Composite lamination system and method
The system enhances composite material layup accuracy by using a dual-sensor system for precise positioning and real-time monitoring, addressing overlapping and gap issues in composite material lamination.
Patent Information
- Application Number
- JP2024107643
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-07-17
- Filing Date
- 2024-07-03
- Publication Date
- 2025-01-29
AI Technical Summary
The lamination of composite materials often results in variations such as overlapping and gaps due to the layering process, which current technologies struggle to accurately address.
A system and method utilizing a first and second measurement system with sensors to precisely position the automatic fiber placement head, enabling full resolution conversion and real-time monitoring to enhance the accuracy of composite material layup, reducing or eliminating gaps and overlaps.
The system significantly increases the accuracy of composite material layup, achieving precision within 0.005 inches and reducing defects by minimizing linear interpolation, thereby improving the quality and efficiency of composite part manufacturing.
Smart Images
Figure 2025014110000001_ABST
Abstract
Description
[Technical field]
[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to manufacturing, and more specifically to composite layup. [Background technology]
[0002] In the manufacture of composite structures, plies of composite material are typically laid up on a mandrel or the like. The plies may be laid up, for example, in tape, tow, or other suitable form. In some cases, the fiber plies are infused or pre-impregnated with resin. Composite materials that are pre-impregnated with resin are commonly referred to as prepregs.
[0003] A number of different prepreg plies are laid up in various orientations, and the number of plies used can vary depending on the thickness of the composite structure being manufactured. The plies can be laid up using automated laying equipment, such as a tape laying machine or a fiber placement system.
[0004] Composite layups are subject to some variation, sometimes involving multiple composite plies, which can result in defects such as laps and gaps in the composite part.
[0005] It would therefore be desirable to provide a method and apparatus that takes into account at least some of the above-mentioned problems, as well as other possible problems. Summary of the Invention
[0006] In an embodiment of the present disclosure, a system for positioning an automated fiber placement head on a surface of a substrate is provided, the system including a first measurement system including a first group of sensors configured to scan the surface of the substrate, a second measurement system including a second group of sensors configured to identify a position of the automated fiber placement head, and a data management device configured to generate a full resolution transform using measurements from the first measurement system and to identify a position of the automated fiber placement head using data from the second measurement system.
[0007] In another embodiment of the present disclosure, a method for performing composite layup is provided, in which an initial mandrel scan of a substrate is performed in a manufacturing environment using a first measurement system, a position of an automated fiber placement head is identified in the manufacturing environment using a second measurement system, a full resolution transform is generated using results of the initial mandrel scan, and a layup is initiated on the substrate by the automated fiber placement head based on the full resolution transform and the position.
[0008] In another embodiment of the present disclosure, a method is provided for performing composite layup, in which a surface of a substrate is scanned using a first group of sensors to generate first measurements; an automated fiber placement head is located using a second group of sensors; the automated fiber placement head is positioned relative to the substrate based on the first measurements; and after positioning the automated fiber placement head, a composite material is laid up relative to the surface of the substrate using the automated fiber placement head.
[0009] The features and functions can be achieved individually in various embodiments of the present disclosure and can also be combined in other embodiments, details of which will become apparent from the following description and drawings. [Brief description of the drawings]
[0010] The novel features believed characteristic of the exemplary embodiments are set forth in the appended claims, and the exemplary embodiments and preferred modes of use, as well as their objects and features, will be best understood by reference to the following detailed description of exemplary embodiments of the present disclosure in conjunction with the accompanying drawings, in which:
[0011] [Figure 1] FIG. 1 is an illustration of an aircraft in accordance with an illustrative embodiment. [Diagram 2] 1 is a block diagram illustrating a manufacturing environment in accordance with an illustrative embodiment. [Diagram 3] FIG. 1 illustrates an isometric view of a manufacturing environment in accordance with an illustrative embodiment. [Figure 4] FIG. 1 illustrates a first measurement system and a second measurement system in a manufacturing environment in accordance with an exemplary embodiment. [Diagram 5] 1 is a flowchart illustrating a method for performing a composite layup in accordance with an illustrative embodiment. [Figure 6] 1 is a flowchart illustrating a method for performing a composite layup in accordance with an illustrative embodiment. [Figure 7] 1 is a block diagram illustrating an aircraft manufacturing and service method in accordance with an illustrative embodiment. [Figure 8] 1 is a block diagram illustrating an aircraft in which an illustrative embodiment may be implemented; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The illustrative embodiments recognize and take into account several issues. For example, the illustrative embodiments recognize and take into account that currently probing is performed on the mandrel prior to composite layup. The illustrative embodiments recognize and take into account that probing on a large part can take more than an hour. The illustrative embodiments recognize and take into account that the only data obtained from probing is at the probe points. The probe points are spaced apart. In some instances, the distance between probe points is between 4 feet and 8 feet. In some instances, there may be up to 50 probe points on a large tool. Currently, a linear interpolation (transformation) is performed between the probe points.
[0013] In the illustrative embodiments, it is recognized and contemplated that defects can be reduced by increasing the accuracy of composite layup. In the illustrative embodiments, systems and methods are provided that can reduce or eliminate linear interpolation of the mandrel. In the illustrative embodiments, the accuracy of the composite layup is increased by increasing the accuracy of the mandrel measurement. In the illustrative embodiments, an accuracy of at least 0.010 inches is achieved. In the illustrative embodiments, an accuracy sufficient to reduce or prevent gaps or overlaps in the composite laid up on the mandrel radii is achieved.
[0014] 1, an aircraft is shown in accordance with an exemplary embodiment. Aircraft 100 has wing 102 and wing 104 attached to fuselage 106. Aircraft 100 also includes engine 108 attached to wing 102 and engine 110 attached to wing 104.
[0015] The fuselage 106 has a tail section 112. A horizontal stabilizer 114, a horizontal stabilizer 116, and a vertical stabilizer 118 are attached to the tail section 112 of the fuselage 106.
[0016] Aircraft 100 is an example of an aircraft that may include composite parts laid up using embodiment examples. Aircraft 100 is an example of an aircraft that may have wing spars, stiffeners, or other composite parts laid up using embodiment methods and systems.
[0017] With reference now to Figure 2, a block diagram of a manufacturing environment is shown in accordance with an illustrative embodiment. A system 202 in manufacturing environment 200 may be used to lay up composite parts for aircraft 100 as shown in Figure 1.
[0018] The system 202 can be used to position 258 the automated fiber placement head 230 over the surface 234 of the substrate 232. The system 202 includes a first measurement system 204, a second measurement system 206, and a data management device 207. The first measurement system 204 includes a first group of sensors 210 configured to scan the surface 234 of the substrate 232. In some embodiments, the first measurement system 204 is also referred to as a first metrology system 208.
[0019] The second measurement system 206 includes a second group of sensors 214 configured to determine the position of the automated fiber placement head 230. In some embodiments, the second measurement system 206 is also referred to as a second metrology system 212. The data management device 207 is configured to generate a full resolution transform 276 using the measurements 246 from the first measurement system 204 and to determine the position 250 of the automated fiber placement head 230 using data from the second measurement system 206.
[0020] Unlike conventional probing, no interpolation is performed since the full resolution conversion 276 has sufficient measurements 246 provided by the first measurement system 204. In some embodiments, the accuracy of the first group of sensors 210 is 0.005 inches or better. In some embodiments, scanning of the substrate 232 is performed at a frame rate with an accuracy of 0.010 inches.
[0021] In some embodiments, the first group of sensors 210 includes one or more of an array of light detection and ranging (LIDAR) devices 218, an array of special phase imaging sensors 220, an array of time-of-flight sensors 222, an array of stereo cameras 224, an array of light field cameras 226, or an array of high resolution cameras 228. In some embodiments, the second group of sensors includes one or more of an array of light detection and ranging (LIDAR) devices 218, an array of special phase imaging sensors 220, an array of time-of-flight sensors 222, an array of stereo cameras 224, an array of light field cameras 226, or an array of high resolution cameras 228.
[0022] The substrate 232 may be in the form of a mandrel 236 having a layup surface 238, or a composite ply 240 disposed on the mandrel 236. If the substrate 232 includes a composite ply 240, the first measurement system 204 scans a surface 242 of the composite ply 240. If the substrate 232 is a mandrel 236, the first measurement system 204 scans a layup surface 238 of the mandrel 236. In some embodiments, the composite ply 240 is a partial ply, and both the surface 242 and the exposed surface of the layup surface 238 are scanned by the first measurement system 204.
[0023] The first measurement system 204 performs an initial mandrel scan 256 on the substrate 232. After the initial mandrel scan 256 is performed, a full resolution conversion 276 is performed using the measurements 246 obtained in the initial mandrel scan 256.
[0024] Positioning 258 of the automated fiber placement head 230 relative to the substrate 232 is performed in a time 260 that is significantly less than conventional processes because the initial mandrel scan 256 takes less time compared to physical probing of the mandrels 236. The time 260 for positioning 258 can be significantly less than the time it takes to position using probing.
[0025] In some embodiments, the second measurement system 206 directly tracks the automated fiber placement head 230 in the manufacturing environment 200. In some embodiments, a tracked object 252 is coupled to the automated fiber placement head 230. In these embodiments, the second group of sensors 214 is configured to track the position of the tracked object 252. For example, the tracked object 252 is a reflective object.
[0026] In some embodiments, the substrate 232 is a composite ply 240 on a mandrel 236, and the data management device 207 is configured to use measurements 246 from the first group of sensors 210 to determine a thickness 241 of the composite ply 240. In these embodiments, the thickness 241 of the composite ply 240 can be used to modify the first layup plan 264.
[0027] First layup plan 264 includes a first tool path 266 and compactions 268. In some embodiments, at least one of first tool path 266 and compactions 268 are modified based on thickness 241 of composite ply 240. Modifying first layup plan 264 can reduce or prevent accumulation of defects in the composite part. Also, modifying first layup plan 264 can reduce additional defects in the composite part.
[0028] In some embodiments, substrate 232 is composite ply 240 on mandrel 236, and data management device 207 is configured to form a model 278 of composite ply 240 in near real-time relative to measurements 246 being made by first measurement system 204. By forming model 278 in near real-time relative to measurements 246 being made, model 278 can be used in real-time monitoring 262. In some embodiments, accuracy 280 of model 278 of composite ply 240 is within about 0.005 inches relative to composite ply 240. In some embodiments, future layup plan 270 is revised based on model 278.
[0029] In some embodiments, the substrate 232 is a mandrel 236 and the data management system 207 is further configured to position the automated fiber placement head 230 relative to the mandrel 236 using the full resolution conversion 276 and the position 250 of the automated fiber placement head 230. In some embodiments, the accuracy of the data 248 from the second measurement system 206 is greater than the accuracy of the machine controller 254.
[0030] In some embodiments, first measurement system 204 is configured to perform both positioning 258 and real-time monitoring 262. In real-time monitoring 262, measurements 246 may be measurements taken of composite material 244 placed by automated fiber placement head 230 as composite material 244 on substrate 232. In some embodiments, composite material 244 can be used to modify future layup plan 270.
[0031] Future layup plan 270 includes a second tool path 272 and a press 274. In some embodiments, at least one of second tool path 272 and press 274 are modified based on the layup of composite material 244. Modifying future layup plan 270 can reduce or prevent accumulation of defects in the composite part. Additionally, modifying future layup plan 270 can reduce additional defects in the composite part.
[0032] In some embodiments, the second measurement system 206 is configured to perform real-time monitoring 262. The real-time monitoring 262 of the automated fiber placement head 230 can continuously track the position 250 of the automated fiber placement head 230. The accuracy of the real-time monitoring 262 of the automated fiber placement head 230 can be greater than the accuracy of the tracking of the automated fiber placement head 230 by the machine controller 254.
[0033] In some embodiments, system 202 can be described as including a plurality of sensors 216 configured to perform initial mandrel scan 256 and identify the position of automated fiber placement head 230. In these embodiments, first group of sensors 210 and second group of sensors 214 are sensors within sensors 216.
[0034] The illustration of manufacturing environment 200 in FIG. 2 is not intended to provide 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. Additionally, the blocks illustrated are intended to illustrate functional components. One or more of these blocks may be combined, divided, or combined and then divided into different blocks when implemented in an illustrative embodiment.
[0035] In some embodiments, multiple successive layers of composite material are placed on the mandrel 236. In some embodiments, additional layup plans are present for laying up additional composite layers to the mandrel 236.
[0036] With reference now to Figure 3, an isometric view of a manufacturing environment is shown in accordance with an illustrative embodiment. Manufacturing environment 300 is a physical embodiment of manufacturing environment 200 shown in Figure 2. Portions of aircraft 100 may be manufactured in manufacturing environment 300.
[0037] Present in manufacturing environment 300 is an automated fiber placement head 302. Automated fiber placement head 302 is configured to place a composite material onto a substrate, such as substrate 304. In this embodiment, substrate 304 takes the form of a mandrel 306.
[0038] In the manufacturing environment 300, there is a first measurement system 308 and a second measurement system 310. The first measurement system 308 and the second measurement system 310 may be used to improve the accuracy of the layup of the composite material on the substrate 304. The first measurement system 308 may be used to position the automated fiber placement head 302 relative to the mandrel 306. The first measurement system 308 may be used for real-time monitoring of the composite material being laid up on the mandrel 306.
[0039] The second measurement system 310 is configured to determine the position of the automated fiber placement head 302. The second measurement system 310 can be used to position the automated fiber placement head 302 relative to the mandrel 306 prior to depositing the composite material. In some embodiments, the second measurement system 310 can be used for real-time monitoring of the automated fiber placement head 302.
[0040] The first measurement system 308 includes a first group of sensors 312 configured to scan the surface of the substrate 304. The first group of sensors 312 includes one or more of an array of light detection and ranging (LIDAR) devices, an array of special phase imaging sensors, an array of time-of-flight sensors, an array of stereo cameras, an array of light field cameras, or an array of high resolution cameras. The second measurement system 310 includes a second group of sensors 314 configured to determine a position of the automated fiber placement head 302. The second group of sensors 314 includes one or more of an array of light detection and ranging (LIDAR) devices, an array of special phase imaging sensors, an array of time-of-flight sensors, an array of stereo cameras, an array of light field cameras, or an array of high resolution cameras.
[0041] 4, a diagram illustrating a first measurement system and a second measurement system in a manufacturing environment is shown in accordance with an exemplary embodiment. In view 400, a first group of sensors 312 of the first measurement system 308 and a second group of sensors 314 of the second measurement system 310 are depicted along the length of the mandrel 306. As can be seen in view 400, the first group of sensors 312 and the second group of sensors 314 are distributed along the length of the substrate 304. By distributing the first group of sensors 312 along the length of the substrate 304, the entire substrate 304 can be scanned. Also, distributing the first group of sensors 312 along the length of the substrate 304 can increase the accuracy of positioning compared to performing probing at individual locations and then performing interpolation.
[0042] By distributing the second group of sensors 314 along the length of the substrate 304, the position of the automated fiber placement head 302 can be identified at any processing location within the manufacturing environment 300. Also, by distributing the second group of sensors 314 along the length of the substrate 304, these second group of sensors 314 can be used to provide initial positioning and real-time monitoring of the automated fiber placement head 302 along the length of the substrate 304.
[0043] As can be seen from view 400, the first group of sensors 312 and the second group of sensors 314 are distributed on two sides of the substrate 304. In view 400, the first group of sensors 312 and the second group of sensors 314 are distributed on sidewall 402 and sidewall 404. As shown, substrate 304 is disposed between sidewall 402 and sidewall 404, and automated fiber placement head 302 moves between sidewall 402 and sidewall 404 to lay up composite material on substrate 304.
[0044] In this figure, the first group of sensors 312 and the second group of sensors 314 are shown mounted directly to the side walls 402 and 404, however, the first group of sensors 312 and the second group of sensors 314 may be mounted in other manners. In some embodiments, at least one of the first group of sensors 312 and / or the second group of sensors 314 may be mounted on a stand between the side walls 402 and 404.
[0045] With reference now to Figure 5, a flowchart of a method for performing composite layup is shown in accordance with an illustrative embodiment. Method 500 may be used to lay up a composite part for aircraft 100 as shown in Figure 1. Method 500 may be performed using system 202 in manufacturing environment 200 as shown in Figure 2. Method 500 may be performed using first measurement system 308 and second measurement system 310 in manufacturing environment 300 as shown in Figures 3 and 4.
[0046] The method 500 performs an initial mandrel scan of a substrate in a manufacturing environment using a first measurement system (step 502). The method 500 identifies a position of an automated fiber placement head in the manufacturing environment using a second measurement system (step 504). The method 500 generates a full resolution transform using the results of the initial mandrel scan (step 506). The method 500 initiates layup on the substrate by the automated fiber placement head based on the full resolution transform and the position (step 508). The method 500 then ends.
[0047] In some embodiments, the method 500 includes moving the mandrel to a manufacturing environment that includes an automated fiber placement head, step 510. In some embodiments, performing the initial mandrel scan includes scanning a surface of the mandrel.
[0048] In some embodiments, performing the initial mandrel scan includes scanning a composite ply disposed on the mandrel, step 512. In some embodiments, performing the initial mandrel scan includes identifying a thickness of the composite ply disposed on the mandrel.
[0049] In some embodiments, the method 500 monitors the position of the automated fiber placement head during the layup using a second measurement system (step 514). In some embodiments, the method 500 adjusts the position of the automated fiber placement head during the layup based on the monitoring by the second measurement system (step 516).
[0050] In some embodiments, the method 500 includes scanning the composite material placed by the automated fiber placement head with a first measurement system while the automated fiber placement head is performing the layup (step 518). In some embodiments, scanning the composite material placed by the automated fiber placement head during layup can inspect the composite material for defects. In some embodiments, scanning the composite material placed by the automated fiber placement head during layup can reduce or eliminate each future positioning step. In some embodiments, scanning the composite material placed by the automated fiber placement head during layup can obtain data of the substrate surface including the composite material during processing to reduce downtime.
[0051] In some embodiments, the method 500 modifies a future layup plan based on the scan of the composite material laid down by the automated fiber placement head (step 520). For example, the future layup plan may be a plan for laying down a subsequent composite material. Future tool paths for laying down the subsequent composite material may be modified to account for the physical layup of the composite material. In these embodiments, by accounting for the position and dimensions of the composite material as laid down, the accumulation of defects in the thickness of the composite layup may be reduced.
[0052] In some embodiments, performing the initial mandrel scan includes scanning the substrate using at least one of an array of light detection and ranging (LIDAR) devices, an array of special phase imaging sensors, an array of time-of-flight sensors, an array of stereoscopic cameras, an array of light field cameras, or an array of high resolution cameras (step 522). In some embodiments, the accuracy of the first measurement system is 0.005 inches or better, and the initial mandrel scan is performed at a frame rate with an accuracy of 0.010 inches (step 524).
[0053] With reference now to Figure 6, a flowchart of a method for performing composite layup is shown in accordance with an illustrative embodiment. Method 600 may be used to lay up a composite part for aircraft 100 shown in Figure 1. Method 600 may be performed using system 202 in manufacturing environment 200 shown in Figure 2. Method 600 may be performed using first measurement system 308 and second measurement system 310 in manufacturing environment 300 shown in Figures 3 and 4.
[0054] The method 600 scans a surface of a substrate using a first group of sensors to generate first measurements (step 602). The method 600 identifies a position of an automated fiber placement head using a second group of sensors (step 604). The method 600 positions the automated fiber placement head relative to the substrate based on the first measurements (step 606). After positioning the automated fiber placement head, the method 600 uses the automated fiber placement head to lay up a composite material on the surface of the substrate (step 608). The method 600 then ends.
[0055] In some embodiments, the method 600 calculates a full resolution transformation to move the automated fiber placement head to achieve a substantial design match between the first measurements and a layup plan for the automated fiber placement head (step 610). In some embodiments, the method 600 moves the automated fiber placement head according to the full resolution transformation (step 612). In some embodiments, the method 600 includes using the first measurements to modify a first layup plan for the automated fiber placement head, the first layup plan including a first toolpath for depositing composite material on a substrate (step 614).
[0056] In some embodiments, the substrate is a mandrel and scanning the surface of the substrate includes scanning a layup surface of the mandrel (step 616). In some embodiments, the substrate is a composite ply on a mandrel and scanning the surface of the substrate includes scanning the composite ply and further includes determining a thickness of the composite ply using measurements from the first group of sensors (step 618).
[0057] In some embodiments, the accuracy of the first group of sensors is 0.005 inches or better, and the scanning is performed at a frame rate with an accuracy of 0.010 inches (step 620). By achieving the desired accuracy, scanning using the first group of sensors can be employed to improve the quality of the resulting composite part. Also, by achieving the desired accuracy, the first group of sensors can be used to reduce defects in the resulting composite part.
[0058] In this specification, when the phrase "at least one" is used in conjunction with a list of elements, it means that one or more of the listed elements may be used in various combinations, or only one of each listed element may be required. For example, without limitation, "at least one of element A, element B, or element C" may include element A, element A and element B, or element C. This example may also include element A, element B, and element C, or element B and element C. Of course, any combination of these elements may be used. In other examples, "at least one" may be, for example, without limitation, two elements A, one element B, and ten elements C, or four elements B and seven elements C, or any other suitable combination. An element may be a specific object, thing, or category. That is, "at least one" means that any number of the listed elements may be used in any combination, but may not require all of the listed elements.
[0059] As used herein, the phrase "a number of" when used in reference to an element means one or more of the element.
[0060] The flowcharts and block diagrams of the various illustrated embodiments illustrate the structure, functionality, and operation of some possible implementations of the apparatus and methods in the exemplary embodiments. In this regard, each block in the flowcharts or block diagrams represents at least one of a module, a segment, a function, or a portion of an operation or step.
[0061] In some alternative aspects of the exemplary embodiments, one or more functions noted in the blocks may be executed out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially simultaneously or in the reverse order, depending on the functionality involved. Also, other blocks may be added to the blocks shown in the flowchart or block diagram. Some blocks may be optional. For example, steps 510 to 524 may be optional. Also, for example, steps 610 to 620 may be optional.
[0062] An example embodiment of the disclosure may be described with reference to an aircraft manufacturing and service method 700 as shown in Figure 7 and an aircraft 800 as shown in Figure 8. Referring initially to Figure 7, a block diagram of an aircraft manufacturing and service method is shown in accordance with an example embodiment. During pre-production, aircraft manufacturing and service method 700 includes specification and design 702 and material procurement 704 of aircraft 800 as shown in Figure 8.
[0063] During production, component and subassembly manufacturing 706 and systems integration 708 of the aircraft 800 takes place. The aircraft 800 then goes through certification and delivery 710 and enters service 712. While in customer service 712, the aircraft 800 is scheduled for routine maintenance and service 714, which may include upgrades, reconfigurations, modifications, or other maintenance and maintenance.
[0064] Each process of aircraft manufacturing and service method 700 may be performed or implemented by a system integrator, a third party, and / or an operator. In these examples, the operator may be a customer. Note that the system integrator may include any number of aircraft manufacturers and major system subcontractors. The third parties may include any number of vendors, subcontractors, and suppliers. The operator may be, for example, an airline, a leasing company, a military entity, a service organization, etc.
[0065] Referring to Figure 8, a block diagram of an aircraft in which an illustrative embodiment may be implemented is shown. In this example, aircraft 800 is manufactured according to aircraft manufacturing and service method 700 as shown in Figure 7 and includes an airframe 802 and an interior 806 with a number of systems 804. Examples of systems 804 include one or more of a drive train 808, an electrical system 810, a hydraulic system 812, and an environmental system 814, as well as any number of other systems.
[0066] Apparatus and methods embodied herein may be employed during at least one stage of aircraft manufacturing and service method 700. For example, one or more illustrative embodiments may be manufactured or used during at least one of component and subassembly manufacturing 706, system integration 708, in-service 712, or maintenance and service 714 shown in FIG.
[0067] In the above embodiments, a system and method for composite layup is provided that allows for better positioning of the layup head over curved or angled parts during layup and pressing operations.
[0068] Exemplary embodiments perform the following steps: move layup mandrel (LM); perform scan of LM and head; generate full resolution transform; start layup; and adjust layup head as needed to accommodate the part. Exemplary embodiments provide a more accurate and faster way to consistently position the layup machine relative to the layup mandrel and current part. Exemplary embodiments enable high speed composite manufacturing. Exemplary embodiments can reduce or eliminate time-sensitive probing.
[0069] In a linear flow manufacturing line, multiple positioning operations can be performed. Exemplary embodiments allow rapid positioning. In some exemplary embodiments, positioning can be performed in approximately 15 minutes.
[0070] Exemplary embodiments can provide full mesh resolution and do not require linear interpretations between probe points. Exemplary embodiments can provide continuous monitoring for changes during the build (such as collisions or movements). Changing pressure levels on contoured parts affect the nominal surface definition. Continuous monitoring can monitor the nominal surface definition with different levels of pressure. Exemplary embodiments can also provide monitoring on the part itself (as is) rather than on the tool.
[0071] The system can be used to constantly measure and monitor the position of an automated fiber placement head, thereby increasing the accuracy of the head. Exemplary embodiments can provide accurate machine-to-tool information and can compensate for machine variations and changes. Exemplary embodiments can reduce costs by eliminating the use of probe heads and can save time over high speed programs.
[0072] Exemplary embodiments allow for as much pressure as necessary, if necessary. Exemplary embodiments allow for rescanning, if necessary, without affecting flow. Exemplary embodiments allow for rapid positioning at the start of processing.
[0073] Exemplary embodiments can provide measurements that can compensate for part thickness. Exemplary embodiments take into account surface quality and part build. Exemplary embodiments compensate for variations found in composite layups. Exemplary embodiments can reduce or eliminate overlaps / gaps that can develop toward the end of a build.
[0074] The exemplary embodiments provide improved quality and process control in composite manufacturing. The exemplary embodiments allow for pressing without affecting surface quality. The exemplary embodiments take into account that pressing thick sections is time sensitive.
[0075] The description of the various exemplary embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or to limit the present invention to the practice of the disclosed forms. Many modifications or variations will be apparent to those skilled in the art. Furthermore, the various exemplary embodiments may provide different characteristics than other exemplary embodiments. The selected embodiments have been chosen and described in order to best explain the principles and practical applications of the embodiments, and to enable those skilled in the art to understand the disclosure for the various embodiments with various modifications suitable for the particular applications envisioned.
[0076] This disclosure includes the following notes:
[0077] Appendix 1. A system (202) for positioning (258) an automated fiber placement head (230, 302) over a surface (234) of a substrate (232, 304), comprising: a first measurement system (204, 308) including a first group of sensors (210, 312) configured to scan the surface (234) of the substrate (232, 304); a second measurement system (206, 310) including a second group of sensors (214, 314) configured to determine a position of the automated fiber placement head (230, 302); and a data management device (207) configured to generate a full resolution transform (276) using measurements (246) from the first measurement system (204, 308) and to identify a position (250) of the automated fiber placement head (230, 302) using data from the second measurement system (206, 310).
[0078] Appendix 2. The system (202) of Appendix 1, wherein the first group of sensors (210, 312) includes one or more of an array of light detection and ranging (LIDAR) devices (218), an array of special phase imaging sensors (220), an array of time-of-flight sensors (222), an array of stereoscopic cameras (224), an array of light field cameras (226), or an array of high-resolution cameras (228).
[0079] Appendix 3. The system (202) of claim 1 or 2, wherein the second group of sensors (214, 314) includes one or more of an array of light detection and ranging (LIDAR) devices (218), an array of special phase imaging sensors (220), an array of time-of-flight sensors (222), an array of stereoscopic cameras (224), an array of light field cameras (226), or an array of high-resolution cameras (228).
[0080] Appendix 4. A system (202) described in any of Appendix 1 to 3, further comprising a tracking object (252) connected to the automatic fiber placement head (230, 302), and the second group of sensors (214, 314) is configured to track the position of the tracking object (252).
[0081] Appendix 5. 5. The system (202) of any one of claims 1 to 4, wherein the substrate is a composite layer (240) on a mandrel (236), and the data management device (207) is configured to determine a thickness of the composite layer (240) using measurements from the first group of sensors (210, 312).
[0082] Appendix 6. 5. The system (202) of any one of claims 1 to 4, wherein the substrate is a composite layer (240) on a mandrel (236), and the data management device (207) is configured to form a model of the composite layer (240) in near real time to the generation of measurements (246) by the first measurement system (204, 308).
[0083] Appendix 7. 7. The system (202) of claim 6, wherein the accuracy (280) of the model (278) of the composite layer (240) is within about 0.005 inches relative to the composite layer (240).
[0084] Appendix 8. 5. The system (202) of any one of claims 1 to 4, wherein the substrate (232) is a mandrel (236), and the data management device (207) is further configured to position the automated fiber placement head (230, 302) relative to the mandrel (236) using the full resolution conversion (276) and the position (250) of the automated fiber placement head (230, 302).
[0085] Appendix 9. 9. The system (202) of any one of claims 1 to 8, wherein the first measurement system (204, 308) is configured to perform both positioning (258) and real-time monitoring (262).
[0086] Appendix 10. The system (202) of any one of claims 1 to 9, wherein the second measurement system (206, 310) is configured to perform real-time monitoring (262).
[0087] Appendix 11. A method (500) for performing a composite layup, comprising: performing an initial mandrel (236) scan of the substrate within the manufacturing environment using a first measurement system (204, 308); identifying an initial position (250) of an automated fiber placement head (230, 302) within the manufacturing environment using a second measurement system (206, 310); generating a full resolution transform (276) using the results of the initial mandrel (236) scan; and initiating a layup on the substrate by the automated fiber placement head (230, 302) based on the full resolution transformation (276) and the initial position (250).
[0088] Appendix 12. 12. The method (500) of claim 11, wherein performing the initial mandrel (236) scan includes scanning a composite ply (240) disposed on the mandrel (236).
[0089] Appendix 13. 13. The method (500) of claim 11 or 12, further comprising monitoring the position (250) of the automated fiber placement head (230, 302) during the layup using a second measurement system (206, 310).
[0090] Appendix 14. 14. The method of claim 13, further comprising adjusting the position of the automated fiber placement head during the layup based on monitoring by the second measurement system.
[0091] Appendix 15. 15. The method (500) of any of claims 11 to 14, further comprising scanning a composite material placed by the automated fiber placement head (230, 302) with the first measurement system (204, 308) while the automated fiber placement head (230, 302) is performing a layup.
[0092] Appendix 16. 16. The method (500) of claim 15, further comprising modifying a future layup plan based on a scan of the composite material laid down by the automated fiber placement head (230, 302).
[0093] Appendix 17. 17. The method (500) of any of claims 11 to 16, wherein performing the initial mandrel (236) scan includes scanning the substrate using at least one of an array of light detection and ranging (LIDAR) devices (218), an array of special phase imaging sensors (220), an array of time-of-flight sensors (222), an array of stereoscopic cameras (224), an array of light field cameras (226), or an array of high resolution cameras (228).
[0094] Appendix 18. 12. The method (500) of claim 11, wherein the accuracy of the first measurement system (204, 308) is 0.005 inches or better and the initial mandrel (236) scan is performed at a frame rate with an accuracy of 0.010 inches.
[0095] Appendix 19. A method (600) for performing a composite layup, comprising: scanning a surface (234) of a substrate (232, 304) using a first group of sensors (210, 312) to generate an initial mandrel scan (256) (246); determining a position of the automated fiber placement head (230, 302) using a second group of sensors (214, 314); positioning (258) the automated fiber placement head (230, 302) relative to the substrate based on the initial mandrel scan (256, 246); and after positioning (258) the automated fiber placement head (230, 302), laying up a composite material against the surface (234) of the substrate (232, 304) using the automated fiber placement head (230, 302).
[0096] Appendix 20. calculating a full resolution transformation (276) for moving the automated fiber placement head (230, 302) to achieve a substantial design match between the initial mandrel scan (256)(246) and a layup plan for the automated fiber placement head (230, 302); 20. The method (600) of claim 19, further comprising moving the automated fiber placement head (230, 302) according to the full resolution transformation (276).
[0097] Appendix 21. 21. The method (600) of any of claims 19 or 20, further comprising using the initial mandrel scan (256) (246) to modify a first layup plan (264) for the automated fiber placement head (230, 302), the first layup plan (264) including a first tool path (266) for placing a composite material on the substrate.
[0098] Appendix 22. 22. The method (600) of any one of claims 19 to 21, wherein the substrate is a mandrel (236), and scanning the surface (234) of the substrate (232, 304) includes scanning a layup surface of the mandrel (236).
[0099] Appendix 23. 23. The method (600) of any of claims 19-22, wherein the substrate is a composite layer (240) on a mandrel (236), and scanning the surface (234) of the substrate (232, 304) includes scanning the composite layer (240), and further including determining a thickness of the composite layer (240) using measurements from the first group of sensors (210, 312).
[0100] Appendix 24. 20. The method (600) of claim 19, wherein the accuracy of the first group of sensors (210, 312) is 0.005 inches or better and the scanning is performed at a frame rate with an accuracy of 0.010 inches.
Claims
1. 1. A system for positioning an automated fiber placement head on a surface of a substrate, comprising: a first measurement system including a first group of sensors configured to scan the surface of the substrate; a second measurement system including a second group of sensors configured to determine a position of the automatic fiber placement head; and a data management device configured to generate a full resolution transform using measurements from the first measurement system and to identify a position of the automated fiber placement head using data from the second measurement system.
2. 2. The system of claim 1, wherein the first group of sensors and the second group of sensors comprise one or more of an array of light detection and ranging (LIDAR) devices, an array of special phase imaging sensors, an array of time-of-flight sensors, an array of stereoscopic cameras, an array of light field cameras, or an array of high-resolution cameras.
3. The system of claim 1 , further comprising a tracked object coupled to the automated fiber placement head, the second group of sensors configured to track a position of the tracked object.
4. 10. The system of claim 1, wherein the substrate is a composite ply on a mandrel, and the data management device is configured to determine a thickness of the composite ply using measurements from the first group of sensors.
5. 2. The system of claim 1, wherein the substrate is a composite ply on a mandrel, and the data management device is configured to form a model of the composite ply in near real-time to measurements being made by the first measurement system.
6. 2. The system of claim 1, wherein the substrate is a mandrel, and the data management device is further configured to position the automated fiber placement head relative to the mandrel using the full resolution conversion and the position of the automated fiber placement head.
7. The system of claim 1 , wherein the first measurement system is configured to perform both positioning and real-time monitoring.
8. The system of claim 1 , wherein the second measurement system is configured to perform real-time monitoring.
9. 1. A method for performing a composite layup, comprising: performing an initial mandrel scan of a substrate in a manufacturing environment using a first measurement system; identifying a position of an automated fiber placement head within the manufacturing environment using a second measurement system; generating a full resolution transform using results of the initial mandrel scan; and initiating a layup on the substrate by the automated fiber placement head based on the full resolution conversion and the position.
10. The method of claim 9 , wherein performing the initial mandrel scan further comprises scanning a composite ply mounted on the mandrel.
11. The method of claim 9 , further comprising monitoring the position of the automated fiber placement head during the layup using a second measurement system.
12. The method of claim 11 , further comprising adjusting the position of the automated fiber placement head during the layup based on monitoring by the second measurement system.
13. The method of claim 9 , further comprising scanning a composite material placed by the automated fiber placement head with the first measurement system while the automated fiber placement head is performing a layup.
14. The method of claim 13 , further comprising: modifying a future layup plan based on a scan of the composite material laid down by the automated fiber placement head.
15. 10. The method of claim 9, wherein performing the initial mandrel scan includes scanning the substrate using at least one of an array of light detection and ranging (LIDAR) devices, an array of special phase imaging sensors, an array of time-of-flight sensors, an array of stereoscopic cameras, an array of light field cameras, or an array of high resolution cameras.
16. 1. A method for performing a composite layup, comprising: scanning a surface of the substrate using a first group of sensors to generate first measurements; determining a position of the automatic fiber placement head using a second group of sensors; positioning the automated fiber placement head relative to the substrate based on the first measurement; and after positioning the automated fiber placement head, laying up a composite material against the surface of the substrate using the automated fiber placement head.
17. performing a full resolution transformation calculation for moving the automated fiber placement head to achieve a substantial design match between the first measurements and a layup plan for the automated fiber placement head; The method of claim 16 , further comprising: moving the automated fiber placement head according to the full resolution conversion.
18. 17. The method of claim 16, further comprising using the first measurements to modify a first layup plan for the automated fiber placement head, the first layup plan comprising a first tool path for placing a composite material on the substrate.
19. The method of claim 16 , wherein the substrate is a mandrel and scanning the surface of the substrate comprises scanning a layup surface of the mandrel.
20. the substrate is a composite ply on a mandrel, and scanning the surface of the substrate includes scanning the composite ply; and The method of claim 16 , comprising determining a thickness of the composite layer using measurements from the first group of sensors.