Automated fiber placement of plies with staggering

Abstract

To provide a method, an apparatus, a composite manufacturing system and a computer program product for designing a composite hollow body.SOLUTION: The method comprises: selecting ply layers for a hollow composite body, where the ply layers comprise courses having course edges; and, for a design of the hollow composite body, positioning the course edges between the ply layers throughout the hollow composite body, and creating staggering of the course edges between the ply layers for the design of the hollow composite body.SELECTED DRAWING: Figure 6

Description

[Technical field]

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

[0002] Vehicles such as submarines and aircraft are increasingly being designed and manufactured using composite materials. Composite materials are used in submarines. For example, submarine hulls, bow domes, periscope fairings, and other components can be manufactured using composite materials. Submarine hulls made from composite materials can withstand large compressive pressures. Additionally, the use of composite materials reduces problems with corrosion.

[0003] In another example, composite materials are used in aircraft to reduce the weight of the aircraft, which improves performance characteristics such as payload and fuel efficiency, and also provides longer service life for various components of the aircraft.

[0004] A composite material can be a strong, lightweight material made by combining two or more functional components. For example, a composite material can include reinforcing fibers bound with a polymer resin matrix. The fibers can be unidirectional or in the form of a woven fabric or cloth. The fibers and resin are arranged and cured to form a composite structure.

[0005] Manufacturing composite parts, such as hollow composite bodies for submarine hulls or aircraft fuselages, can be challenging. For example, achieving a desired level of smoothness for a hollow composite body is more difficult than one would like.

[0006] It would therefore be desirable to have a method and apparatus that takes into account at least some of the above-mentioned problems, as well as other possible problems. For example, it would be desirable to have a method and apparatus that overcomes the technical problems associated with manufacturing hollow composite bodies. Summary of the Invention

[0007] An embodiment of the present disclosure provides a method for designing a hollow composite body. A computer system selects ply layers for a hollow composite body. The ply layers include courses having course edges. The computer system arranges the course edges between the ply layers throughout the hollow composite body and creates a staggering of the course edges between the ply layers for the hollow composite body design. Other exemplary embodiments provide an apparatus, computer system, and computer program product for designing a hollow composite body.

[0008] An embodiment of the present disclosure provides a method for designing a hollow composite body. A method for designing a hollow composite body, wherein a computer system selects a ply layer in a ply layer in a hollow composite body design to form a selected ply layer. The computer system performs course edge staggering between the selected ply layer in the ply layer and other ply layers in the ply layer in an iterative manner, resulting in increasing course edge staggering between the ply layers, which is used in a next iteration with another selected ply layer until a desired level of staggering occurs. Other exemplary embodiments provide an apparatus, computer system, and computer program product for designing a hollow composite body.

[0009] According to an aspect of the present disclosure, a method for designing a hollow composite body includes: selecting, by a computer system, a ply layer of a hollow composite body, the ply layer comprising a course having a course edge; placing, by the computer system, course edges between the plies throughout the hollow composite body and creating a staggering of the course edges between the plies for the hollow composite body design.

[0010] Advantageously, the method includes the steps of: placing, by a computer system, course edges between plies throughout the hollow composite body to create a staggering of course edges between plies for a hollow composite body design; A method includes rotating, by a computer system, selected ply layers in the ply layers so that the course edges have more staggering between the ply layers to create a hollow composite body design.

[0011] Preferably, the method includes the steps of: placing, by a computer system, course edges between plies throughout the hollow composite body to create staggering of course edges between plies for a hollow composite body design; and varying, by a computer system, a width of the courses in the selected ply layers so that the course edges have more staggering between the ply layers.

[0012] Preferably, the method further comprises varying, by the computer system, a width of the courses in the selected ply layers such that the course edges in the selected ply layers have more staggering of the course edges between the ply layers; adding, by the computer system, a number of tows to a first course in the selected ply layer; and removing, by the computer system, some of the tows from a second course in the selected ply layer, where the course edges in the selected ply layer have more staggering of the course edges between the ply layers.

[0013] Preferably, the method further comprises adding, by the computer system, a number of tows to a first course in the selected ply layer; selecting, by a computer system, a first course having a first course edge in the selected ply layer that has minimal staggering from other course edges in the other ply layers; adding, by the computer system, a number of tows to the selected first course; The method includes:

[0014] Preferably, the method further comprises removing by the computer system some tows from the second course in the selected ply layer; selecting, by the computer system, a second course having a second course edge in the selected ply layer that has a maximum staggering from another of the course edges in the other ply layers; removing some of the tows from the selected second course; The method includes:

[0015] Preferably, the method further comprises the steps of: placing, by a computer system, course edges between plies throughout the hollow composite body to create staggered course edges between plies in the design of the hollow composite body; rotating selected plies in the ply layers by a computer system to increase course edge staggering between the plies; in response to rotating the selected ply layer not producing a desired level of course edge staggering between the ply layers, alternating, by the computer system, some of the tows between the courses of the selected ply layer to increase course edge staggering at the course edges of other ply layers; The method includes:

[0016] Preferably, the method is one in which, in response to the absence of the desired level of staggering, the computer system repeats the rotating and alternating steps for a next ply layer in the ply layers.

[0017] Preferably, the method further comprises the steps of: locating, by a computer system, course edges between ply layers throughout the hollow composite body to generate a staggering of course edges between ply layers for a hollow composite body design; selecting, by the computer system, a next ply layer in the ply layers for processing; rotating a subsequent ply layer by a computer system to increase staggering of course edges between the plies; responsive to rotating the next ply layer not achieving a desired level of course edge staggering between the ply layers, alternating some of the tows between the courses of the next ply layer to increase course edge staggering between the next ply layer; repeatedly selecting the next ply layer, rotating the next ply layer, and alternating some of the tows between the courses of the next ply layer by the computer system until all of the ply layers have been processed; The method further comprises:

[0018] Preferably, the method comprises the steps of: laying up a composite material in a course using a design for creating plies in a hollow composite body; curing the ply layers laid up using the design to create a hollow composite body; wherein the staggering of the course edges between the plies results in reducing undesirable misalignment of the hollow composite body occurring in the plies.

[0019] Preferably, the method further comprises the steps of: laying up the composite material in courses using a design for building plies into a hollow composite body; The method includes laying up tows in courses using a design to create ply layers in a hollow composite body.

[0020] Preferably, the method is one in which there is no overlap between course edges for the courses across the entire ply layer.

[0021] Preferably, the method is one in which the overlap between course edges for the courses occurs every nth layer throughout the ply layers.

[0022] Preferably, the method is one in which the ply layers have the same orientation selected from the group including 0 degrees and 45 degrees.

[0023] Preferably, the method is one in which course edges between the courses of the ply layers form at least one of a gap, an overlap, and an abutted edge.

[0024] Preferably, the method is one wherein the hollow composite body is selected from the group comprising a submersible hull, a submarine hull, a wing, a rocket, and a fuselage.

[0025] According to another aspect of the present disclosure, a method for designing a hollow composite body includes: selecting, by a computer system, a ply layer among the ply layers in a hollow composite body design to form the selected ply layer; and staggering the course edges between a selected ply layer in the ply layers and other ply layers in the ply layers in an iterative manner by the computer system, resulting in increasing staggering of the course edges between the ply layers, which is used in a next iteration with another selected ply layer until a desired level of staggering is produced.

[0026] Advantageously, the method comprises staggering the course edges in an iterative manner by a computer system between selected plies in the ply layers and other plies in the ply layers, rotating the selected ply layer by a computer system to result in increased staggering of course edges between the selected ply layer and course edges in the other ply layers; repeating the rotation of each ply layer within the other ply layers by the computer system based on the increased staggering until a desired level of staggering occurs; The method includes:

[0027] Preferably, the method further comprises staggering the course edges between selected plies in the ply layers and other plies in the ply layers in an iterative manner by a computer system; Varying, by a computer system, a width of the courses in the selected ply layer that results in increased staggering of course edges between the selected ply layer and other ply layers; repeating the change in width of the course by the computer system for each other ply layer based on the staggering caused by the width change until a desired level of staggering is achieved; The method includes:

[0028] Preferably, the method further comprises staggering the course edges between selected plies in the ply layers and other plies in the ply layers in an iterative manner by a computer system; rotating, by a computer system, the selected ply layer to result in increased staggering between the selected ply layer and course edges in other ply layers; Varying, by the computer system, a width of the courses in the selected ply layer to result in increased staggering of course edges between the selected ply layer and other ply layers; repeating the rotation and alteration by the computer system for each of the other ply layers until a desired level of staggering is achieved; The method includes:

[0029] Preferably, the method is one in which the selected ply layer is a newly added ply layer.

[0030] Preferably, the method is one in which the selected ply layer is an existing ply layer within the ply layers.

[0031] According to another aspect of the present disclosure, a composite manufacturing system includes: A computer system; a composite structure manager in a computer system; The composite structure manager comprises: For a hollow composite body, selecting a ply layer including a course having a course edge; For hollow composite body designs, locating course edges between plies throughout the hollow composite body to create course edge staggering between plies; It works like this.

[0032] Advantageously, the system comprises: The composite structure manager further comprises: Manufacturing equipment is controlled to lay up the composite material in courses using designs to create ply layers for the hollow composite body.

[0033] Preferably, the system further comprises determining, for a hollow composite body design, whether or not a course edge is located between plies throughout the hollow composite body to create a staggered course edge between the plies; The system includes rotating selected ply layers in a ply stack so that the course edges have more staggering between the ply layers to create a hollow composite body design.

[0034] Preferably, the system further comprises determining, for a hollow composite body design, whether or not a course edge is located between plies throughout the hollow composite body to create a staggered course edge between the plies; The system involves varying the width of the courses in selected ply layers so that the course edges have more staggering between the ply layers.

[0035] Preferably, the system is adapted to vary a width of the courses in the selected ply layer such that the course edges in the selected ply layer have more staggering of the course edges between the ply layers; adding a number of tows to a first course in the selected ply layer; and removing some of the tows from a second course in the selected ply layer, the course edges in the selected ply layer having more course edge staggering between the ply layers.

[0036] Preferably, the method further comprises the steps of: adding some tows to a first course in the selected ply layer; selecting a first course having a first course edge in the selected ply layer that has minimal staggering from other course edges in the other ply layers; adding a number of tows to the selected first course; The system includes:

[0037] Preferably, the system further comprises removing some tows from a first course in the selected ply layer; selecting a second course having a second course edge in the selected ply layer that has a maximum amount of staggering from another of the course edges in the other ply layers; removing some of the tows from the selected second course; The system includes:

[0038] Preferably, the system includes a step of: locating course edges between plies throughout the hollow composite body to create staggered course edges between plies in the design of the hollow composite body; rotating selected plies in the ply layers to increase course edge staggering between the ply layers; responsive to rotating the selected ply layer not producing a desired level of course edge staggering between the ply layers, alternating some of the tows between the courses of the selected ply layer to increase course edge staggering at the course edges of other ply layers; The system includes:

[0039] Preferably, the system is one that, in response to the absence of the desired level of staggering, repeats the rotating and alternating steps for the next ply layer in the ply layers.

[0040] Preferably, the system further comprises: locating inter-ply course edges throughout the hollow composite body to create inter-ply course edge staggering for a hollow composite body design; selecting a next ply layer in the ply layers for processing; Rotating subsequent plies to increase staggering of course edges between plies; responsive to rotating the next ply layer not achieving a desired level of course edge staggering between the ply layers, alternating some of the tows between the courses of the next ply layer to increase course edge staggering between the ply layers; repeating the steps of selecting the next ply layer, rotating the next ply layer, and alternating some of the tows between courses of the next ply layer until all of the ply layers have been processed; The system further includes:

[0041] Preferably, the system further includes laying up the composite material in courses using the design for creating ply layers for the hollow composite body.

[0042] According to yet another aspect of the present disclosure, a composite manufacturing system includes: A computer system; a composite structure manager in a computer system; The composite structure manager comprises: selecting a ply layer among the ply layers for a hollow composite body design to form a selected ply layer; and staggering the course edges between a selected ply layer in the ply layer and other ply layers in the ply layer in an iterative manner, resulting in increasing staggering of the course edges between the ply layers, which is used in the next iteration with another selected ply layer until the desired level of staggering is achieved.

[0043] According to yet another aspect of the present disclosure, there is provided a computer program product for designing a hollow composite body, the computer program product comprising a computer readable storage medium having program instructions embodied therein, the program instructions being executable by a computer system, the computer program product comprising: A method for selecting a ply layer for a hollow composite body, the ply layer comprising courses having course edges; A method for designing a hollow composite body, the method including arranging course edges between plies throughout the hollow composite body to create staggered course edges between plies; is executed on the computer system.

[0044] According to yet another aspect of the present disclosure, there is provided a computer program product for designing a hollow composite body, the computer program product comprising a computer readable storage medium having program instructions embodied therein, the program instructions being executable by a computer system, the computer program product comprising: selecting a ply layer from among the ply layers in a hollow composite body design to form a selected ply layer; A computer system is caused to execute a method for staggering course edges between a selected ply layer in the ply layers and other ply layers in the ply layers in an iterative manner, resulting in increasing staggering of the course edges between the ply layers, which is used in a next iteration with another selected ply layer until a desired level of staggering is produced.

[0045] These features and functions can be achieved independently in various embodiments of the present disclosure or can be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.

[0046] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims, however the illustrative embodiments, together with preferred modes of use, further objects and features thereof, will best be understood by reference to the following detailed description of the illustrative embodiments of the present disclosure taken in conjunction with the accompanying drawings. [Brief description of the drawings]

[0047] [Figure 1] 1 is an illustration of a network of data processing systems in which an illustrative embodiment may be implemented. [Diagram 2] FIG. 1 is an illustration of a block diagram of a composite manufacturing environment in accordance with an illustrative embodiment. [Diagram 3] 1 is an illustration of a cross-sectional view of a ply layer in a design for a submersible hull in accordance with an illustrative embodiment; [Figure 4] 1 is an illustration of a cross-sectional view of a rotated ply layer in a design for a submersible hull in accordance with an illustrative embodiment; [Diagram 5] 1 is an illustration of a rotated course and steered tow of ply layers in a design for a submersible hull in accordance with an illustrative embodiment; [Figure 6] FIG. 1 is an illustration of a flow diagram of a process for designing a hollow composite body in accordance with an illustrative embodiment; [Figure 7] 1 is a flowchart of a process for locating a course edge in accordance with an illustrative embodiment; [Figure 8] 1 is a flowchart of a process for locating a course edge in accordance with an illustrative embodiment; [Figure 9] FIG. 10 is a flow diagram of a process for varying course width in accordance with an illustrative embodiment; [Figure 10] FIG. 10 is a flow diagram of a process for varying course width in accordance with an illustrative embodiment; [Figure 11] FIG. 10 is a flow diagram of a process for varying course width in accordance with an illustrative embodiment; [Figure 12] 1 is a flowchart of a process for locating a course edge in accordance with an illustrative embodiment; [Figure 13] 1 is a flowchart of a process for locating a course edge in accordance with an illustrative embodiment; [Figure 14] FIG. 1 illustrates a flow diagram of a process for manufacturing a hollow composite body in accordance with an illustrative embodiment. [Figure 15] FIG. 1 is an illustration of a flow diagram of a process for designing a hollow composite body in accordance with an illustrative embodiment; [Figure 16] FIG. 10 is an illustration of a flow diagram of a process for staggering course edges in an iterative manner in accordance with an illustrative embodiment; [Figure 17] FIG. 10 is an illustration of a flow diagram of a process for staggering course edges in an iterative manner in accordance with an illustrative embodiment; [Figure 18] FIG. 10 is an illustration of a flow diagram of a process for staggering course edges in an iterative manner in accordance with an illustrative embodiment; [Figure 19A] FIG. 10 is an illustration of a flow diagram of a process for creating a design for a hollow composite body in accordance with an illustrative embodiment; [Figure 19B] FIG. 10 is an illustration of a flow diagram of a process for creating a design for a hollow composite body in accordance with an illustrative embodiment; [Figure 20] FIG. 13 is an illustration of a ply layer location according to an illustrative embodiment. [Figure 21] 1 is an illustration of a block diagram of a data processing system in accordance with an illustrative embodiment; [Figure 22] FIG. 1 is a block diagram of a product management system in accordance with an illustrative embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] The exemplary embodiments recognize and take into account one or more different considerations. For example, the exemplary embodiments recognize and take into account that the design and manufacture of a hollow composite body may involve the presence of gaps between course edges of the courses in the ply layers. The exemplary embodiments recognize and take into account that overlap gaps between courses through the ply layers of a hollow composite body may cause wrinkles to form when curing a light emitting composite material for the hollow composite body.

[0049] The illustrative embodiments recognize and take into account that current techniques for creating hollow composite body designs do not adequately control course-to-course staggering through ply layers. The illustrative embodiments recognize and take into account that current designs using starting points can result in localized overlap of plies as the circumference of a cylindrical hollow composite body increases. The illustrative embodiments recognize and take into account that current techniques only consider the previous ply and do not account for overlap between course edges throughout the entire ply layer of the composite hollow body.

[0050] Thus, the illustrative embodiments provide a method, apparatus, system, and computer program product for manufacturing a composite hollow body having a desired level of staggering between course edges throughout the ply layers. In an illustrative example, the staggering is performed in an iterative manner to enable convergence and optimize the design for laying up composite material in courses in the ply layers of the hollow composite body.

[0051] In one exemplary embodiment, course edges are identified throughout the ply layers of a composite hollow body. Alignment of the course edges is staggered throughout the ply layers. At least one of rotating the ply layers or changing the course widths of the courses within the ply layers can be performed to increase the staggering of the course edges throughout the ply layers. This type of adjustment can be repeated for each ply layer throughout the thickness of the composite hollow body to obtain a composite hollow body design with more staggering, which can meet a desired tolerance for the staggering of the course edges of the composite hollow body.

[0052] Referring now to the figures, and in particular to Figure 1, an illustration of a network of data processing systems in which exemplary embodiments may be implemented is shown. Network data processing system 100 is a network of computers in which exemplary embodiments may be implemented. Network data processing system 100 contains network 102, which is the medium used to provide communications links between various devices and computers connected together within network data processing system 100. Network 102 may include connections, such as wired, wireless communications links, or fiber optic cables.

[0053] In the illustrated embodiment, server computer 104 and server computer 106 are connected to network 102 along with storage unit 108. Additionally, client system 110 is a physical hardware system connected to network 102. As illustrated, client system 110 includes client computer 112, client computer 114, and client computer 116. Client system 110 may be, for example, a computer, a workstation, a network computer, a data processing system, a building, a warehouse, a manufacturing floor, or any other structure implementing a data processing system. In the illustrated embodiment, server computer 104 provides information (such as boot files, operating system images, and applications) to client system 110. Additionally, client system 110 may include other types of client devices (such as mobile phone 118, tablet computer 120, and manufacturing facility 122). In this exemplary embodiment, server computer 104, server computer 106, storage unit 108, and client system 110 are network devices connected to network 102, and network 102 is the communication medium for these network devices. Some or all of the client systems 110 may form an “Internet of Things (IoT)” in which these physical devices are connected to network 102 and may exchange information with each other through network 102 .

[0054] In this example, client system 110 is a client to server computer 104. Network data processing system 100 may include additional server computers, client computers, and other devices not shown. Client system 110 is connected to network 102 using at least one of a wired connection, a fiber optic connection, or a wireless connection.

[0055] Program instructions located within network data processing system 100 may be stored on a computer recordable storage medium and downloaded for use to a data processing system or other device. For example, program instructions may be stored on a computer recordable storage medium of server computer 104 and downloaded over network 102 to client system 110 for use by client system 110.

[0056] In the depicted example, network data processing system 100 is the Internet with network 102, which represents a worldwide collection of networks and gateways that use the TCP / IP (Transmission Control Protocol / Internet Protocol) suite of protocols to communicate with one another. At the heart of the Internet is a backbone of high-speed data communication lines between major nodes or host computers consisting of thousands of commercial, governmental, educational, and other computer systems that route data and messages. Of course, network data processing system 100 may be implemented using a number of different types of networks. For example, network 102 may be comprised of at least one of the Internet, an intranet, a local area network (LAN), a metropolitan area network (MAN), or a wide area network (WAN). FIG. 1 is intended as an example, and not as an architectural limitation for the different illustrative embodiments.

[0057] As used herein, "a number of" when used in reference to an item means one or more of the item. For example, "a number of different types of networks" means one or more different types of networks.

[0058] Additionally, the phrase "at least one of" when used with enumerated items means that various combinations of one or more of the enumerated items may be used and that only one of each enumerated item may be required. In other words, "at least one of" means that any combination of items and any number of items from the enumeration may be used, and not all of the enumerated items are required. An item may be a specific object, article, or category.

[0059] For example, and without limitation, "at least one of item A, item B, and item C" may include "item A," "item A and item B," or "item B." This example could also include "item A, item B, and item C," or "item B and item C." Combinations of any of these items may of course also be present. In some illustrative examples, "at least one of" may be, by way of example and without limitation, "two items A, one item B, and ten items C," "four items B, and seven items C," or other suitable combinations.

[0060] In this illustrative example, composite part manager 130 may create design 132 for a composite hollow body, such as a submarine hull or an aircraft fuselage, at manufacturing facility 122. Creation of design 132 by composite part manager 130 may be performed by input 134 received from user 136 at client computer 112. For example, user 136 may provide specifications in input 134 for design 132. The specifications may include, for example, the number of ply layers, compressive strength, dimensions, ply orientation, and other specifications for the composite hollow body.

[0061] In this illustrative example, design 132 for a composite hollow body may include a ply layer 140 having courses 142 with course edges 144. Composite part manager 130 may assist in creating design 132 or optimizing design 132 by reducing overlap between course edges 144 at different ply layers in ply layer 140.

[0062] In other words, composite part manager 130 may increase the staggering of ply layers 140 in design 132 in a manner that reduces undesirable inconsistencies such as wrinkles, dents, or other undesirable inconsistencies that may be outside of the tolerances of design 132. In this illustrative example, a tolerance may be specified in design 132 for input 134, and an undesirable inconsistency is a inconsistency that is outside of the tolerances for design 132.

[0063] Composite part manager 130 may use design 132 to send instructions 150 to manufacturing facility 122 for manufacturing hollow composite body 152. In this illustrative example, instructions 150 may be at least one of program code, data, design 132, or other information that may be used by manufacturing facility 122 to manufacture hollow composite body 152.

[0064] With reference now to Figure 2, a block diagram of a composite manufacturing environment is depicted in accordance with an illustrative embodiment. In this illustrative example, composite manufacturing environment 200 includes components that may be implemented in hardware (e.g., the hardware depicted in network data processing system 100 in Figure 1).

[0065] As shown, composite manufacturing system 202 may generate a design 204 for a composite part 206. Composite part 206 may take the form of a hollow composite body 208. Hollow composite body 208 may take a number of different forms. For example, hollow composite body 208 may be selected from the group including a submersible hull, a submarine hull, a wing, a rocket, an aircraft fuselage, and a composite structure having a hollow portion. In this illustrative example, hollow composite body 208 may have a cross-section in the shape of a circle, an ellipse, a racetrack, a wing, a teardrop, or any other suitable cross-sectional shape.

[0066] In this illustrative example, composite manufacturing system 202 includes a computer system 210 and a composite structure manager 212. Composite structure manager 212 is disposed within computer system 210.

[0067] Composite Structure Manager 212 may be implemented in software, hardware, firmware, or a combination thereof. If software is used, the operations performed by Composite Structure Manager 212 may be implemented as program code configured to run on hardware, such as a processor unit. If firmware is used, the operations performed by Composite Structure Manager 212 may be implemented in program code and data that may be stored in persistent memory and executed on a processor unit. If hardware is employed, the hardware may include circuitry that operates to perform the operations in Composite Structure Manager 212.

[0068] In an exemplary embodiment, the hardware may take the form of at least one selected from a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or any other suitable type of hardware configured to perform certain operations. When a programmable logic device is used, the device may be configured to perform certain operations. The device may be later reconfigured or may be permanently configured to perform certain operations. Programmable logic devices include, for example, programmable logic arrays, programmable array logic, field programmable logic arrays, field programmable gate arrays, and other suitable hardware devices. Additionally, the processing may be implemented in organic components integrated with inorganic components and may be entirely composed of non-human organic components. For example, the processing may be implemented as circuitry in organic semiconductors.

[0069] Computer system 210 is a physical hardware system and includes one or more data processing systems. When multiple data processing systems are present in computer system 210, the data processing systems communicate with each other using a communication medium. The communication medium may be a network. The data processing systems may be selected from at least one of a computer, a server computer, a tablet computer, or any other suitable data processing system.

[0070] As shown, the computer system 210 includes a number of processor units 214 that can execute program code 216 to implement processing in an exemplary embodiment. As used herein, a processor unit of the number of processor units 214 is a hardware device, consisting of hardware circuitry (such as circuitry on an integrated circuit that responds to and processes instructions and program code to operate a computer). When the number of processor units 214 execute program code for processing, the number of processor units 214 are one or more processor units that may be on the same computer or on different computers. In other words, processing may be distributed among processor units on the same computer or different computers of a computer system. Furthermore, the number of processor units 214 may be the same type of processor unit or different types of processor units. For example, the number of processor units may be selected from at least one of a single-core processor, a dual-core processor, a multi-processor core, a general-purpose central processing unit (CPU), a graphics processor unit (GPU), a digital signal processor (DSP), or other types of processor units.

[0071] In these illustrative examples, design 204 is a planner specification for the construction of an object or system, such as composite part 206. Design 204 may include at least one of geometry, materials, processes of manufacture, computer numerical control instructions, or any other information used to manufacture composite part 206, such as hollow composite body 208. In these illustrative examples, design 204 is in a form usable by computer system 210. For example, design 204 may be stored in a digital form, such as an electronic file or other data structure that can be read by computer system 210. In one illustrative example, design 204 is implemented as a computer-aided design (CAD).

[0072] In this illustrative example, composite structure manager 212 may analyze and adjust design 204 for hollow composite body 208. For example, composite structure manager 212 may be operable to select ply layer 218 for hollow composite body 208. In this illustrative example, ply layer 218 comprises courses 220 having course edges 222.

[0073] In this example, one of the course edges 222 is parallel to the fibers forming the course 220. The course 220 also has a course end 223. One of the course ends 223 is an end or edge where the fibers terminate or are cut. The course edge is longer than the course end in these example examples.

[0074] In an exemplary embodiment, course edge 222 is parallel to the fibers 227 that form course 220, regardless of the orientation of course 220. For example, if course 220 has a 0 degree orientation, then the fibers of course 220 have a 0 degree orientation. Course edge 222 is parallel to the fibers that run through course 220, and also has a 0 degree orientation.

[0075] When the orientation of the course 220 is 45 degrees, the fibers 227 forming the course 220 also run in a 45 degree direction. The course edges 222 are at the 45 degree position and are parallel to the direction of the fibers 227 forming the course 220. In other words, the course edges 222 remain parallel to the fibers 227 even when the orientation of the course 220 is changed in different designs for the hollow composite body 208.

[0076] Ply layer 218 is comprised of composite material 224. These composite materials can be, for example, fiber reinforced polymers or fiber reinforced plastics that include a polymer matrix reinforced with fibers. Composite material 224 can be arranged in courses 220. In this exemplary embodiment, tows 226 can be laid up to form courses 220. A course in courses 220 is a group of laid down composite material. In an exemplary embodiment, a course includes a group of tows laid down in one operation by an automated fiber placement (AFP) machine. In another exemplary embodiment, a course includes a group of laid down composite tapes.

[0077] In this illustrative example, composite structure manager 212 places course edges 222 between ply layers 218 throughout hollow composite body 208 to create staggering 230 of course edges 222 between ply layers 218 for hollow composite body 208 design 204. The course edges 222 between courses 220 in a ply layer in ply layer 218 may form at least one of a gap, an overlap, and an abutting edge.

[0078] In this illustrative example, ply layers 218 may have the same orientation. For example, ply layers 218 may have an orientation selected from 0 degrees, 45 degrees, or other orientations. The 0 degree orientation may be courses 220 extending concentrically relative to an axis extending through the center of hollow composite body 208.

[0079] In this illustrative example, additional ply layers 228 may be present in design 204 of hollow composite body 208. Additional ply layers 228 may have a different orientation than ply layer 218. For example, ply layer 218 may have a 0 degree orientation, while additional ply layer 228 may have a 45 degree or 90 degree orientation. Additional ply layers 228 may be interspersed within ply layer 218.

[0080] In the illustrated embodiment, the level of staggering 230 of course edges 222 between ply layers 218 is reduced to an undesirable misalignment 232 during manufacture of hollow composite body 208. The undesirable misalignment 232 may be at least one of a wrinkle, a dip, a ridge, or other misalignment that falls outside the tolerance of hollow composite body 208. The tolerance is dictated by the specifications of other locations, design 204. In this exemplary embodiment, staggering 230 of course edges 222 between ply layers 218 does not include course edges 222 in the same ply layer. In other words, staggering 230 is not determined with respect to course edges 222 of the same ply layer in ply layer 218.

[0081] In one illustrative example, placement of the course edges 222 between ply layers 218 throughout the hollow composite body 208 in the design 204 may be performed in a number of different ways. For example, placement of the course edges 222 may be performed by the composite structure manager 212 rotating a selected ply layer 234 in the ply layer 218 when creating the design 204 for the hollow composite body 208 such that the course edges 222 have more staggering between the ply layers 218. The rotation of the selected ply layer 234 causes all of the course edges 222 in the selected ply layer 234 to reposition and move relative to the course edges 222 of the other ply layers 246 in the ply layer 218.

[0082] As another example of positioning, the composite structure manager 212 can vary the width 236 of the course 220 in the selected ply layer 234 such that the course edges 222 in the selected ply layer 234 have more staggering of the course edges 222 between the ply layers 218. By varying the width 236 of the course 220, adjustments of the course edges 222 and the selected ply layer 234 can be performed with greater precision compared to rotating the selected ply layer 234. In other words, by adjusting the width 236 of the course edges 222 in the selected ply layer 234, one or more course edges 222 can be moved or adjusted within the selected ply layer 234 relative to the course edges 222 of the other ply layers 246 in the ply layer 218.

[0083] In different illustrative examples, the selected ply layer 234 may be selected in any of a number of different ways. For example, the selected ply layer 234 may be the innermost ply layer and ply layer 218. In another illustrative example, the selected ply layer 234 may be the outermost ply layer in ply layer 218. For example, the selected ply layer 234 may be a newly added ply layer. In another illustrative example, the selected ply layer 234 may be an existing ply layer in ply layer 218.

[0084] In an example embodiment, the change in width 236 of the selected ply layer 234 may be performed by the composite structure manager 212 in a number of different ways. The composite structure manager 212 may add some tows 226 to a first course 238 of the selected ply layer 234. The composite structure manager 212 may remove some tows 226 from a second course 240 of the selected ply layer 234. With this change in the two courses, the course edges 222 in the selected ply layer 234 have more staggering of the course edges 222 between the ply layers 218.

[0085] The selection of the first course 238 to add some tows 226 and the selection of the second course 240 to remove some tows 226 can be performed in a number of different ways. For example, the first course 238 can be selected by the composite structure manager 212 as a course having a first course edge 242 in the selected ply layer 234 that has minimal staggering 244 from another course edge 245 in the course edge 222 in another ply layer 246 in the ply layer 218. The composite structure manager 212 can add some tows 226 to the selected first course 238.

[0086] Further, iterations do not necessarily need to be performed for each ply layer in the ply layer 218. For example, the iterative process may be stopped when the staggering 230 of the course edges 222 in the ply layer 218 meets a desired level or value of staggering 230. The desired level of staggering 230 may be based on when undesirable mismatch 232 does not occur at an undesirable level during manufacturing of the hollow composite body 208. The desired level of staggering may be performed based on empirical data of manufacturing hollow composite bodies with different levels of staggering 230. In another illustrative example, the desired level of staggering 230 may be determined by simulation.

[0087] In this example, the selection of the second tows to remove some of the tows 226 may be performed in a number of different ways. For example, the second course 240 may be selected by the composite structure manager 212 as the course having a second course edge 248 in the selected ply layer 234 that has a maximum staggering 250 from another course edge 245 in the course edge 222 in another ply layer 246. The composite structure manager 212 may remove some of the tows 226 from the selected second course 240.

[0088] In this example, tows are added and removed for two courses in the selected ply layer 234. In other example examples, tows 226 may be added or removed for some other courses in the selected ply layer 234. For example, courses may be added or removed for three courses, five courses, or some other courses in the selected ply layer 234.

[0089] In an example embodiment, at least one of rotating the selected ply layer 234 or altering the width 236 of the course 220 and selected ply layer 234 may be performed by the composite structure manager 212 to increase the staggering 230 of the course edges 222 between the ply layers 218. In other words, the staggering 230 may be increased across different ply layers in the ply 218 by the composite structure manager 212 using one or both of these operations.

[0090] The steps of rotating the ply layers and adding and removing tows 226 from the ply layers may be performed in response to a desired level of staggering 230 not being present between the course edges 222 in the hollow composite body 208 design 204: The process may be repeated for the next ply layer 252 in the ply layer 218. For example, the composite structure manager 212 may select the next ply layer 252 in the ply layer 218 for processing. The composite structure manager 212 may rotate the next ply layer to increase the staggering of the course edges 222 between the ply layers 218. In response to rotating the next ply layer 252 not resulting in a desired level of staggering 230 of the course edges 222 between the ply layers 218, the composite structure manager 212 may alternate some of the tows 226 between the courses 220 of the next ply layer 252 to increase the staggering 230 of the course edges 222 between the ply layers 218.

[0091] The composite structure manager 212 may repeat the process of selecting the next ply layer 252, rotating the next ply layer 252, and alternating several tows 226 between courses 220 of the next ply layer 252 until all of the ply layers 218 have been processed. In another example embodiment, the composite structure manager 212 may stop repeating these steps when a desired level of staggering 230 is present at the course edges 222 between the ply layers 218.

[0092] In another exemplary embodiment, the composite structure manager 212 can iteratively process the ply layers 218 to obtain a desired level of staggering 230 in the ply layers 218 of the hollow composite body 208. For example, the composite structure manager 212 can select one ply layer in the ply layers 218 in the design 204 of the hollow composite body 208 to form a selected ply layer 234. The composite structure manager 212 can then stagger the course edges 222 between the selected ply layer 234 in the ply layer 218 and other ply layers 246 in the ply layer 218 in an iterative manner. In other words, the course edges 222 in the selected ply layer 234 are staggered or repositioned with respect to the course edges 222 in the other ply layers 246.

[0093] This staggering is performed by the composite structure manager 212 to result in increased staggering of the course edges 222 between the ply layers 218. This result is used in the next iteration with another selected ply layer until the desired level of staggering is achieved. This type of iterative process may be performed to stagger the course edges 222 by rotating the selected ply layer 234, changing the width 236 of the course 220 and the selected ply layer 234, or a combination of the two.

[0094] Once design 204 is completed, composite structure manager 212 may use design 204 to manufacture hollow composite body 208. In this illustrative example, composite structure manager 212 may control manufacturing equipment 254 to manufacture hollow composite body 208. For example, manufacturing equipment 254 may include an automated fiber placement (AFP) machine 256 controlled by composite structure manager 212 to lay up composite material 224, such as tows 226, in courses 220 using design 204 to create ply layers 218 of hollow composite body 208. In this illustrative example, one course in courses 220 is formed with each pass of automated fiber placement machine 256.

[0095] In this illustrative example, manufacturing equipment 254 may also include an autoclave 258. Composite structure manager 212 may control autoclave 258 to cure ply layers 218 laid up using design 204 to create hollow composite body 208. In this illustrated example, staggering of course edges 222 between ply layers 218 results in reducing undesirable inconsistencies 232 in the hollow composite body that may occur in the ply layers.

[0096] In this illustrative example, composite structure manager 212 may use sensor system 260 to control the operation of manufacturing equipment 254. As shown, sensor system 260 is a physical hardware system that detects information about manufacturing equipment 254, the environment surrounding manufacturing equipment 254, or both to generate sensor data 262. Sensor system 260 may be comprised of at least one of a camera system, a laser sensor, an ultrasonic sensor, a light detection and ranging scanner, an encoder, a rotational encoder, a temperature sensor, a pressure sensor, an accelerometer, or other suitable type of sensor.

[0097] Sensor system 260 may generate sensor data 262 related to the operation of manufacturing equipment 254. As shown, sensor data 262 may be used by a manufacturing controller 264 in composite structure manager 212 to control the operation of manufacturing equipment 254. In this illustrative example, some or all of sensor system 260 may be associated with or connected to manufacturing equipment 254.

[0098] In this illustrative example, manufacturing controller 264 may use sensor data 262 to generate instructions 266. Instructions 266 may be used to cause manufacturing equipment 254 to perform certain manufacturing operations 268. In this illustrative example, instructions 2845 may include at least one of instructions, data, or other information capable of controlling the operation of manufacturing equipment 254.

[0099] In one exemplary embodiment, there are one or more technical solutions that overcome the technical problems associated with reducing undesirable inconsistencies in hollow composite bodies. As a result, the one or more technical solutions may provide a technical effect of reducing the time and effort required to obtain a level of staggering between course edges in ply layers to reduce undesirable inconsistencies in the manufacture of hollow composite bodies.

[0100] Computer system 210 may be configured to perform at least one of the steps, operations, or actions described in various exemplary embodiments using software, hardware, firmware, or a combination thereof. As a result, computer system 210 operates as a special-purpose computer that enables composite structure manager 212 of computer system 210 to process a desired level of staggering in the design of a composite part, such as a hollow composite body. In particular, composite structure manager 212 transforms computer system 210 into a special-purpose computer system as compared to currently available general computer systems that do not have composite structure manager 212.

[0101] In this exemplary embodiment, the use of the composite structure manager 212 in the computer system 210 integrates the process with the practical application of the composite hollow body design methodology, thereby improving the performance of the computer system 210. In other words, the composite structure manager 212 of the computer system 210 targets the practical application of the process integrated in the composite structure manager 212 of the computer system 210 that allows the design of a composite hollow body in a manner that obtains course edge staggering to reduce undesirable inconsistencies when manufacturing the composite hollow body, as compared to current techniques. In this exemplary embodiment, the composite structure manager 212 of the computer system 210 can reduce the time required to create a composite hollow body design that creates undesirable inconsistencies. The use of the composite structure manager 212 can reduce the amount of rework that may be required or avoid rework when undesirable inconsistencies occur. Additionally, the use of the composite structure manager 212 of the computer system 210 can reduce the need for personnel to go back and make revisions to the design.

[0102] The illustration of composite manufacturing environment 200 in FIG. 2 is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the illustrated components may be used. Some components may not be required. Also, blocks are illustrated to illustrate some functional components. When implemented in an illustrative embodiment, one or more of these blocks may be combined, divided into different blocks, or both combined and divided.

[0103] For example, composite structure manager 212 may be used to manufacture other composite parts in addition to hollow composite body 208. As another illustrative example, manufacturing equipment 254 may include other equipment in addition to automated fiber placement machine 256 and autoclave 258, and other types of composite materials may be used in addition to or instead of tows 226. For example, composite tapes may be laid up into courses 220 by an automated tape laying (ATL) machine of manufacturing equipment 254.

[0104] As another example, a first portion of ply layer 218 can be laid up and cured during the layup of the ply layers to produce hollow composite body 208. Then, design 204 can be used to lay up a second portion of ply layer 218 and cure. In other words, the layout and curing of the ply layers can be done all at once or sequentially.

[0105] Turning now to Figure 3, an illustration of a cross-section of ply layers in a design for a submersible hull is shown in accordance with an illustrative embodiment. In this illustrated example, submersible hull 300 design is an example of hollow composite body 208 shown in block form in Figure 2. In this illustrative example, submersible hull 300 is comprised of ply layers 302, such as ply layer 304, ply layer 306, ply layer 308, ply layer 310, and ply layer 314.

[0106] As shown, ply layer 302 is at a 0 degree orientation. The courses of ply layer 302 extend in a direction parallel to an axis 316 that extends centrally through submersible hull 300. For example, ply layer 304 is made up of courses, such as course 318 and course 320. Ply layer 306 has courses, such as course 322. In this illustrative example, each course is formed in a single pass of an automated fiber placement (AFP) machine head used to lay up composite materials, such as tows.

[0107] Each course is made up of several tows that have an orientation of 0 degrees. For example, course 318 has tow 330, tow 332, tow 334, and tow 336.

[0108] As shown, the courses have course edges with a gap between them. For example, course 318 has course edge 338 and course 320 has course edge 340 with a gap 342 between the two course edges. In other example embodiments, there may be an overlap between the course edges, or the course edges may abut or contact one another.

[0109] In this example embodiment, the course edge staggering is not at a desired level. In this example embodiment, when gaps exist between the course edges, a measurement of the ply edge staggering may be determined based on the arc of the gap measured in different ply layers relative to each other from axis 316.

[0110] For example, the staggering of these course edges results in overlap between the gaps. For example, an undesirable overlap of the gaps exists in section 341 and section 343. For example, an overlap exists between gap 342 and gap 344. As another example, an overlap exists between gap 346 and gap 348.

[0111] In this illustrative example, the staggering between the course edges or gaps may be determined based on the angle or arc between the two course edges or two gaps relative to axis 316. For example, the staggering between course edges 370 and 372 may be arc 374 or angle 376 between line 378 and line 380 that extend from axis 316.

[0112] These overlaps (e.g., at sections 341 and 343) may result in undesirable misalignment when ply layers 302 are laid up and cured to form submersible hull 300. For example, the undesirable misalignment may include one or more wrinkles (not shown) on surface 300 of submersible hull 300. Composite structure manager 212 (not shown) of FIG. 2 may be operable to increase the staggering of the course edges, which results in less overlap between gaps in different ply layers. As depicted in this example, the perimeter of each ply layer is greater than the ply layers closer to axis 316. For example, ply layer 304 has a greater perimeter than ply layer 306. In other words, the perimeter of the ply layers increases as the ply layers move radially outward away from axis 316.

[0113] Additionally, the course edges run parallel to the fibers of the tows that are laid up to form the course. For example, course edges 351 and 353 of course 355 run not only longitudinally parallel to axis 316, but also parallel to tows 357, 359, 361, and 362 that are laid up longitudinally parallel to axis 316. As depicted in this figure, course 355 has course ends 365 that are the sides of course 355 where the fibers end. In the exemplary embodiment, the course edges are of greater length and where the course ends.

[0114] 4, a cross section of a rotated ply layer in a submersible hull design is shown in accordance with an exemplary embodiment. In the illustrative examples, the same reference numbers may be used in more than one figure. Repeated use of a reference number in different figures represents the same element in the different figures.

[0115] In this exemplary embodiment, the ply layers 302 are rotated relative to one another to increase the ply edge staggering. This increased course edge staggering results in a reduction in the gap overlap as previously seen in sections 341 and 343 of FIG. 3. Although the course edge staggering has been increased, gap overlap between the course edges still remains as shown in this figure. For example, gap staggering still remains in sections 400, 402, 404, 406, 408, 410, and 412. The depth of the gap overlap has been reduced in a manner that may reduce undesirable misalignment compared to the gap overlap shown in FIG. 3. Additional operations can be performed to further increase the staggering of the ply layers 302 depending on the specific design and the desired level of staggering.

[0116] With reference to Figure 5, a rotated course and steered tow diagram is shown for the ply layers of a submersible hull design in accordance with an illustrative embodiment. In addition to rotating the ply layers 302 of Figure 4 to reduce staggering, the composite structure manager 212 can further reduce staggering by varying the course width depicted in this diagram.

[0117] In this exemplary embodiment, the width of the courses in ply layer 302 is varied to increase the staggering of the ply edges between ply layers 302. For each ply layer in ply layer 302, the width of the courses can be adjusted by increasing the width of the courses or decreasing the width of the courses in a manner that maintains a consistent perimeter. This adjustment can be used to shift the position of the ply edges in one or more courses. This type of adjustment provides greater precision in adjusting the course edges compared to rotating a ply layer. In other words, this type of adjustment can adjust the position of one or more course edges in a ply layer, whereas rotating a ply layer adjusts the position of all of the course edges in the ply layer.

[0118] For example, in ply layer 304, one tow is removed from course 500 and added to course 502. As a result, course 500 has three tows, while course 502 has five tows. This adjustment to these two courses moves the position of course edge 504 and course edge 506, which in turn moves the position of gap 508. As a result, only these, if no other tows are moved. For example, one or more tows can be removed from one course in the ply layer and added to another course. If a gap exists between the ply edges, one tow of one course in the ply layer may be added without removing a tow from another course, possibly depending on the size of the gap. In another embodiment, one tow may be removed from one course without adding a tow to another course in the ply layer.

[0119] As shown, the submersible hull 300 design in this figure has a desired level of staggering of the course edges between the ply layers. When the submersible hull 300 is manufactured using the design depicted in this figure, the staggering of the ply edges and gaps between the ply edges will be such that undesirable overlap is reduced to a level that reduces undesirable misalignment.

[0120] An illustration of a submersible hull 300 design is depicted in Figures 3-5 and is provided as an illustration of one manner in which a submersible hull may be implemented. This illustration is not intended to limit the manner in which other embodiments may be implemented. For example, in addition to six ply layers, several other ply layers may be used. In the illustrated embodiment, six ply layers were selected to illustrate the features of the exemplary embodiment. In other exemplary embodiments, the submersible hull may have 70, 100, 135, or other numbers of ply layers.

[0121] Additionally, although not shown, other ply layers may be present in addition to ply layer 302. For example, other ply layers at other orientations other than 0 degrees may be present in the design of submersible hull 300. These ply layers are not shown to avoid obscuring the presentation of features of the illustrated embodiment.

[0122] Additionally, staggering can be performed on ply layers laid up at other orientations than 0 degrees. In another exemplary embodiment, the courses are laid up at 45 degrees rather than 0 degrees longitudinal as depicted in Figures 3-5. In this orientation, the course edges are oriented at 45 degrees but still parallel to the fibers forming the course. In other words, the tows for changing the orientation of the courses are laid up at 45 degrees such that the fibers are oriented at 45 degrees parallel to the course edges that are oriented at 45 degrees. Staggering performed on the course edges can be performed in the same manner as these orientations of the course edges.

[0123]

[0031] Referring now to Figure 6, a flow diagram of a process for designing a hollow composite body is illustrated in accordance with an exemplary embodiment. The process of Figure 6 may be implemented in hardware, software, or both. If implemented in software, the process may take the form of program code executed by one or more processor units located in one or more hardware devices in one or more computer systems. For example, the process may be implemented in composite structure manager 212 in the computer system of Figure 2.

[0124] The process begins by selecting a ply layer for a hollow composite body (operation 600). In operation 600, the ply layer includes courses having course edges. The process places course edges between ply layers throughout the hollow composite body to create staggering of course edges between ply layers for the hollow composite body design (operation 602). The process then ends.

[0125] In operation 602, a level of staggering of the course edges between ply layers reduces undesirable inconsistencies during manufacturing of the hollow composite body. In one exemplary embodiment, no overlap between course edges or gaps may be a criterion for a desired level of staggering that reduces undesirable inconsistencies. In another exemplary embodiment, overlap between course edges of courses occurring every nth layer throughout the ply layers may be acceptable depending on the amount that reduces undesirable inconsistencies. This overlap may also be determined based on the gaps between the course edges.

[0126] With reference to Figure 7, a flow diagram of a process for locating a course edge is depicted in accordance with an illustrative embodiment. The process of Figure 7 is an example of an implementation of operation 602 of Figure 6.

[0127] The process rotates selected ply layers in the ply layers so that the course edges have more staggering between the ply layers to create a hollow composite body design (operation 700). The process then ends.

[0128]

[0046] With reference now to Figure 8, a flow diagram of a process for locating a course edge is depicted in accordance with an illustrative embodiment. The process of Figure 8 is an example of an implementation of operation 602 of Figure 6.

[0129] The process varies the width of the courses in the selected ply layers so that the course edges have more staggering between the ply layers (operation 800). The process then ends.

[0130] 9, a flow diagram of a process for varying a course width is depicted in accordance with an example embodiment. The process of FIG. 9 is an example of an implementation of operation 800 of FIG.

[0131] The process begins by adding some tows to a first course of a selected ply layer (operation 900). The process removes some tows from a second course of the selected ply layer such that the edges of the selected ply layer have more course edge staggering between the ply layers (operation 902). The process then ends.

[0132] 10, a flow diagram of a process for varying course width is depicted in accordance with an illustrative embodiment. The process of FIG. 10 is an example of an implementation of operation 900 of FIG.

[0133] The process selects a first course having a first course edge in the selected ply layer that has minimal staggering from other course edges in the other ply layers (operation 1000). The process adds a number of tows to the selected first course (operation 1002). The process then ends.

[0134] 11, a flow diagram of a process for varying course width is depicted in accordance with an illustrative embodiment. The process of FIG. 11 is an example of an implementation of operation 900 of FIG.

[0135] The process begins by selecting a first course having a first course edge in a selected ply layer that has minimal staggering from other course edges in other ply layers (operation 1100). The process adds a number of tows to the selected first course (operation 1102).

[0136] The process selects a second course having a second course edge in the selected ply layer that has a maximum amount of staggering from another course edge in the other ply layers (operation 1104). The process removes some tows from the selected second course (operation 1106). The process then ends.

[0137] 12, a flow diagram of a process for locating a course edge is depicted in accordance with an illustrative embodiment. The process of FIG. 12 is an example of an implementation of operation 602 of FIG.

[0138] The process begins by rotating a selected ply layer in the ply layer to increase course edge staggering between the ply layers (operation 1200). In response to rotating the selected ply layer not producing a desired level of course edge staggering between the ply layers, the process alternates some of the tows between the courses of the selected ply layer to increase course edge staggering at the course edges of the other ply layers (operation 1202). This process can be repeated for the next ply layer in the file layer in response to the absence of a desired level of staggering between the course edges. In an exemplary embodiment, the next ply level layer is the ply layer that contacts the ply layer being processed by rotating or alternating the tows.

[0139] 13, a flow diagram of a process for locating a course edge is depicted in accordance with an illustrative embodiment. The process of FIG. 13 is an example of an implementation of operation 602 of FIG.

[0140] The process begins by selecting a next ply layer in the ply layers for processing (operation 1300). The process rotates the next ply layer to increase course edge staggering between the ply layers (operation 1302). In response to rotating the next ply layer not producing a desired level of course edge staggering between the ply layers, the process alternates some of the tows between courses of the next ply layer to increase course edge staggering between the ply layers (operation 1304).

[0141] The process repeats the process of selecting the next ply layer, rotating the next ply layer, and alternating some of the tows between the courses of the next ply layer (operation 1306) until all ply layers have been processed. The process then ends.

[0142] With reference to Figure 14, a flow diagram of a process for manufacturing a hollow composite body is shown in accordance with an illustrative embodiment. The process illustrated in Figure 14 is an example of additional steps that may be performed after the composite hollow body design is completed in the process of Figure 6.

[0143] The process begins by laying up composite material in courses using a design to create ply layers for a hollow composite body (operation 1400). In operation 1400, the composite material laid out can be, for example, a tow.

[0144] The process includes curing the plies laid up with the design to create a hollow composite body, where the staggering of course edges between the plies results in reducing undesirable inconsistencies in the hollow composite body that may occur in the plies (operation 1402). The process then terminates.

[0145] 15, a flow diagram of a process for designing a hollow composite body is illustrated in accordance with an exemplary embodiment. The process of FIG. 15 may be implemented in hardware, software, or both. If implemented in software, the process may take the form of program code executed by one or more processor units located in one or more hardware devices in one or more computer systems. For example, the process may be implemented in composite structure manager 212 in the computer system of FIG. 2.

[0146] The process begins by selecting one ply layer in a ply layer in a hollow composite body design to form a selected ply layer (operation 1500). The process staggers course edges between the selected ply layer in the ply layer and other ply layers in the ply layer in an iterative manner, resulting in increasing staggering of course edges between the ply layers, which is used in the next iteration with another selected ply layer until a desired level of staggering occurs (operation 1502). The process then terminates.

[0147] In this exemplary embodiment, the iteration moves from one ply layer to the next adjacent ply layer. In other words, the process does not skip a ply layer during the process as long as the ply layers have the same orientation. In the design, there are other ply layers in addition to the one-day process of FIG. 15, but these ply layers are not considered during this process.

[0148]

[00136] Referring now to Figure 16, a flow diagram of a process for staggering course edges in an iterative manner is illustrated in accordance with an illustrative embodiment. The process illustrated in Figure 16 is an example of an implementation of operation 1502 of Figure 15.

[0149] The process begins by rotating a selected ply layer to result in increased staggering of course edges between the selected ply layer and course edges in the other ply layers (operation 1600). The process repeats the rotation for each ply layer in the other ply layers based on the increased staggering result until a desired level of staggering is achieved (operation 1602). The process then ends.

[0150] In Figure 17, a flow diagram of a process for staggering course edges in an iterative manner is shown in accordance with an example embodiment. The process shown in Figure 17 is an example of an implementation of operation 1502 of Figure 15.

[0151] The process begins by varying the width of the courses in a selected ply layer to result in increased staggering of the course edges between the selected ply layer and the other ply layers (operation 1700). The process repeats the process of varying the width of the courses for each other ply layer in the other ply layers based on the staggering caused by the width change until a desired level of staggering occurs (operation 1702). The process then ends. Referring to FIG. 18, a flow diagram of a process for staggering course edges in an iterative manner is shown in accordance with an exemplary embodiment. The process illustrated in FIG. 18 is an example of an implementation of operation 1502 of FIG. 15.

[0152] The process begins by rotating a selected ply layer to result in increased staggering between the selected ply layer and course edges in other ply layers (operation 1800). The process varies the width of the courses in the selected ply layer to result in increased staggering of course edges between the selected ply layer and other ply layers (operation 1802).

[0153] The process repeats the iterative rotation and modification for each other ply layer in the other ply layers until the desired level of staggering occurs (operation 1804). The process then terminates.

[0154] 19A and 19B, a flow diagram of a process for creating a hollow composite body design is shown in accordance with an example embodiment. The processes of FIGS. 19A and 19B may be implemented in hardware, software, or both. If implemented in software, the processes may take the form of program code executed by one or more processor units located in one or more hardware devices in one or more computer systems. For example, the processes may be implemented in the composite structure manager 212 in the computer system of FIG. 2.

[0155] During the creation of the design, the process has several different sections. In section 1901, the process identifies information and calculates values ​​to create the design. In section 1903, the process defines plies for the design. The process optimizes the plies based on the previous ply in section 1905. In this phase, the objective is to maximize the average distance between course edges and minimize the mark distance throughout the thickness of the ply layer. In section 1907, the process is applied iteratively to each ply that has been laid down and optimized.

[0156] The process begins by inputting the plies to be laid, tool information, ply information, and machine tolerances (operation 1900) at section 1901. The process determines the circumference and radiance for each ply (operation 1902).

[0157] The process continues in section 1903 with determining how many courses of an optimal number of tows will fit into each ply (operation 1904). This operation takes into account that a conference increases with the number of plies. In other words, in the design, the outermost plies have a longer circumference than the innermost plies.

[0158] In an exemplary embodiment, the optimal number of tows may be determined by the limitations of the compression roller of the automated fiber placement (AFP) machine that lays up the tows and the ability of the compression roller to conform to the contour. For 0 degree oriented plies on small bends, the number of tows may be reduced to ensure adequate compression.

[0159] Also, for larger contours not limited by roller compatibility, the optimum number of tows can be the number of tows allowed by the Automated Fiber Placement (AFP) machine head. This number can be reduced by one or more tows to provide flexibility in selection when adding tows to the course.

[0160] The optimal number of tows may also be the number of tows necessary to cover the circumference without causing overlap. This selection of the number of tows may result in a gap up to the size of a tow width. In an exemplary embodiment, this gap is evenly distributed with smaller equal gaps between each course.

[0161] For each ply layer, the process determines the portion of the perimeter not filled by the course with the optimal number of tows, determines how many tows can be added, and distributes the additional tows around the course (operation 1906). In one exemplary embodiment, if the last course does not have the optimal course width, the remaining portion of the tows can be distributed among the other courses. For example, if eight tows is the optimal number for a course, but the last course only needs five tows to complete the ply, these five tows can be evenly distributed around the perimeter by adding one to five different courses. The distribution of the additional tows can keep the staggering pattern generally even.

[0162] The process distributes the gap length that cannot be filled by the additional tows as gap between courses (operation 1908). In this operation, after adding the additional tows, there may still be space around the perimeter of the ply layer. This is the gap length. If there is no gap length, then no gap exists between the course edges.

[0163] The process determines how effective the initial attempt was at staggering the course edges (operation 1910). In operation 1910, the amount of staggering between the course edges of different ply layers is determined and may be compared to a tolerance or standard for a desired level of staggering. In this example embodiment, the arc distance (average and minimum) between the course edges of the courses is determined throughout the thickness of the ply layers. In this example embodiment, a calculation may also be made regarding the gap between the course edges.

[0164] Processing continues to section 1905 to determine whether all iterations have been exhausted for the current ply layer (operation 1912). In other words, operation 1912 determines whether some iterations have been performed for the ply layer. The number of iterations performed for a ply layer may be selected in a number of different ways. For example, the number of iterations for a ply layer may be selected based on a determination of how many iterations are required to optimize a particular ply layer. As the number of layers increases in the design, this number also increases. For example, for a design having 110 ply layers, 100 iterations may be selected.

[0165] If no iterations have been performed for the current ply layer, the process determines whether the current ply position has the optimal staggering for all iterations performed (operation 1914). In this exemplary embodiment, the current ply layer position is the position of the ply layer relative to the other ply layers in the design. In an exemplary embodiment, the ply layer position includes the position of the course of the course edges. The ply layer position also includes the position of the gaps. The positions of these different features may be based on polar coordinates relative to an axis that runs through the design of the hollow composite body.

[0166] If the current ply layer position is the best position of all iterations, the process saves the current ply position as the best position (operation 1916). The process rotates the ply layer to an angular position with optimal staggering (operation 1918). In operation 1918, the optimal staggering is the best course edge staggering with respect to the course edges of the other ply layers. The process then determines whether the quality of the staggering has changed (operation 1920). In operation 1920, the evaluation criterion can be a minimum distance. A large number for the minimum distance can indicate a better design. In one embodiment, the quality of the staggering can be measured using the arc length between course edges (relative to the layer below). In this embodiment, the minimum arc length to another course edge in the thickness direction is maximized.

[0167] If the staggering quality does not change, the process swaps the tows between the course with the maximum staggering distance to the course edge in the thickness direction and the course with the minimum reference distance to another course edge in the thickness direction (operation 1922). The process then returns to operation 1912. In this example embodiment, the staggering distance can be a measure of the arc length or angle that the two course edges are separated.

[0168] Referring again to operation 1920, if this has not changed, processing returns directly to operation 1912. Referring back to operation 1912, once the set number of iterations have been performed for the ply layer, processing moves to section 1907 where, once the current ply layer has been optimized, it is determined whether the previous ply layer has been optimized again (operation 1924). In this illustrative example, processing also proceeds from operation 1912 to operation 1924 if all iterations have been performed for the current ply layer being optimized.

[0169] If the previous ply layer is not optimized, the process iterates back to the previous ply layer by selecting another ply layer to be processed (operation 1926). The process then returns to operation 1912.

[0170] Referring again to operation 1924, if the previous ply layer has been re-optimized, the process determines whether all ply layers have been laid down (operation 1928). This operation is used to determine whether the design is complete.

[0171] If all ply layers have not been laid down, the process switches to the next ply layer (operation 1928). The process then returns to operation 1912 described above.

[0172] When all ply layers have been laid down, see operation 1926, the process plots the locations of the gaps in the ply layers (operation 1928). The process then ends. Operation 1928 provides visualization of the staggering to operating personnel.

[0173] The flow diagrams and block diagrams in the various illustrated embodiments illustrate the architecture, functionality, and operation of some possible implementations of the apparatus and methods in the exemplary embodiments. In this regard, each block in the flow diagrams or block diagrams may represent at least one of a module, a segment, a function, or a portion of an operation or step. For example, one or more blocks may be implemented as program code, hardware, or a combination of program code and hardware. If implemented in hardware, the hardware may take the form of, for example, an integrated circuit that is manufactured or configured to perform one or more processes in the flow diagrams or block diagrams. If implemented as a combination of program code and hardware, the implementation may take the form of firmware. Each block in the flow diagrams or block diagrams may be implemented using a dedicated hardware system that performs various operations or various combinations of dedicated hardware and program code executed by the dedicated hardware.

[0174] In some alternative implementations of the exemplary embodiments, one or more functions noted in the blocks may be performed out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be performed substantially simultaneously, or the blocks may sometimes be performed in the reverse order, depending on the functionality involved. Also, other blocks may be added in addition to the blocks noted in the flow diagrams or block diagrams.

[0175] 20, locations for ply layers are shown in accordance with an exemplary embodiment. In this exemplary example, graph 2000 is an example of a graph generated by a plotting application in operation 1928 of the flow diagram of FIG. 19. In this exemplary example, graph 2000 represents a design having 110 ply layers for a submersible hull. The orientation of these ply layers is 0 degrees in the laid out example. Line 2002 radiates from axis 2004 to the centerline of the gaps in the ply layers. As shown, axis 2004 extends through the center of the submersible hull design. The length of line 2002 identifies ply layers where gaps exist between course edges of the courses in the ply layer. To identify staggering between ply layers in the design, an arc or angle can be determined between the lines of different ply layers.

[0176] 21, a block diagram of a data processing system is shown in accordance with an exemplary embodiment. Data processing system 2100 may be used to implement server computer 104, server computer 106, or client system 110 of FIG. 1. Data processing system 2100 may also be used to implement computer system 210 of FIG. 2. In this illustrative example, data processing system 2100 includes a communications framework 2102. The communications framework provides communications between processor unit 2104, memory 2106, persistent storage 2108, communications unit 2110, input / output (I / O) unit 2112, and display 2114. In this example, communications framework 2102 takes the form of a bus system.

[0177] The processor unit 2104 is responsible for executing instructions for software that may be loaded into the memory 2106. The processor unit 2104 includes one or more processors. For example, the processor unit 2104 may be selected from at least one of a central processing unit (CPU), a graphics processing unit (GPU), a physics processing unit (PPU), a digital signal processor (DSP), a network processor, or other suitable types of processors. Furthermore, the processor unit 2104 may be implemented using one or more heterogeneous processor systems in which a main processor exists on a single chip along with secondary processors. As another illustrative example, the processor unit 2104 may be a symmetric multi-processor system in which several processors of the same type are included on a single chip.

[0178] Memory 2106 and persistent storage 2108 are examples of storage device 2116. A storage device is any hardware that can temporarily and / or persistently store at least one of, for example, but not limited to, data, information such as program code in a functional form, or other suitable information. Storage device 2116 may also be referred to as a computer-readable storage device, in these illustrative examples. Memory 2106, in these examples, may be, for example, a random access memory, or any other suitable volatile or non-volatile storage device. Persistent storage 2108 may take various forms depending on the particular implementation.

[0179] For example, persistent storage 2108 may include one or more components or devices. For example, persistent storage 2108 may be a hard drive, a solid-state drive (SSD), a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of these. The medium used by persistent storage 2108 may also be removable. For example, a removable hard drive may be used for persistent storage 2108.

[0180] In these illustrative examples, communications unit 2110 provides for communication with other data processing systems or devices, hi these illustrative examples, communications unit 2110 is a network interface card.

[0181] The input / output devices 2112 allow for the input and output of data with other devices that may be connected to the data processing system 2100. For example, the input / output devices 2112 may provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Additionally, the input / output devices 2112 may send output to a printer. The display 2114 provides a mechanism for displaying information to a user.

[0182] Instructions for at least one of the operating system, applications, or programs may be located in storage device(s) 2116, which are in communication with processor unit 2104 via communications framework 2102. The processes of the different embodiments may be performed by processor unit 2104 using computer-implemented instructions, which may be located in a memory, such as memory 2106.

[0183] These instructions, which may be referred to as program code, computer usable program code, or computer readable program code, may be read and executed by a processor in processor unit 2104. In different embodiments, the program code may be embodied in different physical or computer readable storage media, such as memory 2106 or persistent storage 2108.

[0184] Program code 2118 may be functionally disposed on a selectively removable computer readable medium 2120 and loaded onto or transmitted to data processing system 2100 for execution by processor unit 2104. In these illustrative examples, program code 2118 and computer readable medium 2120 form a computer program product 2122. In the illustrative example, computer readable medium 2120 is a computer readable storage medium 2124.

[0185] Computer readable storage medium 2124 is a physical or tangible storage device used to store program code 2118, rather than a medium that propagates or transmits program code 2118. As used herein, computer readable storage medium 2124 should not be interpreted as, per se, a transitory signal such as an electric wave or other freely propagating electromagnetic wave, an electromagnetic wave propagating through a wave guide or another transmission medium (e.g., a light pulse passing through a fiber optic cable), or an electrical signal transmitted over a wire.

[0186] Alternatively, program code 2118 may be transmitted to data processing system 2100 using a computer readable signal medium. The computer readable signal medium may be, for example, a propagated data signal containing program code 2118. For example, the computer readable signal medium may be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals may be transmitted over a connection, such as a wireless connection, a fiber optic cable, a coaxial cable, a wire, or any other suitable type of connection.

[0187] Additionally, as used herein, "computer readable medium 2120" may be singular or plural. For example, program code 2118 may be located in computer readable medium 2120 in the form of a single storage device or storage system. In another example, program code 2118 may be located in computer readable medium 2120 that is distributed across several data processing systems. In other words, some instructions in program code 2118 may be located in one data processing system, while other instructions in program code 2118 may be located in one data processing system. For example, a portion of program code 2118 may be located in computer readable medium 2120 in a server computer, while another portion of program code 2118 may be located in computer readable medium 2120 located in a set of client computers.

[0188] The different components illustrated for data processing system 2100 are not meant to provide architectural limitations to the manner in which different embodiments may be implemented. In some illustrative examples, one or more of the components may be integrated into or otherwise form a part of another component. For example, in some illustrative examples, memory 2106, or portions thereof, may be integrated within processor unit 2104. The different illustrative embodiments may be implemented in a data processing system including components in addition to or instead of those illustrated for data processing system 2100. Other components illustrated in FIG. 21 may differ from the illustrated example. The different embodiments may be implemented using any hardware device or system capable of running program code 2118.

[0189] 22, an example of a block diagram of a product management system is depicted in accordance with an illustrative embodiment. Product management system 2200 is a physical hardware system. In this illustrative example, product management system 2200 includes at least one of a manufacturing system 2202 or a maintenance system 2204.

[0190] Manufacturing system 2202 is configured to manufacture products, such as submersible vehicles, aircraft, spacecraft, or other suitable platforms. As shown, manufacturing system 2202 includes manufacturing equipment 2206. Manufacturing equipment 2206 includes at least one of fabrication equipment 2208 or assembly equipment 2210.

[0191] Fabrication equipment 2208 is equipment used to manufacture components (e.g., composite parts) for products such as composite hollow bodies. For example, fabrication equipment 2208 may include machines and tools. These machines and tools may be at least one of a drill, a hydraulic press, an oven, an autoclave, a mold, a composite tape laying machine, an automated fiber placement (AFP) machine, a vacuum system, a robotic pick and place system, a flatbed cutting machine, a laser cutter, a computer numerically controlled (CNC) cutting machine, a lathe, or other suitable type of equipment. Fabrication equipment 2208 may be used to fabricate at least one of a metal part, a composite part, a semiconductor, a circuit, a fastener, a rib, a skin panel, a spar, an antenna, or other suitable type of part.

[0192] Assembly equipment 2210 is equipment used to assemble parts to form a platform. Specifically, assembly equipment 2210 is used to assemble components and parts to form a platform. Assembly equipment 2210 may also include machines and tools. Such machines and tools may be at least one of a robotic arm, a crawler, a fastener installation system, a rail-based drilling system, or a robot.

[0193] In this illustrative example, maintenance system 2204 includes maintenance equipment 2212. Maintenance equipment 2212 may include any equipment necessary to perform maintenance on the platform. Maintenance equipment 2212 may include tools for performing various operations on parts on the product. These operations may include at least one of disassembling the part, refurbishing the part, inspecting the part, reworking the part, manufacturing a replacement part, or other operations for performing maintenance on the platform. These operations may be for routine maintenance, inspection, upgrades, refurbishing, or other types of maintenance operations.

[0194] In this illustrative example, maintenance equipment 2212 may include ultrasonic inspection devices, x-ray imaging systems, vision systems, drills, crawlers, and other suitable devices. In some cases, maintenance facility 2212 may include fabrication equipment 2208, assembly equipment 2210, or both, for manufacturing and assembling parts required for maintenance.

[0195] The product management system 2200 also includes a control system 2214. The control system 2214 is a hardware system and may also include software or other types of components. The control system 2214 is configured to control the operation of at least one of the manufacturing system 2202 or the maintenance system 2204. In particular, the control system 2214 may control the operation of at least one of the fabrication equipment 2208, the assembly equipment 2210, or the maintenance equipment 2212.

[0196] The hardware of the control system 2214 may be implemented using hardware that may include computers, circuits, networks, and other types of equipment. The control may take the form of direct control of the manufacturing equipment 2206. For example, the control system 2214 may control robots, computer controlled machines, and other equipment. In other illustrative examples, the control system 2214 may manage operations performed by personnel 2216 in performing manufacturing or maintenance of the aircraft A200. For example, the control system 2214 may assign tasks, provide instructions, display models, or perform other operations to manage the processes performed by personnel 2216. In these illustrative examples, the composite structure manager 212 of FIG. 2 may be implemented in the control system 2214 to manage at least one of the manufacturing or maintenance of the product.

[0197] In various demonstrative examples, operations personnel 2216 may operate or interact with at least one of manufacturing equipment 2206, maintenance equipment 2212, or control system 2214. This interaction may occur to manufacture a product, such as a submersible vehicle or aircraft.

[0198] Of course, product management system 2200 may be configured to manage other products besides submersible vehicles or aircraft. For example, other products may include spacecraft, rockets, land vehicles, or other suitable platforms that implement hollow composite buttons. Although product management system 2200 is described in connection with manufacturing in the aerospace industry, product management system 2200 may be configured to manage products for other industries. For example, product management system 2200 may be configured to manufacture products for the automotive industry and any other suitable industry.

[0199] Accordingly, illustrative embodiments provide a method, apparatus, system, and computer program product for designing a hollow composite body. A computer system selects ply layers for a hollow composite body, the ply layers comprising courses having course edges. The computer system arranges the course edges between the ply layers throughout the hollow composite body to create a staggering of the course edges between the ply layers for the hollow composite body design, the level of staggering of the course edges between the ply layers reducing undesirable inconsistencies during manufacturing of the hollow composite body.

[0200] As a result, one or more exemplary embodiments can reduce undesirable inconsistencies in composite hollow bodies manufactured using reduced staggering designs by at least one of rotating ply layers or modifying course widths in ply layers, which can increase the amount of staggering of course edges between ply layers throughout the composite hollow body design. One or more exemplary embodiments can use techniques with different levels of precision for adjusting the course edges. For example, rotating ply layers can provide one level of adjustment of the course edge position, while modifying course widths can provide a high level of precision in adjusting the course edge position. These techniques can be used in an iterative manner that can reduce the overlap of the course edges to a level that reduces the undesirable inconsistencies.

[0201] Clause 1. A method for designing a hollow composite body (208), comprising: selecting (600) for the hollow composite body (208) by a computer system (210) a ply layer (140, 218, 302) comprising courses (142, 220) having course edges (144, 222); placing (602) the course edges (144, 222) between the ply layers (140, 218, 302) through the hollow composite body (208) with the computer system (210) to create a staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) for the hollow composite body (208) design (132, 204); A method comprising:

[0202] Clause 2. With respect to the design (132, 204) of the hollow composite body (208), placing (602) the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) by the computer system (210) to create the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302); 2. The method of claim 1, comprising rotating (700), by the computer system (210), a selected ply layer (234) in the ply layers (140, 218, 302) so that the course edges (144, 222) have more staggering between the ply layers (140, 218, 302) to create the design (132, 204) of the hollow composite body (208).

[0203] Clause 3. With respect to the design (132, 204) of the hollow composite body (208), placing (602) the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) by the computer system (210) to create the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302); 3. The method of claim 1 or 2, comprising varying (800), by the computer system (210), a width of the course (142, 220) in a selected ply layer (234) such that the course edges (144, 222) have more staggering between the ply layers (140, 218, 302).

[0204] Clause 4. Varying (800) the width of the courses (142, 220) in the selected ply layer (234) by the computer system (210) such that the course edges (144, 222) in the selected ply layer (234) have more staggering of the course edges (144, 222) between the ply layers (140, 218, 302); adding (900) a number of tows (226) to a first course (238) in the selected ply layer (234) by the computer system (210); and removing (902) the some of the tows (226) from a second course (240) in the selected ply layer (234) by the computer system (210), wherein the course edges (144, 222) in the selected ply layer (234) have a staggering of more of the course edges (144, 222) between the ply layers (140, 218, 302).

[0205] Clause 5. Adding (902) the number of tows (226) to the first course (238) in the selected ply layer (234) by the computer system (210), selecting (1000) by the computer system (210) a first course (238) having an edge of the first course (238) in the selected ply layer (234) that has minimal staggering from another one of the course edges (245) in another ply layer (246); adding (1002) the number of tows (226) to the selected first course (238) by the computer system (210); 5. The method according to claim 4, comprising:

[0206] Clause 6. Removing (902) the number of tows (226) from the second course (240) in the selected ply layer (234) by the computer system (210); selecting, by the computer system (210), from another one of the course edges (245) in the other ply layer (246), the second course (240) having a second course (240) edge in the selected ply layer (234) that has a maximum staggering (250); removing, by the computer system (210), the number of tows (226) from the selected second course (240); 6. The method according to clause 4 or 5,

[0207] Clause 7. With respect to the design (132, 204) of the hollow composite body (208), placing (602) the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) to create the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302), rotating (1200) selected ply layers (234) in the ply layers (140, 218, 302) to increase the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) by the computer system (210); in response to rotating the selected ply layer (234) not producing a desired level of staggering of the course edges (144, 222) between the ply layers (140, 218, 302), alternating (1202) some tows (226) between the courses (142, 220) of the selected ply layer (234) to increase the staggering (230) of the course edges (144, 222) at the course edges (144, 222) of the other ply layer (246); 7. The method according to any one of clauses 1 to 6, comprising:

[0208] Clause 8. The method of clause 7, wherein in response to the desired level of staggering not being present, the computer system (210) repeats the rotating and alternating steps for a next ply layer (252) of the ply layer (140, 218, 302).

[0209] Clause 9. Placing (602) the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) by the computer system (210) to create the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) for the design (132, 204) of the hollow composite body (208), selecting (1300) a next ply layer (252) in the ply layers (140, 218, 302) for processing by the computer system (210); rotating (1302) a next ply layer (252) by the computer system (210) to increase the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302); in response to rotating the next ply layer (252) not achieving a desired level of staggering of the course edges (144, 222) between the ply layers (140, 218, 302), alternating (1304) some of the tows (226) between the courses (142, 220) of the next ply layer (252) to increase the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302); repeatedly selecting (1306) the next ply layer (252), rotating the next ply layer (252), and alternating the several tows (226) between the courses (142, 220) of the next ply layer (252) by the computer system (210) until all of the ply layers (140, 218, 302) have been processed; 9. The method of any one of clauses 1 to 8, further comprising:

[0210] Clause 10. Laying up (1400) composite material in said courses (142, 220) using said design (132, 204) to create said ply layers (140, 218, 302) for said hollow composite body (208); 10. The method of any one of clauses 1 to 9, further comprising: curing (1402) the ply layers (140, 218, 302) laid up using the design (132, 204) to create the hollow composite body (208), wherein the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) results in reducing undesirable inconsistencies (232) in the hollow composite body (208) occurring in the ply layers (140, 218, 302).

[0211] Clause 11. Laying said composite material in said courses (142, 220) using said design (132, 204) to create said ply layers (140, 218, 302) for said hollow composite body (208) comprises: 11. The method of claim 10, comprising laying up tows (226) in the courses (142, 220) using the design (132, 204) to create the ply layers (140, 218, 302) for the hollow composite body (208).

[0212] Clause 12. The method of any one of clauses 1 to 11, wherein there is no overlap between the course edges (144, 222) of the courses (142, 220) throughout the ply layer (140, 218, 302).

[0213] Clause 13. The method of any one of clauses 1 to 12, wherein an overlap between the course edges (144, 222) of the courses (142, 220) throughout the ply layers (140, 218, 302) occurs every nth layer.

[0214] Clause 14. The method of any one of clauses 1 to 13, wherein the ply layers (140, 218, 302) have the same orientation selected from the group consisting of 0 degrees and 45 degrees.

[0215] Clause 15. The method of any one of clauses 1 to 14, wherein the course edges (144, 222) between the courses (142, 220) in the ply layers (304, 306, 308, 310, 312, 314) form at least one of a gap, an overlap, or an abutted edge.

[0216] Clause 16. The method of any one of clauses 1 to 15, wherein the hollow composite body (208) is selected from the group consisting of a submersible hull, a submarine hull, a wing, a rocket, and a fuselage.

[0217] Clause 17. A method for designing a hollow composite body (208), said method comprising: selecting (1500) ply layers (304, 306, 308, 310, 312, 314) in the ply layers (140, 218, 302) in the design (132, 204) for the hollow composite body (208) to form a selected ply layer (234); and staggering (1502), by the computer system (210), course edges (144, 222) between the selected ply layer (234) in the ply layer (140, 218, 302) and other ply layers (246) in the ply layer (140, 218, 302) in an iterative manner, resulting in increasing staggering of the course edges (144, 222) between the ply layers (140, 218, 302), which is used in a next iteration with another selected ply layer (234) until a desired level of staggering is achieved.

[0218] Clause 18. Staggering (1502) course edges (144, 222) between the selected ply layer (234) in the ply layer (140, 218, 302) and the other ply layer (246) in the ply layer (140, 218, 302) in the iterative manner by the computer system (210), rotating (1600) the selected ply layer (234) by the computer system (210) to result in increased staggering of the course edges (144, 222) between the selected ply layer (234) and the course edges (144, 222) in the other ply layers (246); repeating the rotation (1602) of each ply layer in the other ply layers (246) by the computer system (210) based on the increased staggering until the desired level of staggering is achieved; 17. The method according to claim 16, comprising:

[0219] Clause 19. Staggering (1502) course edges (144, 222) between the selected ply layer (234) in the ply layer (140, 218, 302) and the other ply layer (246) in the ply layer (140, 218, 302) in the iterative manner by the computer system (210), Varying (1700) widths of the courses (142, 220) in the selected ply layer (234) by the computer system (210) resulting in increased staggering of the course edges (144, 222) between the selected ply layer (234) and the other ply layer (246); repeatedly varying (1702) the width of the courses (142, 220) with the computer system (210) for each other ply layer in the other ply layers (246) based on the staggering (230) resulting from the width variation until the desired level of staggering is achieved; 19. The method according to clause 17 or 18, comprising:

[0220] Clause 20. Staggering (1502) course edges (144, 222) between the selected ply layer (234) in the ply layer (140, 218, 302) and the other ply layer (246) in the ply layer (140, 218, 302) in the iterative manner by the computer system (210), rotating (1800) the selected ply layer (234) by the computer system (210) to result in increased staggering of the course edges (144, 222) between the selected ply layer (234) and the other ply layers (246); Varying (1802), by the computer system (210), a width of the courses (142, 220) in the selected ply layer (234) resulting in increased staggering of the course edges (144, 222) between the selected ply layer (234) and the other ply layer (246); repeating (1804) the rotation and alteration by the computer system (210) for each of the other ply layers in the other ply layers (246) until the desired level of staggering occurs; 20. The method of any one of clauses 17 to 19, comprising:

[0221] Clause 21. The method of any one of clauses 17 to 20, wherein the selected ply layer (234) is a newly added ply layer.

[0222] Clause 22. The method of any one of clauses 17 to 21, wherein the selected ply layer (234) is an existing ply layer within the ply layers (140, 218, 302).

[0223] Clause 23. A computer system (210); a composite structure manager in the computer system, the composite structure manager comprising: selecting a ply layer (140, 218, 302) for a hollow composite body (208) comprising courses (142, 220) having course edges (144, 222); and positioning the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) to create a staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) in relation to a design (132, 204) of the hollow composite body (208).

[0224] Clause 24. The method according to claim 2, further comprising the steps of: 24. The composite manufacturing system (202) of claim 23, further comprising: a control section for controlling a layup of composite material in said courses (142, 220) using said designs (132, 204) to create said ply layers (140, 218, 302) for said hollow composite body (208).

[0225] Clause 25. With respect to said design (132, 204) of said hollow composite body (208), disposing said course edges (144, 222) between said ply layers (140, 218, 302) throughout said hollow composite body (208) to create said staggering (230) of said course edges (144, 222) between said ply layers (140, 218, 302); 25. The composite manufacturing system (202) of claim 23 or 24, comprising rotating selected ply layers (234) in the ply layers (140, 218, 302) so that the course edges (144, 222) have more staggering between the ply layers (140, 218, 302) to create the design (132, 204) of the hollow composite body (208).

[0226] Clause 26. With respect to said design (132, 204) of said hollow composite body (208), disposing said course edges (144, 222) between said ply layers (140, 218, 302) throughout said hollow composite body (208) to create said staggering (230) of said course edges (144, 222) between said ply layers (140, 218, 302); 26. The composite manufacturing system (202) of any one of clauses 23 to 25, comprising varying a width of the courses (142, 220) in the selected ply layer (234) such that the course edges (144, 222) have more staggering between the ply layers (140, 218, 302).

[0227] Clause 27. Varying the width of the courses (142, 220) in the selected ply layer (234) such that the course edges (144, 222) in the selected ply layer (234) have more of the staggering of the course edges (144, 222) between the ply layers (140, 218, 302); adding a number of tows (226) to a first course (238) in the selected ply layer (234); and removing the some of the tows (226) from a second course (240) in the selected ply layer (234), wherein the course edges (144, 222) in the selected ply layer (234) have a staggering of more of the course edges (144, 222) between the ply layers (140, 218, 302).

[0228] Clause 28. Adding the number of tows (226) to the first course (238) in the selected ply layer (234) comprises: selecting a first course (238) from another one of the course edges (245) in another ply layer (246) that has an edge of the first course (238) in the selected ply layer (234) that has minimal staggering; adding said number of tows (226) to said selected first course (238); 28. The composite manufacturing system (202) of claim 27, comprising:

[0229] Clause 29. Removing the some of the tows (226) from the second course (240) in the selected ply layer (234) comprises: selecting, from another one of the course edges (245) in the other ply layer (246), a second course (240) having a second course (240) edge in the selected ply layer (234) that has a maximum amount of staggering (250); removing the number of tows (226) from selected one of the second courses (240); and 29. A composite manufacturing system (202) according to claim 27 or 28, comprising:

[0230] Clause 30. With respect to said design (132, 204) of said hollow composite body (208), disposing said course edges (144, 222) between said ply layers (140, 218, 302) throughout said hollow composite body (208) to create said staggering (230) of said course edges (144, 222) between said ply layers (140, 218, 302); rotating selected ply layers (234) in said ply layers (140, 218, 302) to increase said staggering (230) of said course edges (144, 222) between said ply layers (140, 218, 302); in response to rotating the selected ply layer (234) not producing a desired level of staggering of the course edges (144, 222) between the ply layers (140, 218, 302), alternating some of the tows (226) between the courses (142, 220) in the selected ply layer (234) to increase the staggering (230) of the course edges (144, 222) at the course edges (144, 222) in the other ply layer (246); 30. The composite manufacturing system (202) of any one of clauses 23 to 29, comprising:

[0231] Clause 31. The composite manufacturing system (202) of clause 30, wherein in response to the desired level of staggering not being present, the rotating and alternating steps are repeated for a next ply layer (252) in the ply layer (140, 218, 302).

[0232] Clause 32. With respect to the design (132, 204) of the hollow composite body (208), disposing the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) to create the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302); selecting a next ply layer (252) in said ply layers (140, 218, 302) for processing; rotating the next ply layer (252) to increase the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302); in response to rotating the next ply layer (252) not achieving a desired level of staggering of the course edges (144, 222) between the ply layers (140, 218, 302), alternating some of the tows (226) between the courses (142, 220) of the next ply layer (252) to increase the staggering of the course edges (144, 222) between the ply layers (140, 218, 302); repeating the selection of the next ply layer (252), rotating the next ply layer (252), and alternating the several tows (226) between the courses (142, 220) of the next ply layer (252) until all of the ply layers (140, 218, 302) have been processed; 32. The composite manufacturing system (202) of claim 30 or 31, further comprising:

[0233] Clause 33. The composite manufacturing system (202) of any one of clauses 23 to 32, further comprising laying up composite material in the courses (142, 220) using the design (132, 204) to create the ply layers (140, 218, 302) for the hollow composite body (208).

[0234] Article 34. Computer system (208) and a composite structure manager in the computer system, the composite structure manager comprising: selecting ply layers (304, 306, 308, 310, 312, 314) in the ply layers (140, 218, 302) in a design (132, 204) for a hollow composite body (208) to form a selected ply layer (234); and staggering course edges (144, 222) between the selected ply layer (234) in the ply layer (140, 218, 302) and other ply layers (246) in the ply layer (140, 218, 302) in an iterative manner, resulting in (increasing staggering) of the course edges (144, 222) between the ply layers (140, 218, 302) that are used in a next iteration with another selected ply layer (234) until a desired level of staggering is achieved.

[0235] Clause 35. A computer program product for designing a hollow composite body (208), said computer program product comprising a computer readable storage medium having program instructions embodied therein, said program instructions being executable by a computer system (210); selecting a ply layer (140, 218, 302) for the hollow composite body (208) comprising courses (142, 220) having course edges (144, 222); a method for positioning the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) to create a staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) for a hollow composite body (208) design (132, 204); A computer program product for causing the computer system (210) to execute the above.

[0236] Clause 36. A computer program product for designing a hollow composite body (208), said computer program product comprising a computer readable storage medium having program instructions embodied therein, said program instructions being executable by a computer system (210); selecting ply layers (304, 306, 308, 310, 312, 314) in a design (132, 204) for the hollow composite body (208) from ply layers (140, 218, 302) to form a selected ply layer (234); and staggering course edges (144, 222) between the selected ply layer (234) in the ply layer (140, 218, 302) and other ply layers (246) in the ply layer (140, 218, 302) in an iterative manner, resulting in increasing staggering of the course edges (144, 222) between the ply layers (140, 218, 302), which is used in a next iteration with another selected ply layer (234) until a desired level of staggering is achieved.

[0237] The description of different exemplary embodiments is presented for purposes of illustration and description and is not intended to be exhaustive or limited to the disclosed forms of the embodiments. Various exemplary examples describe components that perform actions or operations. In an exemplary embodiment, the components may be configured to perform the described actions or operations. For example, the components may have an arrangement or design of structure that provides the components with the ability to perform the actions or operations described as being performed by the components in the exemplary examples. Furthermore, to the extent that the terms "includes / including," "has," "contains," and similar terms are used herein, such terms are intended to be inclusive, as open-ended terms that do not exclude any additional or other elements, similar to the term "comprises."

[0238] Many variations and modifications will be apparent to those skilled in the art. Furthermore, different exemplary embodiments may provide different features as compared to other preferred embodiments. The selected embodiment or embodiments have been chosen and described in order to best explain the principles, practical applications of the embodiments, and to enable others skilled in the art to appreciate the disclosure of the various embodiments, including various modifications suitable for the particular use contemplated.

Claims

1. A method for designing a hollow composite body (208), comprising: selecting (600) for the hollow composite body (208) by a computer system (210) a ply layer (140, 218, 302) comprising courses (142, 220) having course edges (144, 222); placing (602) the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) with the computer system (210) to create a staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) for the hollow composite body (208) design (132, 204); A method comprising:

2. placing (602) the course edges between the ply layers (140, 218, 302) through the hollow composite body (208) by the computer system (210) to create the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) for the design (132, 204) of the hollow composite body (208); 2. The method of claim 1, comprising rotating (700), by the computer system (210), selected ply layers (234) in the ply layers (140, 218, 302) to create the design (132, 204) of the hollow composite body (208) so that the course edges (144, 222) have more staggering between the ply layers (140, 218, 302).

3. placing (602) the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) by the computer system (210) to create the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) for the design (132, 204) of the hollow composite body (208); 3. The method of claim 1, further comprising: varying (800), by the computer system (210), a width of the course (142, 220) in a selected ply layer (234) so ​​that the course edges (144, 222) have more staggering between the ply layers (140, 218, 302).

4. Varying (800) the width of the courses (142, 220) in the selected ply layer (234) by the computer system (210) so that the course edges (144, 222) in the selected ply layer (234) have more of the staggering at the course edges (144, 222) between the ply layers (140, 218, 302); adding (900) a number of tows (226) to a first course (238) in the selected ply layer (234) by the computer system (210); and removing (902) by the computer system (210) some of the tows (226) from a second course (240) in the selected ply layer (234), wherein the course edges (144, 222) in the selected ply layer (234) have more of the staggering of the course edges (144, 222) between the ply layers (140, 218, 302).

5. adding (902) the number of tows (226) to the first course (238) in the selected ply layer (234) by the computer system (210); selecting (1000) by the computer system (210) a first course (238) having a first course (238) edge in the selected ply layer (234) with minimal staggering from another course edge (245) of the course edges (144, 222) in another ply layer (246); adding (1002) the number of tows (226) to the selected first course (238) by the computer system (210); The method of claim 4, comprising:

6. removing (902) the number of tows (226) from the second course (240) in the selected ply layer (234) by the computer system (210); selecting, by the computer system (210), from another one of the course edges (245) in the other ply layer (246), the second course (240) having a second course (240) edge in the selected ply layer (234) that has a maximum staggering (250); removing, by the computer system (210), the number of tows (226) from the selected second course (240); 6. The method of claim 5, comprising:

7. placing (602) the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) with the computer system (210) to create the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) for the hollow composite body (208); rotating (1200) selected ply layers (234) in the ply layers (140, 218, 302) by the computer system (210) to increase the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302); responsive to rotating the selected ply layer (234) not producing a desired level of staggering of the course edges (144, 222) between the ply layers (140, 218, 302), alternating (1202) some tows (226) between the courses (142, 220) in the selected ply layer (234) to increase the staggering (230) of the course edges (144, 222) at the course edges (144, 222) in the other ply layer (246); The method of claim 5 , comprising:

8. locating (602) the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) with the computer system (210) to create the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) for the design (132, 204) of the hollow composite body (208); selecting (1300) by the computer system (210) a next ply layer (252) in the ply layers (140, 218, 302) for processing; rotating (1302) a next ply layer (252) by the computer system (210) to increase the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302); and in response to rotating the next ply layer (252) not achieving a desired level of staggering of the course edges (144, 222) between the ply layers (140, 218, 302), alternating (1304) some tows (226) between the courses (142, 220) of the next ply layer (252) to increase the staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) by the computer system (210); repeatedly selecting (1306) the next ply layer (252), rotating the next ply layer (252), and alternating the several tows (226) between the courses (142, 220) of the next ply layer (252) by the computer system (210) until all of the ply layers (140, 218, 302) have been processed; The method of claim 6 further comprising:

9. laying up (1400) composite material in the courses (142, 220) using the designs (132, 204) to create the ply layers (140, 218, 302) for the hollow composite body (208); 10. The method of claim 1, further comprising: curing the ply layers laid up using the design to create the hollow composite body, wherein the staggering of the course edges between the ply layers results in reducing undesirable inconsistencies in the hollow composite body.

10. The method of claim 1, wherein there is no overlap between the course edges (144, 222) of the courses (142, 220) throughout the ply layer (140, 218, 302).

11. The method of claim 1, wherein an overlap between the course edges (144, 222) of the courses (142, 220) occurs every nth layer throughout the ply layers (140, 218, 302).

12. The method of claim 1 , wherein the ply layers (140, 218, 302) have the same orientation selected from the group consisting of 0 degrees and 45 degrees.

13. The method of claim 1, wherein the course edges (144, 222) between the courses (142, 220) in the ply layers (304, 306, 308, 310, 312, 314) form at least one of a gap, an overlap, or an abutted edge.

14. a computer system (210); a composite structure manager (212) in the computer system (210), wherein the composite structure manager (212) selecting, for a hollow composite body (208), a ply layer (140, 218, 302) comprising courses (142, 220) having course edges (144, 222); and arranging the course edges (144, 222) between the ply layers (140, 218, 302) throughout the hollow composite body (208) to create a staggering (230) of the course edges (144, 222) between the ply layers (140, 218, 302) for the hollow composite body (208) design (132, 204).

15. The composite structure manager (212) further comprises manufacturing equipment (254, 2208), wherein the manufacturing equipment (254, 2208) 15. The composite manufacturing system of claim 14, wherein the design is used to control laying up composite material in the courses to create the ply layers for the hollow composite body.

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