4. Multiple AFP heads 220 include n AFP heads 220, A manufacturing system 100 according to any one of clauses 1 to 3, wherein multiple head operating mechanisms 200 are configured to space multiple AFP heads 220 from each other by approximately 360 degrees / n in the circumferential direction.

[0126] Article 5. Each head operating mechanism 200 is a six-axis arm that allows movement of each AFP head 220 around six axes, as described in any one of Clauses 1 to 4 of the manufacturing system 100.

[0127] Article 6. The system further includes a head change station, which is located at one of the ends of the layup tool 150 and supports one or more alternate AFP heads 134, each alternate AFP head 134 being supported on a head stand. A manufacturing system 100 according to any one of Clauses 1 to 5, wherein each head operating mechanism 200 is configured to release an AFP head 220 onto an available head stand 132 and engage with an alternative AFP head 134 supported by another head stand 132.

[0128] Article 7. Multiple fiber bundle sensors 234, each attached to multiple AFP heads 220, and each fiber bundle sensor 234 of each AFP head 220 is configured to capture layup data 270 relating to the layup material 252 immediately after it has been laid by the AFP head, Processor 362, The acquisition location of the layup data 270, along with the receipt of the layup data 270, By comparing the layup data 270 with reference data 380, which includes examples of various anomalies 300 that can potentially occur in green state layups, anomalies 300 in the green state layup 264 are detected. In order to enable the physical localization of each anomaly 300 for possible rework, the anomaly type of each anomaly 300 in the layup data 270 is identified based on comparison, and the position of each anomaly 300 in the green state layup 264 is determined based on the capture position in the layup data 270, A processor 362 configured to perform the following: A manufacturing system 100 as described in any one of clauses 1 to 6, further including:

[0129] Clause 8. Processor 362, Constructing a green state digital model 340 of a green state layup 264, wherein the green state digital model 340 includes anomalies 300 identified in the layup data 270, The characteristics of each anomaly 300 are compared with a database of design criteria 382 that defines the maximum and / or minimum values ​​for each anomaly (300) characteristic for each anomaly type to determine whether each anomaly 300 in the green state digital model 340 is acceptable or unacceptable. A manufacturing system 100 as described in Clause 7, configured to perform the following actions.

[0130] Clause 9. Processor 362, The inspection measurement value 348 obtained from the non-destructive testing of the green state layup 264 is received, and the inspection measurement value 348 is compared with the value of the reference layup, thereby detecting an anomaly 300 in the green state layup. To construct a non-destructive inspection (NDI) digital model 344 of a green state layup 264, including anomalies 300 detected via inspection measurement values ​​348, By comparing the Green State Digital Model 340 with the NDI Digital Model 344, the Green State Digital Model 340 is validated, and any differences between the Green State Digital Model 340 and the NDI Digital Model 344 are identified. A manufacturing system 100 as described in Clause 8, configured to perform the following:

[0131] Clause 10. Processor 362, Recording one or more processing parameters associated with manufacturing a green state layup 264, wherein the processing parameters are Instrument parameters associated with AFP head 220, Material parameters associated with the layup material 252 supplied by the AFP head 220 Record one or more processing parameters, including at least one of the following: The processing parameters, The time required to produce a green layup, Anomaly in a green layup: 300 To correlate with at least one of the following, For each subsequent manufactured green condition layup 264, Reduction in completion time, and Reduction of the amount of abnormal 300 Adjust one or more processing parameters so that at least one of the following can be obtained, A manufacturing system 100 as described in Clause 9, configured to perform the following actions.

[0132] Article 11. Composite material layup system, A layup tool 150 having a barrel shape, a tool surface 154, and a tool axis 152 around which the layup tool 150 can rotate, A plurality of rails 118 arranged around the layup tool 150 in a relationship parallel to each other, wherein each rail 118 is oriented substantially parallel to the tool axis 152, Multiple head operating mechanisms 200, each connected to a dedicated rail among the rails 118, wherein the multiple head operating mechanisms 200 are movable along the longitudinal direction of the corresponding rail, Multiple automatic fiber placement (AFP) heads, each coupled to a dedicated head operating mechanism 200 within the head operating mechanism 200, Equipped with, A composite material layup system comprising a head operating mechanism 200 configured to position AFP heads 220 circumferentially spaced apart from one another around the tool surface 154 of the layup tool 150, wherein the total number of AFP heads 220 includes the maximum number of AFP heads 220 that can be positioned circumferentially on the layup tool 150 while the layup tool 150 is fixed and while the layup tool 150 is rotating around the tool axis 152, laying a course 250 of layup material 252 on the tool surface 154 or a previously laid layup material 252, thereby creating a barrel-shaped green layup 264, while the layup tool 150 is fixed and while the layup tool 150 is rotating around the tool axis 152, with longitudinal alignment of the AFP heads 220 without interfering with each other at the point of the maximum circumference on the layup tool 150.

[0133] Article 12. A composite material layup system as described in Clause 11, wherein the layup tool 150 is molded and configured to produce a fuselage barrel section 390.

[0134] Clause 13. A method for manufacturing a barrel-shaped composite layup, The process involves moving multiple head operating mechanisms 200 along multiple rails 118 arranged parallel to the periphery of a barrel-shaped layup tool 150 having a tool surface 154 and a tool axis 152, wherein each rail 118 is oriented substantially parallel to the tool axis 152, and each head operating mechanism 200 moves multiple head operating mechanisms 200 that support an automatic fiber placement (AFP) head. Using the AFP head 220, a course 250 of the layup material 252 is laid on the tool surface 154 or on the previously laid layup material 252, both when the layup tool 150 is fixed and while it is rotating around the tool axis 152, thereby creating a green layup. While the AFP heads 220 lay the course 250 of the layup material 252 on the layup tool 150, the head operating mechanism 200 is used to maintain the AFP heads 220 around the tool surface 154 in a circumferentially spaced relationship with respect to one another, wherein the total number of AFP heads 220 includes the maximum number of AFP heads 220 that can be positioned circumferentially on the layup tool 150 while laying the course 250 of the layup material 252 on the layup tool 150, such that they are longitudinally aligned with each other without interfering with each other. Methods that include...

[0135] Article 14. The method according to clause 13, further comprising using a head operating mechanism 200 to adjust the head speed of one or more AFP heads 220 so as to stagger the AFP heads 220 longitudinally, in order to prevent interference between the AFP heads 220 during movement along the tapered section 158 of the layup tool 150.

[0136] Article 15. The method according to clause 13 or 14, further comprising using a head operating mechanism 200 to maintain the AFP heads 220 in a longitudinally aligned position relative to each other while the layup tool 150 is moved along its length.

[0137] Article 16. The method according to any one of the clauses 13 to 15, further comprising using at least one head operating mechanism 200 to replace an AFP head 220 currently attached to a head operating mechanism 200 with an alternative AFP head 134 supported on a head stand 132 of a head change station located at one of the ends of a layup tool 150.

[0138] Article 17. Using fiber bundle sensors 234 mounted on each AFP head of the AFP head 220, layup data 270 of the layup material 252 immediately after it is laid by the AFP head is captured. In processor 362, the layup data 270 is received along with the capture position of the layup data 270. The processor 362 is used to detect anomalies 300 in the green state layup by comparing the layup data 270 with reference data 380 which includes examples of various anomalies 300 that may occur in the green state layup 264. To enable the physical localization of each anomaly 300 for possible rework, the processor 362 is used to identify the anomaly type of each anomaly 300 in the layup data 270 based on comparison, and to determine the position of each anomaly 300 on the green state layup 264 based on the capture position in the layup data 270. The method described in any one of the clauses 13 to 16, further including the method described in any one of the clauses 13 to 16.

[0139] Clause 18. Using processor 362, the following: The method involves constructing a green state digital model 340 of a green state layup 264, wherein the green state digital model 340 includes anomalies 300 identified in the layup data 270. The characteristics of each anomaly 300 are compared with a database of design criteria 382 that defines the maximum and / or minimum values ​​for each anomaly (300) characteristic for each anomaly type to determine whether each anomaly 300 in the green state digital model 340 is acceptable or unacceptable. The method described in Clause 17, further including the following:

[0140] Clause 19. Using processor 362, the following: The inspection measurement value 348 obtained from the non-destructive testing of the green state layup 264 is received, and the inspection measurement value 348 is compared with the value of the reference layup, thereby detecting an anomaly 300 in the green state layup. To construct a non-destructive inspection (NDI) digital model 344 of a green state layup 264, including anomalies 300 detected via inspection measurement values ​​348, By comparing the Green State Digital Model 340 with the NDI Digital Model 344, the Green State Digital Model 340 is validated, and any differences between the Green State Digital Model 340 and the NDI Digital Model 344 are identified. The method described in Clause 18, further including the following:

[0141] Clause 20. Using processor 362, the following: Recording one or more processing parameters associated with manufacturing a green state layup 264, wherein the processing parameters are Instrument parameters associated with AFP head 220, Material parameters associated with the layup material 252 supplied by the AFP head 220 Record one or more processing parameters, including at least one of the following: The processing parameters, The time required to produce a green layup, Anomaly in a green layup: 300 To correlate with at least one of the following, For every subsequent manufactured green state layup of 264, Reduction in completion time, and Reduction in the quantity and / or type of abnormal 300 To obtain this, adjust one or more processing parameters, To do The method described in Article 19, further including the method described in Article 19.

[0142] A person skilled in the art, who understands the merits of the teachings presented in the preceding description and the associated drawings, will be able to recall several variations and other modifications and examples of the present disclosure. The modifications and examples described herein are illustrative and are not intended to be limiting or exhaustive. Certain terms are used herein, but they are used in a general and descriptive sense only and are not intended to be limiting. In addition to those enumerated herein, functionally equivalent methods and apparatus that fall within the scope of the present disclosure are possible from the preceding description. Such variations and modifications are intended to fall within the scope of the appended claims. The present disclosure is limited only by the entire scope of the appended claims and the equivalents to which such claims are granted.

Claims

1. A manufacturing system (100), comprising: a plurality of rails (118) arranged in parallel relation to one another around a periphery of a barrel-shaped layup tool (150), each rail (118) being oriented generally parallel to a tool axis (152) of said layup tool; a plurality of head operating mechanisms (200) each coupled to a dedicated rail among the rails (118), the plurality of head operating mechanisms (200) being movable along the length direction of the corresponding rail (118); a plurality of automated fiber placement (AFP) heads (220) each coupled to a dedicated head operating mechanism (200) among the head operating mechanisms (200); Equipped with a head operating mechanism configured to position the AFP heads in a circumferentially spaced-apart relationship relative to one another around the tool surface of the layup tool, the total number of AFP heads comprising a maximum number of AFP heads that can be positioned circumferentially in longitudinal alignment with one another at a point of maximum circumference on the layup tool while the plurality of AFP heads lay courses of layup material against the tool surface or previously laid layup material, thereby creating a barrel-shaped green state layup, when the layup tool is fixed and during rotation of the layup tool about the tool axis.

2. 2. The manufacturing system of claim 1, wherein the head operating mechanism is configured to adjust head speeds of at least some of the AFP heads to longitudinally stagger the AFP heads relative to one another to avoid interference between the AFP heads while moving along the tapered section of the layup tool.

3. 3. The manufacturing system (100) of claim 1 or 2, wherein the head operating mechanism (200) is configured to maintain the multiple AFP heads (220) in longitudinal alignment (224) with one another during movement along the length of the layup tool (150).

4. the plurality of AFP heads (220) includes n AFP heads (220); The manufacturing system (100) of claim 1, wherein the plurality of head handling mechanisms (200) are configured to circumferentially space the plurality of AFP heads (220) from one another by approximately 360 degrees / n.

5. 10. The manufacturing system (100) of claim 1, wherein each head handling mechanism (200) is a six-axis arm that allows movement of each AFP head (220) about six axes.

6. a head change station (130) located at one of opposite ends of the layup tool (150) and supporting one or more alternate AFP heads (134), each alternate AFP head (134) supported on a head stand (132); 2. The manufacturing system (100) of claim 1, wherein each head operating mechanism (200) is configured to release an AFP head (220) on an empty head stand (132) and engage an alternative AFP head (134) supported by another head stand (132).

7. a plurality of fiber bundle sensors (234), each attached to one of the plurality of AFP heads (220), the fiber bundle sensor (234) of each AFP head (220) configured to capture layup data (270) related to the layup material (252) immediately after it has been laid by the AFP head (220); a processor (362) comprising: receiving the layup data (270) along with a capture location of the layup data (270); detecting anomalies (300) in the green state layup (264) by comparing the layup data (270) with reference data (380) containing examples of various anomalies (300) that may potentially occur in the green state layup (264); identifying an anomaly type for each anomaly (300) in the layup data (270) based on the comparison, and determining a location of each anomaly (300) in the green state layup (264) based on the captured location of the layup data (270) to enable physical location of each anomaly (300) for possible rework; a processor (362) configured to: The manufacturing system (100) of claim 1, further comprising:

8. The processor (362) constructing a green-state digital model (340) of the green-state layup (264), the green-state digital model (340) including the anomalies (300) identified in the layup data (270); determining whether each anomaly (300) in the green state digital model (340) is acceptable or unacceptable by comparing the characteristics of each anomaly (300) to a database of design criteria (382) that define maximum and / or minimum values ​​for each anomaly characteristic for each anomaly type; The manufacturing system (100) of claim 7, configured to:

9. The processor (362) receiving inspection measurements (348) obtained from non-destructive testing of the green state layup (264) and comparing the inspection measurements (348) with values ​​from a reference layup, thereby detecting anomalies (300) in the green state layup (264); constructing a non-destructive-inspection (NDI) digital model (344) of the green state layup (264) including the anomalies (300) detected via the inspection measurements (348); comparing the green state digital model (340) with the NDI digital model (344) to validate the green state digital model (340) and identify any discrepancies between the green state digital model (340) and the NDI digital model (344); The manufacturing system (100) of claim 8, configured to:

10. The processor (362) and recording one or more process parameters associated with producing the green state layup (264), the process parameters comprising: instrument parameters associated with the AFP head (220); Material parameters associated with the layup material (252) applied by the AFP head (220). recording one or more process parameters, including at least one of: The processing parameters are the completion time required to produce said green state layup (264); Anomalies (300) in the green state layup (264) and correlating with at least one of For each subsequent green state layup (264) produced, a reduction in said completion time; and Reduction in the amount of anomalies (300) adjusting one or more processing parameters to obtain at least one of: The manufacturing system (100) of claim 9, configured to:

11. 1. A method of manufacturing a barrel-shaped composite layup, comprising: moving a plurality of head operating mechanisms (200) respectively along a plurality of rails (118) disposed in parallel relation around a barrel-shaped layup tool (150) having a tool surface (154) and a tool axis (152), each rail (118) being oriented generally parallel to the tool axis (152); moving a plurality of head handling mechanisms (200), each head handling mechanism (200) supporting an automatic fiber placement (AFP) head; using the AFP head (220) to lay courses (250) of layup material (252) against the tool surface (154) or previously laid layup material (252) while the layup tool (150) is stationary and rotating about the tool axis (152), thereby creating a green state layup (264); maintaining the AFP heads (220) in circumferentially spaced-apart relationship relative to one another around the tool surface (154) using the head operating mechanism (200) while the AFP heads (220) lay courses (250) of layup material (252) on the layup tool (150), wherein the total number of AFP heads (220) comprises a maximum number of AFP heads (220) that can be circumferentially positioned in longitudinal alignment (224) with one another at a maximum circumferential point on the layup tool (150) without interfering with one another while laying the courses (250) of layup material (252) on the layup tool (150); A method comprising:

12. 12. The method of claim 11, further comprising adjusting head speeds of one or more of the AFP heads (220) using the head operating mechanism (200) to longitudinally stagger (222) the AFP heads (220) to prevent interference between the AFP heads (220) during movement along the tapered section (158) of the layup tool (150).

13. 13. The method of claim 11 or 12, further comprising using the head operating mechanism (200) to maintain the AFP heads (220) in longitudinal alignment (224) with one another during movement along the length of the layup tool (150).

14. 12. The method of claim 11, further comprising using at least one head operating mechanism (200) to replace an AFP head (220) currently attached to the head operating mechanism (200) with an alternative AFP head (134) supported on a head stand (132) of a head change station (130) located at one of the ends of the layup tool (150).

15. capturing layup data (270) of the layup material (252) immediately after it is laid by the AFP heads (220) using a fiber bundle sensor (234) mounted on each AFP head (220) of the AFP heads (220); receiving, at a processor (362), the layup data (270) along with a capture location of the layup data (270); detecting anomalies (300) in the green state layup (264) by comparing the layup data (270) with reference data (380) containing examples of various anomalies (300) that may potentially occur in the green state layup (264), using the processor (362); using the processor (362) to identify an anomaly type for each anomaly (300) in the layup data (270) based on the comparison and to determine a location of each anomaly (300) on the green state layup (264) based on the captured location of the layup data (270) to enable physical location of each anomaly (300) for possible rework; Using the processor (362), constructing a green-state digital model (340) of the green-state layup (264), the green-state digital model (340) including the anomalies (300) identified in the layup data (270); and determining whether each anomaly (300) in the green state digital model (340) is acceptable or unacceptable by comparing the characteristics of each anomaly (300) to a database of design criteria (382) that define maximum and / or minimum values ​​for each anomaly characteristic for each anomaly type; and The method of claim 11 further comprising:

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