Multiply lamination system

Abstract

To achieve multiply lamination of elongated composite parts, relating to composite manufacturing.SOLUTION: A first cutting system cuts a first group of courses and moves them to a staging position. A placement robot picks up and places the first group of courses from the staging position to a stacking surface to form a first ply of a multi-ply laminate, changing the fiber direction to a desired direction for the first ply. A second cutting system cuts and moves a second group of courses to the staging position while the placement robot picks up and places the first group of courses. The placement robot picks up and places the second group of courses from the staging position to the stacking surface to form a second ply of the multi-ply laminate after the first ply has been formed, and during the pick-up and placement, changes the fiber direction from the initial direction to a desired direction for the second ply.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] This invention relates generally to composite manufacturing, and more particularly to multi-ply layup of elongated composite components. [Background technology]

[0002]

[0002] The proportion of composite materials in aircraft design and manufacturing is increasing. Composite materials are used in aircraft to reduce the weight of the aircraft. This weight reduction can improve performance characteristics such as payload and fuel efficiency. Furthermore, composite materials provide longer life for various components in the aircraft.

[0003]

[0003] 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 combined with a polymer resin matrix, such as carbon fiber reinforced polymer (CFRP). The fibers can be unidirectional, such as tapes or tows, or multidirectional, such as woven fabrics or textiles. The fibers and resins can be arranged and cured to form a composite structure.

[0004]

[0004] Using composite materials to create aerospace composite structures allows portions of an aircraft to be manufactured in larger pieces or sections. For example, the fuselage in an aircraft may be fabricated as multiple cylindrical sections to form the fuselage of the aircraft. Other examples include, but are not limited to, wing components joined to form a wing, or stabilizer components joined to form a stabilizer.

[0005]

[0005] In the manufacture of composite structures, layers of composite material may be laid up on a tool. The layers of composite material may include sheets of fibers. These sheets may take the form of, for example, but not limited to, cloth, tape, tow, or other suitable configurations for sheets. In some cases, resin may be infused or pre-impregnated into the sheets. These types of sheets are commonly referred to as prepregs.

[0006]

[0006] Various layers of prepreg can be laid up in various directions. Various numbers of layers can be used depending on the desired thickness of the composite structure being produced. The layers can be laid up manually or using automated laying equipment such as tape laying machines or fiber placement systems.

[0007]

[0007] After the various layers are laid up on the tool, the layers may be subjected to temperature and pressure to bond and harden, thus forming the final composite structure. Summary of the Invention

[0008]

[0008] One embodiment of the present disclosure provides a multi-ply laying system, including a first cutting system, a second cutting system, a placement robot, and a controller. The first cutting system and the second cutting system are each configured to independently cut a material having fibers oriented in an initial direction to form courses and move the courses to a staging position. The controller is in communication with the first cutting system, the second cutting system, and the placement robot. The controller is configured to control the first cutting system to cut and move a first group of courses to the staging position. The controller is configured to control the placement robot to pick up and place the first group of courses from the staging position onto a laying surface to form a first ply of a multi-ply layup, and to change the orientation of the fibers from the initial orientation to a desired orientation for the first ply during the pick-up and placement. The controller is configured to control the second cutting system to cut and move a second group of courses to the staging position while the placement robot is picking up and placing the first group of courses. The controller is configured to control the placement robot to pick up and place the second group of courses from the staging position onto the laying surface to form a second ply of the multi-ply laminate after the first ply has been formed, and to change the fiber direction from the initial direction to a desired direction for the second ply during the pick-up and placing.

[0009]

[0009] An embodiment of the present disclosure provides a multi-ply laying system, including a first cutting system, a second cutting system, a placement robot, an automated tape laying machine, and a controller. The first cutting system and the second cutting system are each configured to independently cut a material having fibers oriented in an initial direction to form courses and move the courses to a staging position. The automated tape laying machine is arranged to place the material having the fibers in the initial direction on a laying surface. The controller is in communication with the first cutting system, the second cutting system, the placement robot, and the automated tape laying machine. The controller is configured to control the first cutting system to cut and move the first group of courses to the staging position. The controller is configured to control the placement robot to pick up and place the first group of courses from the staging position to the laying surface to form a first ply of the multi-ply layup, and to change the orientation of the fibers from the initial orientation to a desired orientation for the first ply during the pick-up and placement. The controller is configured to control the second cutting system to cut and move the second group of courses to a staging position while the placement robot is picking up and placing the first group of courses. The controller is configured to control the placement robot to pick up and place the second group of courses from the staging position to the laying surface to form a second ply of the multi-ply laminate after the first ply is formed, and to change the fiber direction from an initial direction to a desired direction for the second ply during the pick-up and placing. The controller is configured to control the automated tape laying machine to place the material to form the plies of the multi-ply laminate with the plies having fibers oriented in the initial direction.

[0010]

[0010] Yet another embodiment of the present disclosure provides a method of forming a multi-ply laminate. A first cutting system is controlled to cut and move a first group of courses to a staging position. A placement robot is controlled to pick up and place the first group of courses from the staging position onto a laying surface to form a first ply of the multi-ply laminate, and during the pick-up and placing, change the fiber orientation from an initial orientation to a desired orientation for the first ply. A second cutting system is controlled to cut and move a second group of courses to a staging position while the placement robot is picking up and placing the first group of courses. The placement robot is controlled to pick up and place the second group of courses from the staging position onto a laying surface to form a second ply of the multi-ply laminate after the first ply is formed, and during the pick-up and placing, change the fiber orientation from an initial orientation to a desired orientation for the second ply. An automated tape laying machine is controlled to place the material to form a third ply of a multi-ply laminate, with the third ply having fibers oriented in an initial direction.

[0011]

[0011] These features and functions may be realized individually in various embodiments of the present disclosure or may be combined in yet other embodiments, further details of which can be understood with reference to the following description and drawings.

[0012]

[0012] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments as well as the preferred modes of use, further objects and features thereof will be best understood by reading the following detailed description of the illustrative embodiments of the present disclosure in conjunction with the accompanying drawings. [Brief description of the drawings]

[0013] [Figure 1]

[0013] FIG. 1 is a block diagram of a composite manufacturing environment in accordance with an illustrative embodiment. [Diagram 2]

[0014] FIG. 1 is a schematic diagram of a multi-ply layup in accordance with an illustrative embodiment; [Diagram 3]

[0015] FIG. 1 is a schematic diagram of an inspection system in accordance with an illustrative embodiment. [Figure 4]

[0016] FIG. 1 is a pictorial diagram of a multi-ply stacking system in accordance with an illustrative embodiment; [Diagram 5]

[0017] FIG. 1 is a pictorial diagram of the laying of courses by an automated tape laying machine in a ply laying system in accordance with an illustrative embodiment; [Figure 6]

[0018] FIG. 1 is a pictorial illustration of the laying of courses by a placement robot in a ply laying system in accordance with an illustrative embodiment; [Figure 7]

[0019] FIG. 1 is a pictorial illustration of the laying of courses by a placement robot in a ply laying system in accordance with an illustrative embodiment; [Figure 8]

[0020] FIG. 11 is an illustration of a flowchart of a process for forming limited multi-plies in accordance with an illustrative embodiment; [Figure 9]

[0021] FIG. 11 is an illustration of a flowchart of a process for laying up a third ply in a multi-ply laminate in accordance with an illustrative embodiment. [Figure 10]

[0022] FIG. 10 is an illustration of a flowchart of a process for inspecting a course in accordance with an illustrative embodiment; [Figure 11]

[0023] FIG. 10 is an illustration of a flowchart of a process for inspecting a course in accordance with an illustrative embodiment; [Figure 12]

[0024] FIG. 10 is an illustration of a flowchart of a process for inspecting a course in accordance with an illustrative embodiment; [Figure 13]

[0025] FIG. 10 is an illustration of a flowchart of a process for providing redundancy in a multi-ply stacking system in accordance with an illustrative embodiment. [Figure 14]

[0026] 1 is a block diagram of a data processing system in accordance with an illustrative embodiment; [Figure 15]

[0027] FIG. 1 is an illustration of an aircraft manufacturing and service method in accordance with an illustrative embodiment. [Figure 16]

[0028] FIG. 1 is a block diagram of an aircraft in which an illustrative embodiment may be implemented. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014]

[0029] The illustrative embodiments recognize and take into account one or more of the various assumptions. For example, the illustrative embodiments recognize and take into account the importance of increasing the speed at which composite parts can be produced in manufacturing aircraft. The speed at which multi-ply laminates can be formed is often a limitation in the high speed manufacturing of long, thin, elongated composite parts. The process of forming multi-ply laminates for elongated composite parts, such as wing or fuselage stringers, can be particularly inefficient and can become a bottleneck in the aircraft manufacturing process. Inefficiencies can arise because forming multi-ply laminates often involves laying down individual layers with fibers in different orientations.

[0015]

[0030] As used herein, a course is a single piece of cut material. A ply is a series of courses having the same fiber direction placed side by side or next to each other.

[0016]

[0031] A sequence is also defined as all of the courses and plies in a given direction, where all plies are laid together before a global inspection is performed. The sequence may include plies with multiple fiber directions. In some embodiments, a sequence may have all plies with the same fiber direction.

[0017]

[0032] Currently, conventional tape laying machines cut and move the laying head multiple times during the laying process. Additionally, rework and idle time also cause delays in the production of long slender composite parts, such as wing stringers. As a result, current laying systems are down for large amounts of time for inspection and rework. There is also an undesirable amount of idle time for material input and machine maintenance.

[0018]

[0033] It would therefore be desirable to have methods, apparatus, systems, and computer program products that result in at least one of: reducing the time required to place a non-zero course, reducing offline inspection and rework, or avoiding material input and maintenance downtime. As used herein, the phrase "at least one of" used in conjunction with enumerated items means that various combinations of one or more of the enumerated items may be used and that only one of each of the enumerated items may be required. In other words, "at least one of" means that any combination of items and that some items may be used from among the enumerated, but not necessarily all of the enumerated items are required. An item may be a particular object, article, or category.

[0019]

[0034] For example, without limitation, "at least one of item A, item B, and item C" may include item A, item A and item B, or item B. This example may also include item A, item B, and item C, or item B and item C. Of course, any combination of these items may be present. In some illustrative examples, "at least one of" may be, by way of example and not limitation, "two item A, one item B, and ten item C," "four item B, and seven item C," or any other suitable combination.

[0020]

[0035] In one embodiment of the present disclosure, a multi-ply layup system includes a first cutting system, a second cutting system, a placement robot, and a controller. The first cutting system and the second cutting system are each configured to independently cut a material having fibers oriented in an initial direction to form courses and move the courses to a staging position. The controller is in communication with the first cutting system and the second cutting system and the placement robot. The controller is configured to control the first cutting system to cut and move a first group of courses to the staging position. The controller is configured to control the placement robot to pick up and place the first group of courses from the staging position onto a laying surface to form a first ply of a multi-ply layup, and to change the orientation of the fibers from the initial orientation to a desired orientation for the first ply during the pick up and placement. The controller is configured to control the second cutting system to cut and move a second group of courses to the staging position while the placement robot is picking up and placing the first group of courses. The controller is configured to control the placement robot to pick up and place the second group of courses from the staging position onto the laying surface to form a second ply of the multi-ply laminate after the first ply has been formed, and to change the fiber direction from the initial direction to a desired direction for the second ply during the pick-up and placing.

[0021]

[0036] In this and other embodiments, references to a "first ply" refer to the first ply formed from an arrangement of courses to form a multi-ply for a multi-ply stack, which is not necessarily the very first or last ply in the multi-ply stack formed by the arrangement of courses in forming the ply.

[0022]

[0037] Referring now to Figure 1, a block diagram of a composite manufacturing environment is depicted in accordance with an illustrative embodiment. As shown, a multi-ply layup system 102 operates to create a multi-ply layup 128. In this example, the multi-ply layup 128 is used in a charge that is used to form a part 105. The part 105 may be selected from a group including an elongated composite part, a wing stringer, a fuselage stringer, an empennage stringer, a floor beam, a wing spar, and an empennage spar. The part may be composed entirely of composite materials or may be a mix of composite and non-composite materials.

[0023]

[0038] In this embodiment, the multi-ply lamination system 102 includes several different components. As shown, the multi-ply lamination system 102 includes a first cutting system 120, a second cutting system 122, a placement robot 124, an automated tape lamination machine 126, and a controller 114.

[0024]

[0039] As shown, the first cutting system 120 includes a first cutting machine 132 and a first conveyor 133. Additionally, in this embodiment, the second cutting system 122 includes a second cutting machine 138 and a second conveyor 139.

[0025]

[0040] In this example, first cutting system 120 and second cutting system 122 are each configured to independently cut material 121 having fibers 123 oriented in initial direction 125 to form courses 131 and move courses 131 to staging position 141. Material 121 may be, for example, a carbon fiber fabric including fibers 123. The material may be in the form of a fabric, a tape, or some other form. In some illustrative examples, resin may be infused into material 121. Additionally, material 121 may be in the form of a roll.

[0026]

[0041] In this example, the staging location 141 is a location from which the course 131 is picked up by the placement robot 124 and the course 131 may be placed onto the stacking surface 127. In this example, the staging location 141 is a location on the first conveyor 133 and the second conveyor 139.

[0027]

[0042] For example, in the first cutting system 120, a first cutting machine is configured to cut the course 131, and a first conveyor 133 is configured to move the course 131 cut by the first cutting machine 132 to a staging position 141 on the first conveyor 133 with an initial direction 125. In the second cutting system 122, a second cutting machine 138 is configured to cut the course 131, and a second conveyor 139 is configured to move the course 131 cut by the second cutting machine 138 to a staging position 141 on the second conveyor 139 with an initial direction 125. Furthermore, at least one of the first cutting machine 132 or the second cutting machine 138 is configured to cut the course 131 from the roll of material.

[0028]

[0043] In this example, controller 114 is in communication with first cutting system 120, second cutting system 122, placement robot 124, and automated tape lamination machine 126. In this illustrative example, controller 114 may be implemented in software, hardware, firmware, or a combination thereof.

[0029]

[0044] When software is used, the operations performed by the controller 114 may be implemented with program instructions configured to execute on hardware, such as a processor unit. When firmware is used, the operations performed by the controller 114 may be implemented with program instructions and data, stored in persistent memory, and executed on a processor unit. When hardware is used, the hardware may include circuitry that operates to perform the operations in the controller 114.

[0030]

[0045] In example embodiments, the hardware may take the form of at least one of a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or any other suitable type of hardware configured to perform certain operations. When a programmable logic device is used, the device may be configured to perform certain operations. The device may be permanently configured or may be later reconfigured 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. Furthermore, these processes may be implemented in organic components integrated with inorganic components, or may be entirely composed of non-human organic components. For example, the processes may be implemented as circuits in organic semiconductors.

[0031]

[0046] As used herein, the term "a number of," when used in reference to items, means one or more of the items. For example, "a number of steps" means one or more steps.

[0032]

[0047] Computer system 112 is a physical hardware system and includes one or more data processing systems. When multiple data processing systems are present in computer system 112, 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, a programmable logic controller (PLC) controller, or any other suitable data processing system.

[0033]

[0048] As shown, computer system 112 includes a number of processor units 116 capable of executing program instructions 118 that implement processes in a number of exemplary embodiments. In other words, program instructions 118 are computer readable program instructions.

[0034]

[0049] As used herein, a processor unit of several processor units 116 is a hardware device and is made up of hardware circuitry (such as circuitry on an integrated circuit that responds to and processes instructions and program code that cause a computer to operate).

[0035]

[0050] When several processor units 116 execute program instructions 118 for a process, the several processor units 116 may be one or more processor units on the same computer or on different computers. In other words, a process may be distributed among processor units 116 on the same computer or on different computers within computer system 112.

[0036]

[0051] Furthermore, some of the processor units 116 may be the same type of processor unit or different types of processor units, for example, some of the processor units 116 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 processing unit (GPU), a digital signal processor (DSP), or some other type of processor unit.

[0037]

[0052] In this example, the controller 114 controls the first cutting system 120 to cut and move the first group of courses 131 to a staging location 141. In this example, the first group of courses 131 are cut by a first cutting machine 132 and moved onto a first conveyor 133. The staging location 141 for the first group of courses is on the first conveyor 133.

[0038]

[0053] The controller 114 controls the placement robot 124 to pick up and place the first group of courses 131 from the staging location 141 onto the laying surface 127 to form the first ply 130 of the multi-ply layup 128. In this example, the placement robot 124 may be implemented using any suitable type of robot capable of picking up the courses 131 and placing them onto the laying surface 127. For example, the placement robot 124 may be selected from at least one of a robot arm, a gantry robot, a mobile robot arm, and other suitable types of robots capable of picking up courses from a cutting system and placing the courses onto the laying surface 127.

[0039]

[0054] In this embodiment, the laying surface 127 may be on or part of various types of objects. For example, the laying surface 127 may be on a laying table. In another embodiment, the laying surface 127 may be on a laying conveyor. In yet another exemplary embodiment, the laying surface 127 may be disposed on a mobile or motorized cart.

[0040]

[0055] As part of picking up and placing the first group of courses 131, the placement robot 124 essentially redirects (i.e., rotates) the courses as they are transported from the staging location 141 to the laying surface 127, changing the direction of the fibers 123 from the initial direction 125 to the desired direction 146 for the first ply 130. For example, if the courses are cut from a roll of material in the form of a wide good, the fibers in the courses may initially be in an orientation that aligns with the direction of the rolled material (sometimes referred to as the 0 degree orientation). They are then rotated and placed by the placement robot, such that the fibers have a desired direction 146 that is, for example, 45 degrees relative to the first direction (initial orientation). In this example, the desired orientation of the courses 131 is selected from the group consisting of 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees, 90 degrees, and other orientations relative to the initial orientation 125. By relative to the initial orientation, it is meant that these degrees can be positive or negative. The desired orientation may be determined from a design or other information that specifies the orientation of the courses used to form the multi-ply stack 128.

[0041]

[0056] The controller 114 also controls the second cutting system 122 to cut and move the second group of courses 131 to a staging location 141 while the placement robot 124 picks up and places the first group of courses 131. In this embodiment, the second group of courses 131 are cut by a second cutting machine 138 and moved onto a second conveyor 139. The staging location 141 for the second group of courses 131 is on the second conveyor 139.

[0042]

[0057] In this embodiment, the cutting machines may include one or more different types of cutters. For example, the cutting machines may include ultrasonic cutters, blade cutters, rotary cutters, and other suitable types of cutters. The cutters may cut material from a source such as a wide product on a roll, or otherwise at any desired angle. In this embodiment, the desired angle is relative to the direction of the roll.

[0043]

[0058] Additionally, the controller 114 controls the placement robot 124 to pick up and place the second group of courses 131 from the staging position 141 to the laying surface 127 to form the second ply 134 of the multi-ply stack 128 after the first ply 130 is formed. In this example, the pick-up and placing movement of the first group of courses changes the direction of the fibers 123 from the initial direction 125 to a desired direction 146 for the second ply 134. In this example, the desired direction 146 for the first ply 130 may be different from the desired direction 146 for the second ply 134.

[0044]

[0059] In one exemplary embodiment, the placement robot 124 is configured to change the direction of the fibers 123 of at least one of the courses by redirecting the course when the course is picked up from a staging location and placed on the laying surface 127 to form a ply. The ply has a width defined by an outer edge of the ply. The course may be redirected such that one or more cut edges of the course form part of the outer edge of the ply when placed on the laying surface 127.

[0045]

[0060] Further, in this example, an automated tape lamination (ATL) machine 126 is positioned to place material 145 having fibers 148 in initial direction 125 on laying surface 127. In this example, controller 114 controls automated tape lamination machine 126 to place material 145 on laying surface 127 to form third ply 136 of multi-ply laminate 128, with third ply 136 having fibers 148 oriented in initial direction 125. In some examples, automated tape lamination machine 126 is configured to move along laying surface 127. In this example, the 0 degree ply can be a continuous piece of material laid down by automated tape lamination machine 126 as it moves along laying surface 127.

[0046]

[0061] In this exemplary embodiment, the placing of courses and other materials onto layup surface 127 can be a direct placing of at least one of these courses or materials onto layup surface 127. In other words, at least one of the courses or materials can be in physical contact with layup surface 127. In one exemplary embodiment, placing can also mean that courses and materials are placed onto the layup surface with other courses and materials already laid onto layup surface 127.

[0047]

[0062] For example, a ply may be placed onto layup surface 127 by placing the ply on top of another ply already placed on layup surface 127. In other words, placing a ply or material onto layup surface 127 does not mean that the ply material is placed in direct contact with layup surface 127.

[0048]

[0063] In one non-limiting example, a first ply is at 45 degrees, a second ply is at -45 degrees, a third ply is at 90 degrees, and a fourth ply is laid down at 0 degrees by an automated tape lamination machine 126. In this example, the 0 degree plies may be laid down continuously along the length of the layup by the automated tape lamination machine 126 moving along or above the layup surface 127.

[0049]

[0064] In this illustrative example, controller 114 communicates with first cutting system 120, second cutting system 122, placement robot 124, and automated tape lamination machine 126 using information 129. In this example, controller 114 may send information 129, such as program code, commands, data, and other information used to control the operation of these components.

[0050]

[0065] Additionally, the multi-ply layup system 102 can increase the speed and accuracy with which the plies are laid with integrated inspection performed as part of the process of picking up and placing the courses 131. In one exemplary embodiment, the multi-ply layup system 102 includes an inspection system 149 configured to inspect the courses 131. The inspection system 149 may include at least one of a camera system, a thermal camera, an infrared light camera, a visible light camera, a laser scanner, an x-ray imaging machine, a laser shearography system, or any other suitable inspection system.

[0051]

[0066] In this example, inspection system 149 includes a camera system 150. In this example, camera system 150 is configured to generate images 151 of course 131. Camera system 150 may comprise at least one of a thermal camera, an infrared camera, a visible light camera, or some other suitable type of camera. Inspection system 149 may use other types of devices in addition to or in place of camera system 150. For example, inspection system 149 may include a laser scanning system, an x-ray system, a blue light sensor system, or other suitable sensor system that may detect anomalies 155.

[0052]

[0067] In this example, the camera system 150 may be used to perform an inspection of the courses 131 cut by the first cutting system 120 and the second cutting system 122 before the courses are placed on the layup surface 127. This inspection may be performed to determine whether any of the courses 131 have anomalies 155 that are out of tolerance.

[0053]

[0068] The anomalies 155 may be at least one of foreign objects (FODs), wrinkles, pockets, imperfections, frayed edges, material inconsistencies, or other types of anomalies within the courses 131. In this embodiment, the tolerances for the anomalies 155 may be based on manufacturing standards, design tolerances, regulations, industry standards, government regulations, and other sources. This type of inspection can reduce rework or other issues that may result from laminating courses that have anomalies.

[0054]

[0069] In one exemplary embodiment, the camera system 150 includes a robotic camera 152 connected to the placement robot 124. The robotic camera 152 is positioned to generate top surface images 153 of the top surface of the course 131 as it is cut by the first cutting system 120 and the second cutting system 122. These inspections can be performed with the course 131 moving to or into the staging position 141.

[0055]

[0070] The robotic camera in robotic camera 152 may be connected to an end effector of a robotic arm for a placement robot or other robot, or may be located anywhere near the end effector. In one embodiment, the robotic camera may generate an image of the top surface of a course before picking up the course for placement.

[0056]

[0071] In this example, the controller 114 controls the generation of a top surface image 153 of the top surface of the course 131 in response to the placement robot 124 moving to pick up the course 131. The controller 114 receives the top surface image 153 and analyzes the top surface image 153 for unacceptable anomalies 155. The controller 114 controls the operation of the placement robot 124 to move any of the courses 131 having unacceptable anomalies to a scrap location 154.

[0057]

[0072] Additionally, camera system 150 may include an upward looking camera 160 connected to a camera station. The camera station may be any structure to which upward looking camera 160 may be connected and positioned to generate bottom surface images 162. In this example, upward looking camera 160 is positioned to generate bottom surface images 162 of the bottom surface of course 131 maintained by placement robot 124.

[0058]

[0073] At the upward looking camera 160, the controller 114 controls the generation of a bottom surface image 162 of the bottom surface of the course 131. In one exemplary embodiment, the bottom surface image 162 may be generated by the upward looking camera 160 in response to the placement robot 124 moving the course 131 towards the upward looking camera 160.

[0059]

[0074] In this embodiment, the controller 114 analyzes the bottom surface images 162 for unacceptable anomalies 155. The controller 114 controls the placement robot 124 to move any courses 131 that have unacceptable anomalies 155 to a scrap location 154.

[0060]

[0075] In yet another embodiment, the camera system 150 can include a cutting camera system 170. In this embodiment, the cutting camera system 170 is positioned to generate a top surface image 153 of a top surface of the course 131 in response to the first cutting system 120 and the second cutting system 122 cutting the course 131.

[0061]

[0076] In this example, in response to the first cutting system 120 and the second cutting system 122 cutting the course 131, the controller 114 generates top surface images 153 of the course 131 using the cutting camera system 170. The controller 114 analyzes the top surface images 153 received from the cutting camera system 170 for unacceptable anomalies 155. The controller 114 moves any courses 131 having unacceptable anomalies 155 to a scrap position 154.

[0062]

[0077] In this embodiment, the movement of courses 131 from the cut camera system to the scrap location 154 may be performed using a robot other than the placement robot 124 to increase the speed and efficiency with which the multi-ply layup 128 may be formed. In other embodiments, a conveyor may move courses 131 having out-of-tolerance anomalies 155 to a scrap bin located at the end of the conveyor, in which case these courses will not be picked up by the placement robot 124 for use in forming the multi-ply layup 128.

[0063]

[0078] For example, the multi-ply layup system 102 may include several scrap robots 180 positioned to remove courses 131 cut by the first cutting system 120 and the second cutting system 122 having out-of-tolerance anomalies 155 to a scrap location 154. The scrap robots 180 may be, for example, a robotic arm, a delta arm, a drone, or any other suitable type of robot. In still other example embodiments, the cutting camera system 170 may also include a camera positioned to generate an underside image 162 of the course 131 cut by one of the cutting systems. This inspection may be performed prior to inspection using the images 151 generated by the robotic camera 152.

[0064]

[0079] In this illustrative example, image 151 is analyzed by controller 114. The analysis may be performed using object detection 164, such as machine vision algorithms 163. This type of algorithm may perform image processing, feature extraction, object detection, segmentation, classification, and recognition. The process performed by machine vision algorithms 163 may identify specific objects or patterns or characteristics within image 151 that may be anomalies 155.

[0065]

[0080] In another exemplary embodiment, inspection system 149 may include a lap gap inspection system 171 that is used after all courses in a ply are laid down on layup surface 127. Lap gap inspection system 171 may be used to measure gaps between courses 131. Lap gap inspection system 171 may be connected to an end effector of a robotic arm for a placement robot or other robot, or may be anywhere near the end effector. In this embodiment, lap gap inspection system 171 may include at least one of a laser profilometer, a camera, a thermal camera, an infrared camera, a visible camera, a laser scanner, an x-ray imaging machine, a laser shearography system, or any other suitable inspection system.

[0066]

[0081] In this embodiment, every other course in courses 131 is simultaneously placed on stacking surface 127 by placement robot 124, followed by the remaining courses 131, after which the robot uses its lap gap inspection system to measure the gaps between the courses.

[0067]

[0082] In one exemplary embodiment, a profilometer can be used to measure the gap width between adjacent courses. This tool can also be used to inspect the overall ply boundary location. This inspection can be directed to both the inner boundary edge and the outer boundary edge of the net trim line.

[0068]

[0083] For example, the placement robot 124 places all of the courses for the plies in a sequence. The placement robot 124 scans the nominal course-to-course gaps for all of the courses using a profilometer and records the gap measurement data generated by the profilometer along the gap length. Additionally, the placement robot 124 scans the entire nominal boundaries of all of the plies in the sequence using the profilometer. In this example, a single edge is detected using the profilometer and, in conjunction with the position data of the robot tool center point (TCP), position data of the ply boundary can be determined.

[0069]

[0084] In this example, if the gap and boundary position measurements are within tolerance, the build continues with the next sequence, otherwise intervention may be performed to correct the out-of-tolerance errors, which may include removing and restarting a course or repositioning a course.

[0070]

[0085] In yet another exemplary embodiment, efficiency in forming the multi-ply layup 128 may be achieved using backup components. For example, the multi-ply layup system 102 may include a spare cutting machine 185 that is used in response to one of the first cutting machine 132 and the second cutting machine 138 requiring maintenance. For example, the maintenance may be replacing a roll of material used to cut the courses, replacing a blade, routine maintenance, or other maintenance work.

[0071]

[0086] The spare cutting machine 185 may be used in place of one of the cutting machines. This process may be a hot swap process where starting and reinitializing the cutting process is not required. In other words, the spare cutting machine 185 may take over where the previous cutting machine left off. In one embodiment, the controller 114 synchronizes the operation of the spare cutting machine 185 to cut the course 131 in response to replacing the spare cutting machine 185 with a cutting machine 185 in one of the first cutting system 120 and the second cutting system 122.

[0072]

[0087] Additionally, in example embodiments, interruptions in cutting and placing courses can be minimized when a spare cutting machine 185 is hot swappable. This hot swapping can be implemented using features or components that allow immediate mechanical alignment to the conveyor. For example, mechanisms for quick connection of electrical and communication cables and automatic controller integration within the cutting system can be used.

[0073]

[0088] Thus, in one exemplary embodiment, there exists one or more solutions that overcome the challenges associated with undesirable times for laying up courses in manufacturing composite parts. As a result, the one or more technical solutions can increase the speed of laying out the courses by using a placement robot to lay up the courses for the plies simultaneously.

[0074]

[0089] One or more illustrative embodiments allow for increased efficiency in the placement of courses to form plies with increased efficiency and speed compared to current techniques used to lay courses for composite parts, such as those that may be long and thin. The illustrated embodiments avoid moving the laying head multiple times during the layout process as in current techniques. Additionally, manual inspection may be reduced or avoided by using a camera to generate images to analyze the courses for out-of-tolerance anomalies.

[0075]

[0090] In exemplary embodiments, courses may be cut simultaneously while other (already cut) courses are being placed by a placement robot. There are multiple cutting machines, whereby the cutting machines may cut courses in a particular direction and / or may be synchronized with each other and / or with the motion of the placement robot. The courses cut by each of the cutting machines have a direction based on the sequence of the courses in the design for the composite part. As a result, once the placement robots have completed placing a course in one direction, e.g., to complete a ply of a multi-ply layup, they can begin placing a course in the next direction, e.g., to assemble the next ply of the multi-ply layup, without any wait time or delay.

[0076]

[0091] In example embodiments, simultaneous placement of multiple courses may be performed using placement robots. Additionally, equipment swapping may be implemented to reduce downtime when material input and / or other maintenance is required. In example embodiments, the charge stacking process may be reduced from 12 hours to 1 hour for a wing stringer.

[0077]

[0092] Additionally, inspections can be performed as the courses are picked up for placement. These inspections can be performed automatically, reducing or avoiding manual inspection of the courses used to assemble the plies.

[0078]

[0093] The illustration of composite manufacturing environment 100 in FIG. 1 is not meant to impose physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or instead of the ones illustrated may be used. Some components may be unnecessary. Also, blocks are presented to illustrate some functional components. When implemented in an illustrative embodiment, one or more of these blocks may be combined, divided, or combined and divided into different blocks.

[0079]

[0094] For example, the automated tape lamination machine 126 may be an optional component and may be omitted from the multi-ply lamination system 102 in some embodiments. As another example, there may be one or more cutting systems in addition to the first cutting system 120 and the second cutting system 122 to cut the courses 131. Furthermore, the placement robots 124 may be the same type of robot or different types of robots in various illustrative embodiments. For example, one portion of the placement robot 124 may be a robot arm that is in a fixed position, while another portion of the placement robot 124 may be a mobile robot arm that can move to various positions.

[0080]

[0095] 2, a schematic diagram of a multi-ply lamination system is shown in accordance with an exemplary embodiment. Multi-ply lamination system 200 is an example of one implementation of multi-ply lamination system 102 of FIG.

[0081]

[0096] As shown, the multi-ply layup system 200 has a first cutting machine 202 that cuts the material 203 to form courses 206 having an initial direction on a first conveyor 204. In this example, the material is in the form of a wide good on a roll, the initial direction is 0 degrees, and the fibers are in the direction shown by the arrow 221. In other words, the fibers in the material are oriented in the direction the material is wound on the roll. The courses may be cut by the first cutting machine 202 to have different sizes and shapes, but the same initial direction.

[0082]

[0097] The multi-ply lamination system 200 also has a second cutting machine 207 that cuts the material 201, shown in this example in the form of a wide product on a roll, to form courses 206 on a second conveyor 208, also having an initial direction. These courses can also have various sizes and shapes with an initial direction. As shown, the first conveyor 204 and the second conveyor 208 are parallel to each other.

[0083]

[0098] In this embodiment, multi-ply stacking system 200 also includes placement robot 214. As shown, there are nine placement robots: placement robot 216, placement robot 218, placement robot 220, placement robot 222, placement robot 224, placement robot 226, placement robot 228, placement robot 230, and placement robot 232.

[0084]

[0099] The positions of the first conveyor 204, the second conveyor 208, and the placement robot 214 are such that the placement robot 214 can pick up the courses 206 and place them on the laying surface 234 on the conveyor 236. Additionally, the type and configuration of the placement robot 214 is selected to pick up the courses 206 from the first conveyor 204 and the second conveyor 208 and place the courses on the laying surface 234 on the conveyor 236 as part of forming a ply, such as ply 240. The positions of the first conveyor 204, the second conveyor 208, and the placement robot 214 are such that the placement robot 214 can pick up the courses 206 and place them on the laying surface 234 on the conveyor 236.

[0085]

[0100] In this embodiment, the multi-ply laying system 200 also includes an automated tape laying machine 213. The automated tape laying machine cuts the courses having an initial orientation, which in this embodiment is 0 degrees.

[0086]

[0101] During operation of the multi-ply stacking system 200, the first cutting machine 202 cuts courses 206. The courses 206 form an array of courses 206 on the first conveyor 204. The courses are moved by the first conveyor 204 to a staging position on the first conveyor 204 for the placement robot 214. When the courses 206 have been cut and moved to a staging position on the first conveyor 204, the placement robot 214 picks up the courses 206 from the first conveyor 204 and places them onto the stacking surface 234 on the conveyor 236.

[0087]

[0102] The second cutting machine 207 cuts the course 206 when it is picked up from the first conveyor 204 and placed on the laying surface 234 by the placement robot 214. The course 206 is moved on the second conveyor 208 to a staging position on the second conveyor 208 for the placement robot 214. The timing of cutting the course 206 by these cutting machines can be selected such that the placement robot 214 always has the course 206 in a staging position ready for placement on the laying surface 234.

[0088]

[0103] Once the placement robots 214 have completed picking up and placing the courses 206 from their staging positions on the first conveyor 204, the placement robots 214 begin picking up courses 206 from their staging positions on the second conveyor 208 and placing the courses 206 from their staging positions onto the stacking surface 234. In some embodiments, some of the placement robots 214 may begin picking up and placing courses 206 from the second conveyor 208 before other of the placement robots 214 have finished picking up and placing the first group of courses 206.

[0089]

[0104] In this example, once the first group of courses 206 have been picked up and placed onto the laying surface 234, the first cutting machine 202 begins cutting new courses. These new courses may be placed onto the laying surface 234 in the same or a different orientation than the courses 206 that were picked up from a staging position on the second conveyor 208 and placed onto the laying surface 234. The orientation is selected based on the design of the composite part, which specifies the orientation of the courses that will be placed to form the plies for the composite part.

[0090]

[0105] This process can be repeated with courses being cut by the alternating cutting machine and placed on the laying surface 234 by the placement robot 214. This placement can result in a multi-ply layup. This alternating cutting, picking up, and placing in a desired orientation can increase the efficiency and speed with which plies or multi-plies for a composite part can be laid up. For example, a first ply can be laid up at 45 degrees, a second ply can be laid up at -45 degrees, and a third ply can be laid up at 90 degrees. In this example, a fourth ply is laid down at 0 degrees by the automated tape laying machine 126. In this example, the 0 degree plies can be laid down continuously along the length of the layup by the automated tape laying machine 213 moving along or over the laying surface 234.

[0091]

[0106] In this example, when the courses have a desired orientation that is the same as an initial orientation, such as 0 degrees, the courses may be placed on a laying surface 234 using an automated tape laying machine 213. The automated tape laying machine 213 may move along a conveyor 236 in the direction of arrow 221. The automated tape laying machine 213 may improve performance and efficiency in laying up courses with a 0 degree orientation compared to using a placement robot 214 to lay up courses with a 0 degree orientation.

[0092]

[0107] In this illustrated embodiment, some courses may have a wider width than other courses optimized for tab out. For example, course 270 is wider than course 272.

[0093]

[0108] The diagram of the multi-ply lamination system 200 is shown to illustrate one way in which the multi-ply lamination system 102 of FIG. 1 may be implemented. This diagram is not intended to limit the ways in which the multi-ply lamination system 102 may be implemented. For example, the automated tape lamination machine 213 is an optional component and may be omitted in some embodiments. Even when the automated tape lamination machine 213 is not present, the direction of the course 206 may include a desired direction that is the same as the initial direction.

[0094]

[0109] 3, a schematic diagram of an inspection system is shown in accordance with an illustrative embodiment. In this embodiment, inspection system 300 is an example of one implementation of inspection system 149 in FIG 1. As shown, inspection system 300 is comprised of cameras that are used at various steps in the process of cutting material to form courses and place courses to form plies.

[0095]

[0110] As illustrated in this embodiment, the inspection system 300 includes a camera positioned to generate images of the course for analysis during various times between cutting the course and placing the course on the layup surface.

[0096]

[0111] In this illustrative example, placement robot 310 has robot camera 311 and placement robot 312 has robot camera 313. These robot cameras are connected to the placement robot. When one component is "connected" to another, the connection is a physical connection. For example, a first component, i.e., robot camera 311, may be considered to be physically connected to a second component, i.e., placement robot 310, by at least one of being fixed to the second component, being glued to the second component, being attached to the second component, being welded to the second component, being fastened to the second component, or being connected to the second component in some other suitable manner. The first component may also be connected to the second component with a third component. The first component may also be physically connected to the second component by being formed as a part of the second component, as an extension of the second component, or both.

[0097]

[0112] These robotic cameras can be used to generate images of the top surface of the course prior to or as part of the placement robot picking up the course for placement from either the first conveyor 302 or the second conveyor 304. The top surface in these images can be analyzed for out of tolerance anomalies in the top surface of the course.

[0098]

[0113] Additionally, inspection system 300 also includes upward looking cameras, such as upward looking camera 315 and upward looking camera 317. Up looking camera 315 may be placed within reach of placement robot 310. Up looking camera 317 may be placed within reach of placement robot 312. In this illustrative example, the upward looking cameras are used to generate images of the underside of the course picked up and held by the placement robot. These images may be analyzed to determine if any unacceptable anomalies are present on the underside of the course.

[0099]

[0114] For example, the placement robot 310 may move to pick up the course 330. This movement of the placement robot 310 results in the robot camera 311 being positioned above the course 330. The robot camera 311 may generate an image of the top surface 332 of the course 330. The image may be analyzed to determine whether one or more anomalies that are outside of tolerance are present on the top surface 332 of the course 330.

[0100]

[0115] If unacceptable anomalies are present on the top surface 332 of course 330, the placement robot 310 picks up and places course 330 in scrap bin 340. If unacceptable anomalies are not present on top surface 332, the placement robot 310 picks up course 330. The placement robot 310 moves course 330 to a position above upward looking camera 315. Upward looking camera 315 generates an image of the underside (not shown) of course 330. The image is analyzed to determine if unacceptable anomalies are present on the underside of course 330. If unacceptable anomalies are present, course 330 is placed in scrap bin 340. If unacceptable anomalies are not present on the surface of course 330, the placement robot 310 moves course 330 to a position above stacking surface 320 of conveyor 321 for placement.

[0101]

[0116] The placement robot 312 may generate images of the top surface of the course using robot camera 313 and the bottom surface of the course using upward looking camera 317. The images are analyzed to determine if there are any unacceptable anomalies. In this example, the placement robot 312 places the course with unacceptable anomalies in scrap bin 342. In this example, scrap bin 344 may be used by the placement robot 312 or another robot.

[0102]

[0117] Additionally, inspection of the course may be performed before the placement robot moves to pick up the course. For example, cutting machine 350 has cutting system camera 351 and cutting machine 352 has cutting system camera 353. In this embodiment, cutting system camera 351 is connected to cutting machine 350 and cutting system camera 353 is connected to cutting machine 352.

[0103]

[0118] These cutting system cameras may move as the cutting machine moves, or may move independently of the cutting machine, to generate images of the top surface of the courses cut by the cutting machine. These images may be analyzed for anomalies. In this example, the anomalies may also include the shape and dimensions of the course in addition to any anomalies that may be present in the surface of the course. If anomalies are present, scrap robot 360 picks up the course with the anomaly and places the course in one of scrap bins 340, scrap bin 342, scrap bin 344, or any other scrap bin.

[0104]

[0119] This analysis may be done as the courses are cut or after they are cut. If problems with dimensions and courses are identified as they are being cut, the cutter may cut the material to form unfinished courses that can be discarded. In this manner, waste of material such as fabric or tape may be reduced. Additionally, inspecting the courses before they are laid on a laying surface to form a ply may reduce the time and problems associated with finding inconsistencies later in processing the ply.

[0105]

[0120] In another embodiment, scrap robot 360 may be omitted. In this embodiment, one of placement robot 310 and placement robot 312 may be used in place of scrap robot 360. In another embodiment, courses with out-of-tolerance anomalies remain on first and second conveyors 302, 304 and are moved to drop directly into a large scrap bin (not shown) at the very end of the conveyors.

[0106]

[0121] 4, a pictorial diagram of a multi-ply layup system is shown in accordance with an illustrative embodiment. Multi-ply layup system 400 is an example of one implementation of multi-ply layup system 102 shown in block form in FIG.

[0107]

[0122] The multi-ply lamination system 400 includes a first cutting machine 411 along with a first conveyor 412. Additionally, a second cutting machine 413 and a second conveyor 414 are disposed parallel to the first cutting machine 411 and the first conveyor 412.

[0108]

[0123] In this embodiment, placement robot 420 includes placement robot 421, placement robot 422, placement robot 423, placement robot 424, placement robot 425, placement robot 426, placement robot 427, and placement robot 428. In this embodiment, placement robot 420 is a robotic arm that can pick up courses at staging positions on both first conveyor 412 and second conveyor 414 and place those courses onto laying surface 416 on ply conveyor 417. Additionally, automated tape laying (ATL) machine 430 is positioned to move over laying surface 416 and lay down the courses.

[0109]

[0124] Additionally, a scrap robot 440 is positioned near the first cutting machine 411 and the second cutting machine 413. The scrap robot can place courses that have been incorrectly cut or have other types of abnormalities in a scrap bin 441.

[0110]

[0125] Additionally, in this embodiment, scrap bins 450 are present for use by the placement robot 420. Scrap bins 450 include scrap bin 451, scrap bin 452, scrap bin 453, and scrap bin 454. The placement robot 420 may include a camera that is used to inspect the course that the placement robot 420 has traveled to pick it up. Courses that have anomalies that are outside of the tolerance may be placed into scrap bin 450 by the placement robot 420.

[0111]

[0126] Further, in this embodiment, the spare cutting machine 409 may be hot swapped with the first cutting machine 411 or the second cutting machine 413. This hot swapping may be performed to allow for continuous cutting and placement of courses when needed to provide a continuous supply of courses to the placement robot 420 for forming plies on the layup surface 416.

[0112]

[0127] 5-7 are pictorial diagrams of a process for laying up a course according to one exemplary embodiment. Referring to FIG. 5, a pictorial diagram of laying up a course by an automated tape laying machine in a ply laying system is shown according to one exemplary embodiment. As shown, an automated tape laying machine 430 moves in the direction of arrow 500 to lay a 0 degree course 501 onto a laying surface 416.

[0113]

[0128] 6, a pictorial diagram of the laying of courses by a placement robot in a ply laying system is shown in accordance with an example embodiment. As shown in this figure, the placement robot 420 picks up a course from the first conveyor 412 and places the course on the laying surface 416 in a staggered arrangement 600 with gaps. As shown, there are gaps at every other position.

[0114]

[0129] In this view, a second cutting machine 413 is cutting the courses. The courses are moved by a second conveyor 414 to a staging position on the second conveyor 414 while a placement robot 420 picks up the courses from the staging position on the first conveyor 412 for placement.

[0115]

[0130] 7, a pictorial diagram of a placement robot laying a course in a ply laying system according to an example embodiment is shown, in which a placement robot 420 picks up and places a course from a first conveyor 412 into a gap in a staggered arrangement 600 of courses on a laying surface 416.

[0116]

[0131] In this example embodiment, placement of missing intermediate courses can be performed when the robot vacuum chuck end effector is larger than the length of the course being placed, which could potentially result in collision of the placement robot end effectors if the robot were to attempt simultaneous placement of immediately adjacent courses.

[0117]

[0132] At this point, the placement robots 420 may utilize their on-board lap gap inspection systems to measure the gap between adjacent courses. For example, the placement robots 420 may include a measuring device such as a profilometer. A measuring device such as a profilometer may be used to perform a gap assessment to ensure that adjacent courses are sufficiently close relative to one another.

[0118]

[0133] As shown in this example, the second cutting machine 413 has finished cutting the courses. The courses are now in a staging position on the second conveyor 414. The courses are ready to be picked up and placed onto the stacking surface 416 by the placement robot 420.

[0119]

[0134] This cycle of cutting courses and placing on the layup surface 416 may be performed until multiple plies are completed for the composite part. This process for laying up courses reduces idle time for the placement robot 420 because the placement robot 420 does not have to wait for a new course to become available for placement. Instead, the placement robot 420 can continue to place courses picked up from positions on the first conveyor 412 and second conveyor 414.

[0120]

[0135] Additionally, inspection of the course may be performed before and after it is picked up by the placement robot 420. Courses with anomalies outside of tolerance may be discarded and new courses may be re-cut and placed in position for pick-up and placement by the placement robot 420.

[0121]

[0136] The illustration of the multi-ply stacking system 400 in FIGS. 4-7 is intended as one example for the multi-ply stacking system 102 of FIG. 1. This illustration is not intended to limit the manner in which other exemplary embodiments may be implemented. For example, other numbers of placement robots different from the eight placement robots illustrated in this example may be used. For example, four placement robots, twenty placement robots, or some other number of placement robots may be used. Furthermore, one or more cutting machines and conveyors may be used in addition to the first cutting machine 411 and first conveyor 412, and the second cutting machine 413 and second conveyor 414. These cutting machines and conveyors may be arranged such that the placement robot 420 may reach the course cut by these conditions.

[0122]

[0137] In another exemplary embodiment, another set of placement robots, cutting machines, and conveyors may be arranged in a mirror configuration on the opposite side of the laying surface 416 and the conveyor 417. In this configuration, all of the placement robots can lay courses on the laying surface 416, which is coordinated by the controller 114.

[0123]

[0138] In yet other exemplary embodiments, the inspection system may be omitted. Alternatively, inspection may be performed by the placement robot 420 and not by the cutting machine. In yet other exemplary embodiments, there may be one or more laying planes on a conveyor in addition to the laying plane 416 on the conveyor 417. On the additional laying planes, the placement robot 420 may lay courses for multiple composite parts. Furthermore, in other exemplary embodiments, the courses need not be arranged in a staggered arrangement on the laying plane 416.

[0124]

[0139] Referring now to Figure 8, a diagram of a flow chart of a process for forming limited multiplies according to an exemplary embodiment is shown. The process of Figure 8 may be implemented in hardware, software, or both. When implemented in software, the process may take the form of program instructions 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 controller 114 in computer system 112 of Figure 1.

[0125]

[0140] The process controls a first cutting system to cut and move a first group of courses to a staging location (step 800). The process controls a placement robot to pick up and place the first group of courses from the staging location onto a laying surface to form a first ply of a multi-ply laminate, and during the pick up and placing, changes the fiber direction from an initial direction to a desired direction for the first ply (step 802).

[0126]

[0141] The process controls the second cutting system to cut and move the second group of courses to a staging position while the placement robot is picking up and placing the first group of courses (step 804). The process controls the placement robot to pick up and place the second group of courses from the staging position to the laying surface after the first ply is formed, and to change the fiber direction from the initial direction to a desired direction for the second ply during the pick-up and placing (step 806). The process then ends.

[0127]

[0142] In one embodiment of the process of Figure 8, each subsequent ply for a multi-ply stack is formed by placing at least a portion of the material of each subsequent ply to at least partially overlap a previous ply in the multi-ply stack. Additionally, the direction of the fibers in at least one of the courses is changed by reorienting the course when it is picked up from the staging location and placed on the laying surface to form the ply. Additionally, the ply has a width defined by an outer edge of the ply. The course is reoriented such that one or more cut edges of the course form a portion of the outer edge of the ply when it is placed on the laying surface.

[0128]

[0143] With reference now to Figure 9, an illustration of a flow chart of a process for laying up a third ply in a multi-ply stack is shown in accordance with an illustrative embodiment. The process illustrated in this figure is an example of further steps that may be performed in the steps of Figure 8.

[0129]

[0144] The process controls an automated tape laying machine to place material to form a third ply of a multi-ply laminate, with the third ply having fibers oriented in an initial direction (step 900), after which the process ends.

[0130]

[0145] With reference now to Figure 10, an illustration of a flowchart of a process for inspecting a course is depicted in accordance with an illustrative embodiment. The process in this figure is an example of further steps that may be performed in the steps of Figure 8.

[0131]

[0146] The process generates a top surface image of the top surface of the course using a robotic camera connected to the placement robot as the placement robot moves to pick up the course (operation 1000). The process analyzes the top surface image for out-of-tolerance anomalies (operation 1002).

[0132]

[0147] The process controls the placement robot to move any of the courses having anomalies outside the tolerance range to a scrap position (operation 1004), after which the process ends.

[0133]

[0148] With reference now to Figure 11, an illustration of a flowchart of a process for inspecting a course is depicted in accordance with an illustrative embodiment. The process in this figure is an example of further steps that may be performed in the steps of Figure 8.

[0134]

[0149] The process uses an upward-facing camera connected to a camera station to generate an underside image of the underside of the course held by the placement robot (operation 1100). The process analyzes the underside image for out-of-tolerance anomalies (operation 1102).

[0135]

[0150] The process controls the placement robot to move any of the courses having anomalies outside the tolerance range to a scrap position (operation 1104), after which the process ends.

[0136]

[0151] With reference now to Figure 12, an illustration of a flowchart of a process for inspecting a course is depicted in accordance with an illustrative embodiment. The process depicted in the flowchart is an example of further steps that may be performed in the steps of Figure 8.

[0137]

[0152] The process generates a top surface image of the course using the cutting camera system in response to the first cutting system and the second cutting system cutting the course (operation 1200). The process analyzes the top surface image for out-of-tolerance anomalies (step 1202).

[0138]

[0153] The process controls the robot to move any of the courses having anomalies outside the tolerance range to a scrap location (step 1204). The process then ends. In step 1204, the robots that move the courses having anomalies to their scrap locations can take a number of different forms. For example, these robots can be placement robots. In other illustrative examples, scrap robots are configured to remove the courses having anomalies. These scrap robots are separate robots from the placement robot. The scrap robots can be, for example, a robotic arm, a delta arm, a drone, or some other suitable type of robot.

[0139]

[0154] With reference now to Figure 13, an illustration of a flowchart of a process for providing redundancy in a multi-ply stacking system is depicted in accordance with an illustrative embodiment. The process depicted in the flowchart is an example of further steps that may be performed in the steps of Figure 8.

[0140]

[0155] The process replaces one of the first cutting machine in the first cutting system and the second cutting machine in the second cutting system with a spare cutting machine (step 1300) in response to one of the first cutting machine in the first cutting system and the second cutting machine in the second cutting system requiring maintenance. The process analyzes operation of the spare cutting machine to cut a course in response to replacing the spare cutting machine with one of the first cutting machine and the second cutting machine (step 1302). The process then ends.

[0141]

[0156] The flowcharts and block diagrams in the various illustrated embodiments illustrate the structure, functionality, and operation of some possible implementations of the apparatus and method in an exemplary embodiment. In this regard, each block in the flowcharts 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 of the blocks may be implemented as program instructions, hardware, or a combination of program instructions and hardware. When implemented in hardware, the hardware may take the form of, for example, an integrated circuit that is manufactured or configured to perform one or more steps of the flowcharts or block diagrams. When implemented as a combination of program instructions and hardware, the implementation may take the form of firmware. Each block in the flowcharts 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.

[0142]

[0157] In some alternative implementations of an exemplary embodiment, one or more functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially simultaneously, or the blocks may sometimes be executed in reverse order, depending on the functionality involved. Furthermore, other blocks may be added in addition to the blocks noted in the flowcharts or block diagrams.

[0143]

[0158] Referring now to Figure 14, a block diagram of a data processing system is shown in accordance with an illustrative embodiment. Data processing system 1400 may be used to implement computer system 112 of Figure 1. In this illustrative example, data processing system 1400 includes a communications framework 1402 that provides communications between a processor unit 1404, a memory 1406, a persistent storage device 1408, a communications unit 1410, an input / output (I / O) unit 1412, and a display 1414. In this example, communications framework 1402 takes the form of a bus system.

[0144]

[0159] The processor unit 1404 is responsible for executing instructions for software that may be loaded into the memory 1406. The processor unit 1404 includes one or more processors. For example, the processor unit 1404 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 some other suitable type of processor. Furthermore, the processor unit 1404 may be implemented using one or more heterogeneous processor systems in which a main processor resides on a single chip along with secondary processors. As another illustrative example, the processor unit 1404 may be a symmetric multi-processor system in which multiple processors of the same type are included on a single chip.

[0145]

[0160] Memory 1406 and persistent storage 1408 are examples of storage devices 1416. A storage device is any piece of hardware that can store information such as, but not limited to, data, program instructions in a functional form, or other suitable information, either temporary, persistent, or both temporary and persistent. Storage device 1416 may also be referred to as a computer-readable storage device in these illustrative examples. In these examples, memory 1406 may be, for example, a random access memory or any other suitable volatile or non-volatile storage device. Persistent storage 1408 may take various forms, depending on the particular implementation.

[0146]

[0161] For example, persistent storage 1408 may encompass one or more components or devices. For example, persistent storage 1408 may be a hard drive, a solid-state drive (SSD), a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The medium used by persistent storage 1408 may also be removable. For example, a removable hard drive may be used for persistent storage 1408.

[0147]

[0162] In these illustrative examples, communications unit 1410 provides for communication with other data processing systems or devices. In these examples, communications unit 1410 is a network interface card.

[0148]

[0163] Input / output unit 1412 allows for input and output of data to and from other devices that may be connected to data processing system 1400. For example, input / output unit 1412 may provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, input / output unit 1412 may send output to a printer. Display 1414 provides a mechanism for displaying information to a user.

[0149]

[0164] Instructions for at least one of the operating system, applications, or programs may be located in storage devices 1416, which are in communication with processor unit 1404 through communications framework 1402. The processes of the different embodiments may be executed by processor unit 1404 using computer-implemented instructions, which may be located in a memory, such as memory 1406.

[0150]

[0165] These instructions are referred to as program instructions, computer usable program instructions, or computer readable program instructions, that may be read and executed by a processor in processor unit 1404. The program instructions in the different embodiments may be embodied on different physical or computer readable storage media, such as memory 1406 or persistent storage 1408.

[0151]

[0166] The program instructions 1418 are located in a functional form on a computer readable medium 1420 that is selectively removable and may be loaded or transferred to the data processing system 1400 for execution by the processor unit 1404. The program instructions 1418 and the computer readable medium 1420, in these illustrative examples, generate a computer program product 1422. In one illustrative example, the computer readable medium 1420 is a computer readable storage medium 1424.

[0152]

[0167] The computer readable storage medium 1424 is a physical or tangible storage device used to store the program instructions 1418, rather than a medium that propagates or transmits the program instructions 1418. The computer readable storage medium 1424 may be at least one of an electronic storage medium, a magnetic storage medium, an optical storage medium, an electromagnetic storage medium, a semiconductor storage medium, a mechanical storage medium, or other physical storage medium. Some known types of storage devices that include these media include the following: diskettes, hard disks, random access memory (RAM), read only memory (ROM), erasable programmable read only memory (EPROM or flash memory), static random access memory (SRAM), compact disk read only memory (CD-ROM), digital versatile disk (DVD), memory sticks, floppy disks, mechanically encoded devices (such as punch cards or pits / lands formed on a major surface of a disk), or any suitable combination thereof.

[0153]

[0168] As used in this disclosure, the term computer-readable storage medium 1424 is not to be construed as storage per se in the form of a transitory signal, such as electric waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide, light pulses passing through a fiber optic cable, electrical signals communicated over wires, or at least one of other transmission media.

[0154]

[0169] Additionally, data may be moved at some point during normal operation of the storage device, including access, defragmentation, garbage collection, etc. However, these operations do not render the storage device transient, since the data is not transient while it is stored within the storage device.

[0155]

[0170] Alternatively, the program instructions 1418 may be transmitted to the data processing system 1400 using a computer readable signal medium. The computer readable signal medium may be, for example, a propagated data signal containing the instructions 1418. 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.

[0156]

[0171] Additionally, as used herein, "computer readable medium 1420" may be singular or plural. For example, the program instructions 1418 may be located in computer readable medium 1420 taking the form of a single storage device or system. In another embodiment, the program instructions 1418 may be located in computer readable medium 1420 distributed among multiple data processing systems. In other words, some instructions in the program instructions 1418 may be located in one data processing system while other instructions in the program instructions 1418 may be located in one data processing system. For example, a portion of the program instructions 1418 may be located in computer readable medium 1420 in a server computer while another portion of the program instructions 1418 may be located in computer readable medium 1420 located in a set of client computers.

[0157]

[0172] The different components depicted for data processing system 1400 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 incorporated within or otherwise form a part of another component. For example, memory 1406, or portions thereof, may be incorporated within processor unit 1404 in some illustrative examples. The various illustrative embodiments may be implemented within a data processing system including components in addition to or in place of the components depicted for data processing system 1400. Other components depicted in FIG. 14 may differ from the illustrative examples shown. The various embodiments may be implemented using any hardware device or system capable of executing program instructions 1418.

[0158]

[0173] An example embodiment of the disclosure may be described with reference to aircraft manufacturing and service method 1500 shown in Figure 15 and aircraft 1600 shown in Figure 16. With reference initially to Figure 15, an aircraft manufacturing and service method is illustrated in accordance with an example embodiment. During the pre-production stage, aircraft manufacturing and service method 1500 may include specification and design 1502 and material sourcing 1504 of aircraft 1600 in Figure 16.

[0159]

[0175] During production, component and subassembly manufacturing 1506 and system integration 1508 of the aircraft 1600 of Figure 16 takes place. The aircraft 1600 of Figure 16 then undergoes certification and delivery 1510 and is placed into service 1512. While in customer service 1512, the aircraft 1600 of Figure 16 is scheduled for routine maintenance and service 1514, which may include modifications, reconfigurations, refurbishment, and other maintenance and maintenance.

[0160]

[0175] Each process of aircraft manufacturing and service method 1500 may be performed or carried out by a system integrator, a third party, an entity, or some combination thereof. In some examples, an operator may be the customer. As used herein, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an entity may be an airline, a leasing company, a military entity, a service organization, etc.

[0161]

[0176] 16 , a diagram of an aircraft in which an illustrative embodiment may be implemented is shown. In this example, the aircraft 1600 may be manufactured by the aircraft manufacturing and service method 1500 of FIG. 15 and may include an airframe 1602 having a number of systems 1604 and an interior 1606. Examples of systems 1604 include one or more of a propulsion system 1608, an electrical system 1610, a hydraulic system 1612, and an environmental system 1614. Any number of other systems may be included. Although an aerospace example is shown, various illustrative embodiments may be applied to other industries, such as the automotive industry.

[0162]

[0177] Apparatus and methods embodied herein may be utilized during at least one of the stages of aircraft manufacturing and service method 1500 in Figure 15.

[0163]

[0178] In one illustrative example, components or subassemblies produced in component and subassembly manufacturing 1506 in FIG. 15 may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft 1600 is in service 1512 in FIG. 15. In yet another example, one or more apparatus embodiments, method embodiments, or combinations thereof may be utilized during production stages such as component and subassembly manufacturing 1506 and system integration 1508 in FIG. 15. One or more apparatus embodiments, method embodiments, or combinations thereof may be utilized while aircraft 1600 is in service 1512 in FIG. 15, during maintenance and service 1514, or both. Utilization of some various illustrative embodiments may facilitate significantly more efficient assembly of aircraft 1600, reduce the cost of aircraft 1600, or both significantly more efficient assembly of aircraft 1600 and reduce the cost of aircraft 1600.

[0164]

[0179] In an illustrative example, use of the multi-ply layup system 102 of FIG. 1 during component and subassembly manufacturing 1506 and / or maintenance and service 1514 may expedite assembly and maintenance of the aircraft 1600. The manner in which courses are cut and placed by the multi-ply layup system 102 to form multi-ply layups used in forming charges to manufacture composite parts reduces idle time of the cutting systems and placement robots in the multi-ply layup system 102 and increases throughput in placing courses to form plies.

[0165]

[0180] Thus, one or more illustrative embodiments provide a method, apparatus, system, and computer program product for laying out courses to form a ply.

[0166]

[0181] One or more illustrative embodiments allow for increased efficiency in the placement of courses to form plies with increased efficiency and speed compared to current techniques used to lay courses for composite parts, such as those that may be long and thin. The illustrated embodiments avoid moving the laying head multiple times during the laying process as in current techniques. Additionally, manual inspection is avoided by using a camera to generate images to analyze the courses for out-of-tolerance anomalies.

[0167]

[0182] In example embodiments, simultaneous placement of multiple courses may be performed simultaneously using placement robots. Additionally, equipment swapping may be performed to reduce downtime when material input or other maintenance is required. In example embodiments, the charge stacking process may be reduced from 12 hours to 1 hour for a wing stringer.

[0168]

[0183] The description of various exemplary embodiments has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the embodiments to the disclosed forms. 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 a configuration or structural design that provides the components with the ability to perform the actions or processes described in the examples as being performed by the components. Furthermore, to the extent that the terms "includes / including," "has," "contains," and variations thereof 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."

[0169]

[0184] The present disclosure includes exemplary embodiments in accordance with the following provisions.

[0170]

[0185] Article 1. A multi-ply laying system (102, 200, 400) comprising a first cutting system (120), a second cutting system (122), a placement robot (124, 214, 420), and a controller (114), the first cutting system (120) and the second cutting system (122) are each configured to independently cut a material (121) having fibers (123) oriented in an initial direction (125) to form a course (131) and move the course (131) to a staging position (141); The controller (114) is in communication with the first cutting system (120), the second cutting system (122), and the placement robot (124, 214, 420), and the controller (114) is: controlling the first cutting system (120) to cut and move a first group of courses (131) to the staging position (141); controlling the placement robot (124, 214, 420) to pick up and place the first group of courses (131) from the staging position (141) onto a laying surface (127, 234, 320, 416) to form a first ply (130) of a multi-ply laminate (128) and to change the orientation of the fibers (123) from the initial orientation (125) to a desired orientation (146) for the first ply (130) during the pick-up and placing; controlling the second cutting system (122) to cut and move a second group of courses (131) to the staging location (141) while the placement robot (124, 214, 420) is picking up and placing the first group of courses (131); and a multi-ply layup system (102, 200, 400) configured to: pick up and place the second group of courses (131) from the staging position (141) to the laying surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply layup (128) after the first ply (130) has been formed, and control the placement robot (124, 214, 420) to change the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) for the second ply (134) during the pick-up and placing.

[0171]

[0186] Article 2. The multi-ply lamination system (102, 200, 400) of clause 1, further comprising an automated tape lamination machine (126) arranged to place a material (145) having fibers (148) in the initial direction (125) on the laying surface (127, 234, 320, 416), and the controller (114) is configured to control the automated tape lamination machine (126) to place the material to form the third ply (136) of the multi-ply laminate (128), with the third ply (136) having the fibers (148) oriented in the initial direction (125).

[0172]

[0187] Article 3. The first cutting system (120) comprises: a first cutting machine (132, 202, 132) configured to cut said course (131); and a first conveyor (133, 204, 302, 412) configured to move the course (131) cut by the first cutting machine (132, 202, 132) to the staging position (141) while having the initial direction (125); The second cutting system (122) comprises: a second cutting machine (122, 207, 413) configured to cut said course (131); and A multi-ply lamination system (102, 200, 400) as described in clause 1 or 2, comprising a second conveyor (139, 208, 304, 414) configured to move the course (131) cut by the second cutting machine (122, 207, 413) to the staging position (141) while having the initial direction (125).

[0173]

[0188] Article 4. The multi-ply lamination system (102, 200, 400) described in clause 3, wherein at least one of the first cutting machine (132, 202, 132) and the second cutting machine (122, 207, 413) is configured to cut the courses (131) from a roll of material.

[0174]

[0189] Article 5. 5. The multi-ply lamination system (102, 200, 400) of any one of clauses 1 to 4, further comprising a lamination conveyor, and wherein the lamination surface (127, 234, 320, 416) is on the lamination conveyor.

[0175]

[0190] Article 6. 6. The multi-ply lamination system (102, 200, 400) of any one of clauses 1 to 5, further comprising a laying table, and wherein the laying surface (127, 234, 320, 416) is on the laying table.

[0176]

[0191] Article 7. The multi-ply lamination system (102, 200, 400) of any one of clauses 1 to 6, further comprising an inspection system (149) configured to determine whether any of the courses (131) have an abnormality (155) outside of an acceptable range.

[0177]

[0192] Article 8. the inspection system (149) includes a robotic camera (152) connected to the placement robot (124, 214, 420); the robotic camera (152) is positioned to generate a top-view image (153) of a top view of the course (131); The controller (114) generating the top surface image (153) of the top surface of the course (131) in response to the placement robot (124, 214, 420) moving to pick up the course (131); analyzing the top view image (153) for anomalies (155) outside the tolerance range; and and controlling the placement robot (124, 214, 420) to move any of the courses (131) having an abnormality (155) outside the tolerance range to a scrap position (154).

[0178]

[0193] Article 9. The inspection system (149) includes an upward-facing camera (160) connected to a camera station; the upward-facing camera (160) is positioned to generate an underside image (162) of an underside of the course (131) maintained by the placement robot (124, 214, 420); The controller (114) generating an underside image (162) of the underside of the course (131); analyzing the bottom surface image (162) for the out-of-tolerance anomalies (155); and and controlling the placement robot (124, 214, 420) to move any of the courses (131) having the out-of-tolerance anomaly (155) to a scrap position (154).

[0179]

[0194] Article 10. The inspection system (149) comprises a cutting camera system (170); the cutting camera system (170) is arranged to generate a top surface image (153) of a top surface of the course (131) cut by the first cutting system (120) and the second cutting system (122); The controller (114) generating the top view image (153) of the course (131) in response to the first cutting system (120) and the second cutting system (122) cutting the course (131); analyzing the top view image (153) for anomalies (155) outside the tolerance range; and and controlling the placement robot (124, 214, 420) to move any of the courses (131) having an abnormality (155) outside the tolerance range to a scrap position (154).

[0180]

[0195] Article 11. The multi-ply lamination system (102, 200, 400) of clause 10, further comprising several scrap robots (180) arranged to remove the courses (131) cut by the first cutting system (120) and the second cutting system (122) having the out-of-tolerance anomalies (155) to the scrap location (154).

[0181]

[0196] Article 12. The multi-ply stacking system (102, 200, 400) of any one of clauses 7 to 11, wherein the inspection system (149) includes at least one of a camera system, a thermal camera, an infrared light camera, a visible light camera, a laser scanner, an x-ray imaging machine, and a laser shearography system.

[0182]

[0197] Article 13. A spare cutting machine (132, 409) is further provided, The multi-ply lamination system (102, 200, 400) of any one of clauses 1 to 12, wherein the controller (114) is configured to synchronize operation of the spare cutting machine (132, 409) for cutting the course (131) in response to replacing the spare cutting machine (132, 409) with a cutting machine of one of the first cutting system (120) and the second cutting system (122).

[0183]

[0198] Article 14. 14. The multi-ply stacking system (102, 200, 400) of any one of clauses 1 to 13, wherein the desired orientation of the course (131) is selected from the group consisting of 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees, and 90 degrees relative to the initial orientation (125).

[0184]

[0199] Article 15. 15. The multi-ply stack system (102, 200, 400) of claim 14, wherein a desired direction (146) for the first ply (130) is different from the desired direction (146) for the second ply (134).

[0185]

[0200] Article 16. 16. The multi-ply layup system (102, 200, 400) of any one of clauses 1 to 15, wherein the multi-ply laminate (128) is used in a charge used to form a part selected from the group including elongated composite parts, wing stringers, fuselage stringers, tail stringers, floor beams, wing spars, and tail spars.

[0186]

[0201] Article 17. the placement robot (124, 214, 420) is configured to change the direction of the fibers (123) of at least one of the courses (131) by redirecting the course when the course is picked up from the staging location and placed on the laying surface (127, 234, 320, 416) to form a ply; the ply has a width defined by an outer edge of the ply; 17. The multi-ply layup system (102, 200, 400) of any one of clauses 1 to 16, wherein the courses are redirected such that one or more cut edges of the courses form part of an outer edge of the ply when placed on the layup surface (127, 234, 320, 416).

[0187]

[0202] Article 18. A multi-ply lamination system (102, 200, 400) comprising a first cutting system (120), a second cutting system (122), a placement robot (124, 214, 420), an automated tape lamination machine (126), and a controller (114), the first cutting system (120) and the second cutting system (122) are each configured to independently cut a material (121) having fibers (123) oriented in an initial direction (125) to form courses (131) and move the courses (131) to a staging position (141); the automated tape laying machine (126) is arranged to lay a material (145) having fibers (148) in the initial direction (125) onto a laying surface (127, 234, 320, 416); The controller (114) is in communication with the first cutting system (120), the second cutting system (122), the placement robot (124, 214, 420), and the automated tape lamination machine (126), and the controller (114) is: controlling the first cutting system (120) to cut and move a first group of courses (131) to the staging position (141); controlling the placement robot (124, 214, 420) to pick up and place the first group of courses (131) from the staging position (141) onto the laying surface (127, 234, 320, 416) to form a first ply (130) of a multi-ply laminate (128) and to change the orientation of the fibers (123) from the initial orientation (125) to a desired orientation (146) for the first ply (130) during the pick-up and placing; controlling the second cutting system (122) to cut and move a second group of courses (131) to the staging location (141) while the placement robot (124, 214, 420) is picking up and placing the first group of courses (131); controlling the placement robot (124, 214, 420) to pick up and place the second group of courses (131) from the staging position (141) to the laying surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply stack (128) after the first ply (130) has been formed, and to change the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) for the second ply (134) during the pick-up and placing; and controlling the automated tape laying machine (126) to arrange the material (145) to form the plies of the multi-ply laminate (128), with the plies having the fibers (148) oriented in the initial direction (125).

[0188]

[0203] Article 19. A method of forming a multi-ply laminate (128), comprising the steps of: controlling (800) a first cutting system (120) to cut and move a first group of courses (131) to a staging position (141); controlling (802) a placement robot (124, 214, 420) to pick up and place the first group of courses (131) from the staging position (141) onto a laying surface (127, 234, 320, 416) to form a first ply (130) of the multi-ply laminate (128) and to change the orientation of the fibers (123) from an initial orientation (125) to a desired orientation (146) for the first ply (130) during the pick-up and placing; controlling (804) a second cutting system (122) to cut and move a second group of courses (131) to the staging location (141) while the placement robot (124, 214, 420) is picking up and placing the first group of courses (131); controlling (806) the placement robot (124, 214, 420) to pick up and place the second group of courses (131) from the staging position (141) to the laying surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply laminate (128) after the first ply (130) has been formed, and changing the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) for the second ply (134) during the pick-up and placing; and controlling (900) an automated tape laying machine (126) to place material (145) to form the third ply of the multi-ply laminate (128), with the third ply (136) having the fibers (123) oriented in the initial direction (125).

[0189]

[0204] Article 20. 20. The method of claim 19, wherein each subsequent ply is formed by placing at least a portion of the material of each subsequent ply so as to at least partially overlap the preceding ply.

[0190]

[0205] Article 21. the direction of the fibers (123) of at least one of the courses (131) is changed by redirecting the course when the course is picked up from the staging location and placed on the laying surface (127, 234, 320, 416) to form a ply; the ply has a width defined by an outer edge of the ply; 21. The method of claim 19 or 20, wherein the course is redirected such that one or more cut edges of the course form part of an outer edge of the ply when placed on the layup surface (127, 234, 320, 416).

[0191]

[0206] Article 22. generating (1000) a top surface image (153) of a top surface of the course (131) in response to the placement robot (124, 214, 420) moving to pick up the course (131); analyzing (1002) the top view image (153) for unacceptable anomalies (155); and 22. The method of any one of clauses 19 to 21, further comprising controlling (1004) the placement robot (124, 214, 420) to move any of the courses (131) having the out-of-tolerance anomaly (155) to a scrap position (154).

[0192]

[0207] Article 23. generating (1100) an underside image (162) of an underside of the course (131) maintained by the placement robot (124, 214, 420) using an upward-facing camera (160) connected to a camera station; analyzing (1102) the bottom surface image (162) for out-of-tolerance anomalies (155); and 23. The method of any one of clauses 19 to 22, further comprising controlling (1104) the placement robot (124, 214, 420) to move any of the courses (131) having the out-of-tolerance anomaly (155) to a scrap position (154).

[0193]

[0208] Article 24. generating (1200) a top view image (153) of the course (131) using a cutting camera system (170) in response to the first cutting system (120) and the second cutting system (122) cutting the course (131); analyzing (1202) the top view image (153) for unacceptable anomalies (155); and 24. The method of any one of clauses 19 to 23, further comprising controlling (1204) a robot to move any of the courses (131) having the out-of-tolerance anomalies (155) to a scrap position (154).

[0194]

[0209] Article 25. In response to one of a first cutting machine (132, 202, 132) in the first cutting system (120) and a second cutting machine (122, 207, 413) in the second cutting system (122) requiring maintenance, replacing (1300) one of the first cutting machine (132, 202, 132) and the second cutting machine (122, 207, 413) with a spare cutting machine (132, 409); and 25. The method according to any one of clauses 19 to 24, further comprising synchronising (1302) an operation of the spare cutting machine (132, 409) for cutting the course (131) in response to replacing the spare cutting machine (132, 409) with one of the first cutting machine (132, 202, 132) and the second cutting machine (122, 207, 413).

[0195]

[0210] Numerous modifications and variations 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 and practical applications of the embodiments, and to enable others skilled in the art to understand the disclosure of the various embodiments, including various modifications suitable for the particular use contemplated.

Claims

1. A multi-ply laying system (102, 200, 400) comprising a first cutting system (120), a second cutting system (122), a placement robot (124, 214, 420), and a controller (114), the first cutting system (120) and the second cutting system (122) are each configured to independently cut a material (121) having fibers (123) oriented in an initial direction (125) to form a course (131) and move the course (131) to a staging position (141); The controller (114) is in communication with the first cutting system (120), the second cutting system (122), and the placement robot (124, 214, 420), and the controller (114) is configured to: controlling the first cutting system (120) to cut and move a first group of courses (131) to the staging position (141); controlling the placement robot (124, 214, 420) to pick up and place the first group of courses (131) from the staging position (141) onto a laying surface (127, 234, 320, 416) to form a first ply (130) of a multi-ply laminate (128) and to change the orientation of the fibers (123) from the initial orientation (125) to a desired orientation (146) for the first ply (130) during said pick-up and placing; controlling the second cutting system (122) to cut and move a second group of courses (131) to the staging position (141) while the placement robot (124, 214, 420) is picking up and placing the first group of courses (131); and a multi-ply layup system (102, 200, 400) configured to: pick up and place the second group of courses (131) from the staging position (141) onto the laying surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply layup (128) after the first ply (130) has been formed, and control the placement robot (124, 214, 420) to change the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) for the second ply (134) during the pick-up and placing.

2. 2. The multi-ply laying system of claim 1, further comprising an automated tape laying machine arranged to lay a material having fibers in the initial direction on the laying surface, the controller being configured to control the automated tape laying machine to lay the material to form the third ply of the multi-ply laminate, with the third ply having the fibers oriented in the initial direction.

3. The first cutting system (120) comprises: a first cutting machine (132, 202, 411) configured to cut said course (131); and a first conveyor (133, 204, 302, 412) configured to move the course (131) cut by the first cutting machine (132, 202, 411) to the staging position (141) while having the initial direction (125); The second cutting system (122) comprises: a second cutting machine (122, 207, 413) configured to cut said course (131); and 3. The multi-ply stacking system (102, 200, 400) of claim 1 or 2, further comprising a second conveyor (139, 208, 304, 414) configured to move the course (131) cut by the second cutting machine (122, 207, 413) to the staging position (141) while having the initial orientation (125).

4. 3. The multi-ply lamination system (102, 200, 400) of claim 1 or 2, further comprising an inspection system (149) configured to determine whether any of the courses (131) have an abnormality (155) outside of an acceptable range.

5. 5. The multi-ply stacking system of claim 4, wherein the inspection system comprises at least one of a camera system, a thermal camera, an infrared light camera, a visible light camera, a laser scanner, an x-ray imaging machine, and a laser shearography system.

6. A spare cutting machine (185, 409) is further provided, 3. The multi-ply lamination system (102, 200, 400) of claim 1 or 2, wherein the controller (114) is configured to synchronize operation of the spare cutting machine (185, 409) to cut the course (131) in response to replacing the spare cutting machine (185, 409) with a cutting machine in one of the first cutting system (120) and the second cutting system (122).

7. 3. The multi-ply stacking system (102, 200, 400) of claim 1 or 2, wherein the desired orientation of the course (131) is selected from the group consisting of 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees, and 90 degrees relative to the initial orientation (125).

8. 8. The multi-ply stacking system of claim 7, wherein a desired direction for a first ply is different than the desired direction for a second ply.

9. 3. The multi-ply layup system of claim 1, wherein the multi-ply laminate is used in a charge that is used to form a part selected from the group including elongated composite parts, wing stringers, fuselage stringers, tail stringers, floor beams, wing spars, and tail spars.

10. the placement robot (124, 214, 420) is configured to change the direction of the fibers (123) of at least one of the courses (131) by redirecting the course when the course is picked up from the staging location and placed on the laying surface (127, 234, 320, 416) to form a ply; the ply has a width defined by an outer edge of the ply; 3. The multi-ply layup system (102, 200, 400) of claim 1 or 2, wherein the courses are redirected such that one or more cut edges of the courses form part of an outer edge of the ply when placed on the layup surface (127, 234, 320, 416).

11. A multi-ply lamination system (102, 200, 400) comprising a first cutting system (120), a second cutting system (122), a placement robot (124, 214, 420), an automated tape lamination machine (126), and a controller (114), the first cutting system (120) and the second cutting system (122) are each configured to independently cut a material (121) having fibers (123) oriented in an initial direction (125) to form courses (131) and move the courses (131) to a staging position (141); the automated tape lamination machine (126) is arranged to place a material (145) having fibers (148) in the initial direction (125) onto a laying surface (127, 234, 320, 416); The controller (114) is in communication with the first cutting system (120), the second cutting system (122), the placement robot (124, 214, 420), and the automated tape lamination machine (126), and the controller (114) is: controlling the first cutting system (120) to cut and move a first group of courses (131) to the staging position (141); controlling the placement robot (124, 214, 420) to pick up and place the first group of courses (131) from the staging position (141) onto the laying surface (127, 234, 320, 416) to form a first ply (130) of a multi-ply laminate (128) and to change the orientation of the fibers (123) from the initial orientation (125) to a desired orientation (146) for the first ply (130) during said pick-up and placing; controlling the second cutting system (122) to cut and move a second group of courses (131) to the staging position (141) while the placement robot (124, 214, 420) is picking up and placing the first group of courses (131); controlling the placement robot (124, 214, 420) to pick up and place the second group of courses (131) from the staging position (141) onto the laying surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply laminate (128) after the first ply (130) has been formed, and to change the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) for the second ply (134) during said pick-up and placing; and controlling the automated tape laying machine (126) to arrange the material (145) to form the plies of the multi-ply laminate (128), with the plies having the fibers (148) oriented in the initial direction (125).

12. A method of forming a multi-ply laminate (128), comprising the steps of: controlling (800) a first cutting system (120) to cut and move a first group of courses (131) to a staging position (141); controlling (802) a placement robot (124, 214, 420) to pick up and place the first group of courses (131) from the staging position (141) onto a laying surface (127, 234, 320, 416) to form a first ply (130) of the multi-ply laminate (128) and to change the orientation of the fibers (123) from an initial orientation (125) to a desired orientation (146) for the first ply (130) during the pick-up and placing; controlling (804) a second cutting system (122) to cut and move a second group of courses (131) to the staging position (141) while the placement robot (124, 214, 420) is picking up and placing the first group of courses (131); After the first ply (130) has been formed, controlling (806) the placement robot (124, 214, 420) to pick up and place the second group of courses (131) from the staging position (141) onto the laying surface (127, 234, 320, 416) to form a second ply (134) of the multi-ply laminate (128) and during the pick-up and placing, changing the orientation of the fibers (123) from the initial orientation (125) to the desired orientation (146) for the second ply (134); and controlling (900) an automated tape laying machine (126) to place material (145) to form the third ply of the multi-ply laminate (128), with the third ply (136) having the fibers (123) oriented in the initial direction (125).

13. the direction of the fibers (123) of at least one of the courses (131) is changed by redirecting the course when the course is picked up from the staging location and placed on the laying surface (127, 234, 320, 416) to form a ply; the ply has a width defined by an outer edge of the ply; 13. The method of claim 12, wherein the course is redirected such that one or more cut edges of the course form a portion of an outer edge of the ply when placed onto the layup surface.

14. generating (1000) an upper surface image (153) of an upper surface of the course (131) and / or a lower surface image (162) of a lower surface of the course (131) using a robot camera (152) connected to the placement robot (124, 214, 420) and / or an upward-looking camera (160) connected to a camera station in response to the placement robot (124, 214, 420) moving to pick up the course (131); Analyzing (1002) the top-view image (153) and / or bottom-view image (162) for out-of-tolerance anomalies (155); and 14. The method of claim 12 or 13, further comprising controlling (1004) the placement robot (124, 214, 420) to move any of the courses (131) having the out-of-tolerance anomalies (155) to a scrap position (154).

15. In response to one of a first cutting machine (132, 202, 411) in the first cutting system (120) and a second cutting machine (122, 207, 413) in the second cutting system (122) requiring maintenance, replacing (1300) one of the first cutting machine (132, 202, 411) and the second cutting machine (122, 207, 413) with a spare cutting machine (185, 409); and 14. The method of claim 12 or 13, further comprising synchronizing (1302) an operation of the spare cutting machine (185, 409) for cutting the course (131) in response to replacing the spare cutting machine (185, 409) with one of the first cutting machine (132, 202, 411) and the second cutting machine (122, 207, 413).

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