Methods and automated systems for layup and analysis of composite materials during the fabrication of composite workpieces.

Abstract

This invention provides a method and automated system for layup and analysis of composite materials during the fabrication of composite workpieces. [Solution] A method for laying up and analyzing composite materials during the fabrication of a composite workpiece includes the steps of laying up layers of composite material for a composite workpiece based on design data for the layers and detecting finished data for the layers using a quality detection device. Next, the finished data for the layers is processed to determine the fiber volume filling characteristics at the time of layer completion. Then, the fiber volume filling characteristics at the time of completion are compared with the planned fiber volume filling characteristics based on design data for the layers to determine the predicted fiber volume filling rate for the layers. An automated system for laying up and analyzing composite materials during the fabrication of a composite workpiece includes at least one analytical computing device, a robotic manipulator, a layup mandrel, and a quality detection device.

Description

Technical Field

[0001] The present disclosure relates generally to the layup and analysis of composite materials during fabrication of composite workpieces, and more particularly, to associated methods and automated systems. The method includes the steps of laying up a plurality of layers of composite material and detecting as-completed data for each layer. For example, the as-completed data is processed to determine as-completed fiber volume fill characteristics. The as-completed fiber volume fill characteristics are compared to planned fiber volume fill characteristics based on design data for the composite workpiece. The comparison determines a predicted fiber volume fill ratio for each layer. The predicted fiber volume fill ratio for each layer can be processed to determine a through-thickness predicted fiber volume fill ratio for any combination of the plurality of layers.

Background Art

[0002] At present, the analysis of fiber volume fill of composite workpieces is performed manually with a large amount of engineering and manufacturing operation time and labor time required to evaluate the requirements. Since it relies heavily on cumbersome analysis, it may be prone to errors. Typically, this requires time-consuming manual analysis and part construction processes to evaluate the requirements. To meet a similar set of requirements, it is known that in some cases, large complex parts require more than a year of continuous iterations to design a NC program that meets the requirements.

[0003] Accordingly, those skilled in the art continue research and development efforts to improve techniques for the layup and analysis of composite materials during fabrication of composite workpieces.

Summary of the Invention

Means for Solving the Problems

[0004] Examples of a method for layup and analysis of composite materials during fabrication of a composite workpiece, as well as an automated system for layup and analysis of composite materials during fabrication of a composite workpiece, are disclosed. The following is a non-exhaustive list of examples of the subject matter according to the present disclosure, some of which may or may not be claimed.

[0005] For example, a disclosed method for layup and analysis of composite material during the fabrication of a composite workpiece includes: (1) laying up layers of composite material for a composite workpiece based on design data for the layers; (2) detecting finished data for the layers using a quality detection device; (3) processing the finished data for the layers to determine the finished fiber volume filling characteristics of the layers; and (4) comparing the finished fiber volume filling characteristics with the planned fiber volume filling characteristics based on design data for the layers to determine a predicted fiber volume filling rate for the layers.

[0006] In one example, a disclosed automated system for layup and analysis of composite materials during the fabrication of a composite workpiece includes at least one analytical computing device, a robotic manipulator, a layup mandrel, and a quality detection device. The at least one analytical computing device stores a design data analysis application program, a finished data analysis application program, and a predicted fiber volume filling rate application program. The robotic manipulator is located within the fabrication cell and operably communicates with the at least one analytical computing device. The robotic manipulator includes a composite material placement device. The layup mandrel is located within the fabrication cell and lays up the composite material. The quality detection device is located within the fabrication cell and operably communicates with the at least one analytical computing device.

[0007] In another example, a disclosed method for layup and analysis of a composite material during the fabrication of a composite workpiece includes: (1) laying up a layer of a plurality of layers of the composite material for a composite workpiece based on design data for the layer; (2) detecting finished data for the layer using a quality detection device; (3) processing the finished data for the layer to determine the finished fiber volume filling characteristics of the layer; (4) comparing the finished fiber volume filling characteristics for the layer with the planned fiber volume filling characteristics based on design data for the layer to determine a predicted fiber volume filling rate for the layer; (5) repeating the steps of layup, detection, processing, and comparison for each subsequent layer of the plurality of layers; and (6) processing the predicted fiber volume filling rates for the plurality of layers to determine a predicted fiber volume filling rate for at least one through-thickness.

[0008] In yet another example, a disclosed method for layup and analysis of composite materials during the fabrication of a composite workpiece includes (1) laying up layers on a layup mandrel based on design data; (2) detecting finished data using a quality detection device; (3) processing the finished data to determine the finished fiber volume filling characteristics; and (4) comparing the finished fiber volume filling characteristics with the planned fiber volume filling characteristics to determine a predicted fiber volume filling rate for the layers.

[0009] In another example, a disclosed automated system for layup and analysis of composite materials during the fabrication of a composite workpiece includes an analytical computing device, a composite material placement device, a layup mandrel, and a quality detection device. The analytical computing device stores a design data analysis application program, a finished data analysis application program, and a predicted fiber volume filling rate application program. The composite material placement device communicates operably with the analytical computing device. The layup mandrel lays up the composite material. The quality detection device communicates operably with the analytical computing device.

[0010] For example, a disclosed method for optimizing design data during the fabrication of a composite workpiece includes: (1) laying up layers on a layup mandrel based on design data; (2) detecting finished data using a quality detection device; (3) processing the finished data to determine the finished fiber volume filling characteristics; (4) comparing the finished fiber volume filling characteristics with the planned fiber volume filling characteristics to determine a predicted fiber volume filling rate for the layer; (5) optimizing the design data to form optimized design data for at least one subsequent layer to reduce the risk probability of not achieving the fiber volume filling rate requirement, at least in part based on the predicted fiber volume filling rate; and (6) laying up a second layer on top of the layer on the layup mandrel based on the optimized design data.

[0011] Disclosed methods for layup and analysis of composite materials during the fabrication of composite workpieces, as well as other examples of automated systems for layup and analysis of composite materials during the fabrication of composite workpieces, will become apparent from the following detailed description, accompanying drawings and accompanying claims. [Brief explanation of the drawing]

[0012] [Figure 1]This is a functional block diagram of an example of an automated system for layup and analysis of composite materials during the fabrication of composite workpieces. [Figure 2] This is a side view of an example of a composite workpiece. [Figure 3A] This is a flowchart illustrating an example of a method for layup and analysis of composite materials during the fabrication of composite workpieces. [Figure 3B] This is a flowchart illustrating an example of a method for layup and analysis of composite materials during the fabrication of composite workpieces. [Figure 4] This is a flowchart of another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece, combined with Figure 3A. [Figure 5] This flowchart, combined with Figures 3A and 4, shows yet another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece. [Figure 6] This flowchart, combined with Figures 3A, 4, and 5, shows yet another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece. [Figure 7] Figure 6 is a flowchart illustrating an example of the steps involved in optimizing the design data. [Figure 8] This flowchart, combined with Figures 3A, 4, and 5, shows yet another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece. [Figure 9] This is a functional block diagram of another example of an automated system for layup and analysis of composite materials during the fabrication of composite workpieces. [Figure 10] This block diagram shows an example of design data used in conjunction with the layup and analysis of composite materials during the fabrication of composite workpieces. [Figure 11A] This is a functional diagram showing an example of a ply used in conjunction with the layup of composite materials during the fabrication of a composite workpiece. [Figure 11B] This is a functional diagram showing an example of a tow used in conjunction with the layup of composite materials during the fabrication of a composite workpiece. [Figure 11C] This is a functional diagram showing an example of a tow course used in conjunction with the layup of composite materials during the fabrication of a composite workpiece. [Figure 12A] This is a functional diagram showing an example of gaps between adjacent tows together with the layup and analysis of composite materials during the fabrication of a composite workpiece. [Figure 12B] This is a functional diagram showing an example of overlaps between adjacent tows together with the layup and analysis of composite materials during the fabrication of a composite workpiece. [Figure 13] This is a block diagram showing an example of the composite material placement device of Fig. 9. [Figure 14] This is a block diagram showing an example of as-completed data used together with the layup and analysis of composite materials during the fabrication of a composite workpiece. [Figure 15] This is a block diagram showing an example of the quality detection device of Fig. 9. [Figure 16] This is a functional diagram showing an example of a grid structure of a workpiece used together with the layup and analysis of composite materials during the fabrication of a composite workpiece. [Figure 17] This is a flowchart of another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece. [Figure 18] This is a flowchart of yet another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece, combined with Fig. 17. [Figure 19] This is a flowchart of yet another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece, combined with Fig. 17 and Fig. 18. [Figure 20] This is a flowchart of yet another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece, combined with Fig. 17, Fig. 18 and Fig. 19. [Figure 21] This is a flowchart of an example of the step of optimizing the design data of Fig. 20. [Figure 22] This is a flowchart of another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece, combined with Fig. 17, Fig. 18 and Fig. 19. [Figure 23] This is a flowchart of yet another example of a method for layup and analysis of composite materials during the fabrication of a composite workpiece. [Figure 24] This is a flowchart illustrating an example of a method for optimizing design data during the manufacturing of complex workpieces. [Figure 25] This is a block diagram of an aircraft production and maintenance inspection method that implements one or more examples of methods for layup and analysis of composite materials during the fabrication of composite workpieces disclosed herein. [Figure 26] This is a schematic diagram of an aircraft incorporating components fabricated using one or more of the examples of methods for layup and analysis of composite materials during the fabrication of composite works disclosed herein. [Modes for carrying out the invention]

[0013] Various examples of methods 300, 400, 500, 600, 800, 1700, 1800, 1900, 2000, 2200, and 2300 disclosed herein for layup and analysis of composite material 902 during the fabrication of composite workpiece 200 provide techniques for in-process analysis and control during fabrication. Various examples of automated systems 100 and 900 disclosed herein for layup and analysis of composite material 902 during the fabrication of composite workpiece 200 enable methods 300, 400, 500, 600, 800, 1700, 1800, 1900, 2000, 2200, and 2300, as well as techniques for in-process analysis and control during fabrication. Various examples of method 2400 for optimizing design data 926 during the fabrication of composite workpiece 200 provide techniques for optimizing design data of workpieces during fabrication.

[0014] Various techniques for layup and analysis of composite materials during the fabrication of composite workpieces disclosed herein may be implemented, for example, to address automated composite lamination fill rate risk analysis during the design of numerical control programs, as well as lamination fill rate risk analysis applied during fabrication for monitoring and process control.

[0015] Various methods and automated systems enable rapid analysis and inspection of specific technical requirements associated with the lamination of composite materials. In particular, there is a risk of failing to meet fiber volume filling due to either the relative arrangement of ply, coarse, or tow boundaries, or their convergence, as defined by a numerically controlled program. Various methods and automated systems also enable the optimization of numerically controlled programs specifying ply, coarse, or tow arrangements to minimize the risks associated with meeting fiber volume filling requirements. Furthermore, various methods and automated systems allow for the discretization of fiber volume filling risk analysis into zones within the lamination plane of the workpiece, such as the surface of the part or sub-sections within the part. Various methods and automated systems also enable these analyses to be achieved by the thickness of the part, sub-sections within the part, or more generally, multiple layers of the surface.

[0016] The various methods and additional aspects of automated systems enable alternative methods for refining planning requirements to facilitate in-process measurement, comparative analysis of finished and planned filling rates, and manual optimization of numerical control programming. If a sampling plan is included, this technique can be modified so that the sampling plan can be refined to meet the requirements.

[0017] Various methods and automated systems require input of relevant datasets associated with design, numerical control programming, and engineering requirements. Various methods and automated systems include application programs that generate a gridded data structure for registering data and separate gridded data structures for analysis and requirements capture. Various methods and automated systems include features to aggregate relevant data within the grid structure for analysis and enable thickness analysis. Various automated systems include risk analysis modules to satisfy specific fiber volumes. Various methods include a process of evaluating risk analysis zone by zone and manually optimizing the numerical control program design to minimize risk. Various methods and automated systems also include options for automated optimization of numerical control path starting points to optimize the numerical control program design.

[0018] Referring to Figure 1, in one or more examples, an automated system 100 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200 includes design data 926, an automated composite laydown fill rate analysis device 102, manufacturing equipment 104, real-time quality detection hardware 106, and a real-time defect evaluation device 108. The design data 926 operably communicates with the automated composite laydown fill rate analysis device 102. The design data 926 includes, for example, computer-aided design geometry, original numerical control programs, layup designs, and fill requirements. The manufacturing equipment 104 operably communicates with the real-time quality detection hardware 106. The manufacturing equipment 104 includes a system control unit 110 having programmed machine control parameters 112. The real-time quality detection hardware 106 operably communicates with the real-time defect evaluation device 108. The real-time quality detection hardware 106 includes, for example, a visual system analyzer and a shape measuring instrument. The real-time defect evaluation device 108 communicates operably with the automated composite laydown filling rate analysis device 102. The real-time defect evaluation device 108 includes overlap and gap size / location analysis 114.

[0019] The automated composite laydown fill density analysis device 102 includes a through-thickness path extraction, alignment, and gridding module 116, a requirements grid generation module 118, a planned fill density analysis module 120, measured overlap / gap data alignment 122, and a finished fill density analysis 124. The automated composite laydown fill density analysis device 102 operably communicates with fill density risk 126 output by orientation and through-thickness. The automated composite laydown fill density analysis device 102 also operably communicates with a finished and planned fill density comparison analysis 128.

[0020] The fill density risk 126, output by orientation and penetration thickness, operably communicates with an optimized path plan 130 to minimize the fill density risk. The optimized path plan 130 to minimize the fill density risk operably communicates with an automated laydown 132 of the composite component.

[0021] A comparative analysis of the completed and planned fill rates 128 operably communicates with the improved requirement 134 for the planned fill rate. The improved requirement 134 for the planned fill rate operably communicates with the optimized numerical control programming 136 based on the new requirement. The optimized numerical control programming 136 based on the new requirement operably communicates with the automated layup 138 of the composite parts.

[0022] Referring generally to Figures 2, 3A-3B, 4-10, 11A-11C, 12A-12B, and 14-16, this disclosure relates, as an example, to methods 300, 400, 500, 600, and 800 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 2 provides an example of a composite workpiece 200. Figures 3A and 3B provide an example of method 300 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 4, in combination with Figure 3A, provides an example of method 400 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 5, in combination with Figures 3A and 4, provides an example of method 500 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 6, in combination with Figures 3A, 4, and 5, provides an example of a method 600 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 7 provides an example of step 602 for optimizing the design data 926 from Figure 6. Figure 8, in combination with Figures 3A, 4, and 5, provides an example of a method 800 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200.

[0023] Figure 9 is a functional block diagram of an example of an automated system 900 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 10 is a block diagram of an example of design data 926 used in conjunction with the layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figures 11A to 11C are functional diagrams showing examples of plies 1102, tows 1105, and courses 1106 of tows 1105 used in conjunction with the layup of composite material 902 during the fabrication of a composite workpiece 200. Figures 12A and 12B are functional diagrams showing examples of gaps 1202 and overlaps 1204 between adjacent tows 1105 in conjunction with the layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 14 is a block diagram of an example of finished data 930 used in conjunction with the layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 15 is a block diagram of an example of the quality detection device 944 shown in Figure 9. Figure 16 is a functional diagram showing an example of a grid structure 1600 for a composite workpiece 200, used in conjunction with the layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200.

[0024] Referring again to Figures 2, 3A-3B, 9, 10, 11A-11C, 12A-12B, and 14-16, in one or more examples, a method 300 (see Figures 3A-3B) for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200 includes a step 306 of laying up a layer 946 of composite material 902 for the composite workpiece 200 based on design data 926 for the layer 946. In 308, finished data 930 for the layer 946 is detected using a quality detection device 944. In 310, the finished data 930 for the layer 946 is processed to determine the finished fiber volume filling characteristics 932 of the layer 946. In step 312, in order to determine the predicted fiber volume filling rate 934 for layer 946, the completed fiber volume filling characteristics 932 are compared with the planned fiber volume filling characteristics 928 based on the design data 926 for layer 946.

[0025] In another example of Method 300, a layer 946 of composite material 902 is laid up on a layup mandrel 942 in a fabrication cell 938. A second layer 1604 of composite material 902 is laid up on top of layer 946, and a subsequent layer 950 of composite material 902 is laid up on top of the current layer 1608. In yet another example of Method 300, step 308, in which finished data 930 is detected, is performed while layer 946 is on the layup mandrel 942. In yet another example, Method 300 continues from 312 to 314. In 314, a subsequent layer 950 of composite material 902 for the composite workpiece 200 is laid up based on design data 926 for the subsequent layer 950. In 316, after step 314, in which the corresponding subsequent layer 950 is laid up using a quality detection device 944, finished data 930 is detected for each subsequent layer 950. In step 318, the completed data 930 for the subsequent layers 950 is processed to determine the completed fiber volume filling characteristics 932 for each of the subsequent layers 950. In step 320, the completed fiber volume filling characteristics 932 is processed for layer 946 and for each of the subsequent layers 950 to determine the completed fiber volume filling characteristics 974 for the through-thickness.

[0026] In yet another example of Method 300, the composite material 902 includes a reinforcing material and a base material. In a further example, the reinforcing material includes a fibrous material and the base material includes a resin material. In yet another example, the fibrous material includes a unidirectional fibrous material. In yet another example of Method 300, the design data 926 for layup includes layer construction information 1002. In yet another example of Method 300, the design data 926 for layup includes dimensional information 1004 for the composite material 902, orientation information 1006 for the composite material 902, dimensional information 1004 for the composite workpiece 200, outline information 1008 for the composite workpiece 200, or any other suitable design data for any suitable combination of layups.

[0027] In yet another example of Method 300, the composite workpiece 200 includes multiple layers 946, 950, and the design data 926 for layup includes layer location information 1010 for at least a portion of the design data 926. In yet another example of Method 300, the composite workpiece 200 includes multiple zones 202, and the design data 926 for layup includes zone location information 1012 for at least a portion of the design data 926. In yet another example of Method 300, layer 946 includes at least one of plies 1102 of the composite material 902, multiple tows 1105 of the composite material 902, and multiple courses 1106 of the tows 1105 of the composite material 902. In yet another example of Method 300, the planned fiber volume filling characteristics 928 take into account the planned overlap 1204 and planned gap 1202 for each layer 946, 950 of the composite material 902 in the composite workpiece 200. In yet another example of Method 300, the finished data 930 for layer 946 includes three-dimensional surface information 1402 representing the surface of layer 946 to capture the actual overlap 1204 and actual gap 1202 of layer 946 of the composite material 902. In yet another example of Method 300, the quality detection device 944 includes a shape measuring instrument 1502, a vision system 1504, or any other suitable quality detection device in any suitable combination.

[0028] In another example of Method 300, the finished data 930 is divided into a grid structure 1600 for the composite workpiece 200, which includes multiple data cells 1602 for each layer 946, 950 of the composite workpiece 200, and the finished data 930 includes grid location information 1404. In yet another example of Method 300, the finished fiber volume filling characteristics 932 for layer 946 take into account the measured overlap 1204 and measured gap 1202 of the composite material 902 in the composite workpiece 200 for layer 946. In yet another example, Method 300 also includes a step 302 in which design data 926 for the layup of the composite material 902 is received. In 304, the design data 926 for the layer 946 of the layup is processed to determine the planned fiber volume filling characteristics 928 of layer 946. In this example, the Method continues from 304 to 306.

[0029] Referring again to Figures 2, 3A, 4, 9, and 10, in one or more examples, a method 400 (see Figure 4) for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200 includes method 300 in Figure 3A, followed by 312 to 402, where a fiber volume fill rate requirement 952 for layup is received. In 404, to determine the risk probability 956 of not achieving the fiber volume fill rate requirement 952 for the composite workpiece 200, the predicted fiber volume fill rate 934 for layer 946 is compared with the fiber volume fill rate requirement 952. In another example of method 400, the composite workpiece 200 includes multiple layers 946, 950, and the fiber volume fill rate requirement 952 for layup includes layer location information 1010, individually for each layer 946, 950 of the composite workpiece 200 and collectively for multiple layers 946, 950.

[0030] Referring again to Figures 3A, 4, 5, and 9, in one or more examples, a method 500 (see Figure 5) for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200 includes method 300 in Figure 3A and method 400 in Figure 4. Method 500 continues from 404 to 502 in Figure 4, where a risk threshold 958 for a risk probability 956 is received to classify the risk probability 956 as acceptable or unacceptable. In 504, the risk probability 956 is compared with the risk threshold 958 for the risk probability 956.

[0031] Referring again to Figures 2, 3A, 4-7 and 9, in one or more examples, if the risk probability 956 exceeds the risk threshold 958, the risk probability 956 is unacceptable, and the method 600 (see Figure 6) for layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200 includes method 300 in Figure 3A, method 400 in Figure 4 and method 500 in Figure 5. Method 600 follows 504 to 602 in Figure 5, and in order to reduce the risk probability 956 of not achieving the fiber volume filling requirement 952 for the composite workpiece 200, the design data 926 is optimized to form optimized design data 962 for layup of at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200. In 604, optimized design data 962 for the second layer 1604 of the layup is processed to determine the planned fiber volume filling properties 928 of the second layer 1604. In 606, the second layer 1604 of the composite material 902 is laid up on top of the layer 946 based on the optimized design data 962.

[0032] In another example of Method 600, step 602 of optimizing the design data 926 includes step 702 (see Figure 7) of optimizing the path plan for at least the rest of the composite workpiece 200 so as to form an optimized path plan 964 for the layup of at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200, in order to reduce the probability 956 of risk of not achieving the fiber volume fill rate requirement 952 for the composite workpiece 200. In yet another example of Method 600, step 602 of optimizing the design data 926 includes step 704 of optimizing the fiber volume fill rate requirement 952 for at least the rest of the composite workpiece 200 so as to form an optimized fiber volume fill rate requirement 966 for the layup of at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200, in order to reduce the probability 956 of risk of not achieving the fiber volume fill rate requirement 952 for the composite workpiece 200. In yet another example of Method 600, step 602 of optimizing design data 926 includes step 706 of optimizing numerical control programming for at least the rest of the composite workpiece 200 so as to form an optimized numerical control program 968 for layup of at least one subsequent layer 950 of composite material 902 during the fabrication of the composite workpiece 200, in order to reduce the probability 956 of risk of not achieving the fiber volume filling requirement 952 for the composite workpiece 200.

[0033] Referring again to Figures 3A, 4, 5, 8, 9 and 16, in one or more examples, the risk probability 956 is acceptable if it does not exceed the risk threshold 958, and the method 800 (see Figure 8) for layup and analysis of composite material 902 during the fabrication of composite workpiece 200 includes method 300 in Figure 3A, method 400 in Figure 4 and method 500 in Figure 5. Method 800 continues from 504 to 802 in Figure 5, where design data 926 for the second layer 1604 of the layup is processed to determine the planned fiber volume filling characteristics 928 of the second layer 1604. In 804, the second layer 1604 of the composite material 902 is laid up on top of layer 946 based on the design data 926.

[0034] Referring generally to Figures 2, 9, 10, 11A–11C, 12A–12B, and 13–16, this disclosure, as an example, relates to an automated system 900 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 2 provides an example of a composite workpiece 200. Figure 9 is a functional block diagram of an example of an automated system 900 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 10 is a block diagram showing an example of design data 926 used with the layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figures 11A–11C are functional diagrams showing examples of plies 1102, tows 1105, and courses 1106 of tows 1105 used with the layup of composite material 902 during the fabrication of a composite workpiece 200. Figures 12A and 12B are functional diagrams showing examples of gaps 1202 and overlaps 1204 between adjacent tows 1105, along with the layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200. Figure 13 is a block diagram showing an example of the composite material placement device 940 in Figure 9. Figure 14 is a block diagram showing an example of finished data 930 used with the layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200. Figure 15 is a block diagram showing an example of the quality detection device 944 in Figure 9. Figure 16 is a functional diagram showing an example of a grid structure 1600 for the composite workpiece 200 used with the layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200.

[0035] Referring again to Figures 2, 9, 10, 11A-11C, 12A-12B, and 13-16, in one or more examples, an automated system 900 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200 is disclosed. The automated system 900 includes at least one analytical computing device 904, a robotic manipulator 936, a layup mandrel 942, and a quality detection device 944. The at least one analytical computing device 904 stores a design data analysis application program 918, a finished data analysis application program 920, and a predicted fiber volume filling rate application program 922. The robotic manipulator 936 is located in a fabrication cell 938 and operably communicates with the at least one analytical computing device 904. The robotic manipulator 936 includes a composite material placement device 940. A layup mandrel 942 is located within the fabrication cell 938 and lays up the composite material 902. A quality detection device 944 is located within the fabrication cell 938 and operably communicates with at least one analytical computing device 904. The at least one analytical computing device 904 may also include a user input device 976 and a user display device 978.

[0036] In another example of the automated system 900, at least one analytical computing device 904 includes a network interface 906, at least one processor 910 and associated memory 912, at least one application program storage device 916, and at least one local data storage device 924. The network interface 906 operably communicates with a communication network 908. At least one processor 910 operably communicates with a design data storage device 914 via the network interface 906 and the communication network 908. At least one application program storage device 916 operably communicates with at least one processor 910 and stores a design data analysis application program 918, a finished data analysis application program 920, and a predicted fiber volume filling rate application program 922. At least one application program storage device 916 also stores one or more of the fiber volume filling risk application program 954 and a design data optimization application program 960. At least one local data storage device 924 temporarily stores at least design data 926, planned fiber volume filling characteristics 928, finished data 930, finished fiber volume filling characteristics 932, and predicted fiber volume filling rate 934. At least one local data storage device 924 also temporarily stores at least one or more of the fiber volume filling rate requirements, risk probability, risk threshold, optimized path plan, optimized fiber volume filling rate requirements, and optimized numerical control program.

[0037] In a further example, the design data storage device 914 is configured to store design data 926, design requirements, and verification records for the composite workpiece 200. In yet another further example, the design data 926 for layup includes layer construction information 1002. In yet another further example, the design data 926 for layup includes dimensional information 1004 for the composite material 902, orientation information 1006 for the composite material 902, dimensional information 1004 for the composite workpiece 200, outline information 1008 for the composite workpiece 200, or any other suitable design data for any suitable combination of layups. In yet another further example, the composite workpiece 200 includes multiple layers 946, 950, and the design data 926 for layup includes layer location information 1010 for at least a portion of the design data 926. In yet another further example, the composite workpiece 200 includes multiple zones 202, and the design data 926 for layup includes zone location information 1012 for at least a portion of the design data 926.

[0038] In yet another example of the automated system 900, at least one analytical computing device 904 includes one or more analytical computing devices 904 located at a remote location 948 relative to the fabrication cell 938, one or more analytical computing devices 904 located within the fabrication cell 938, or any suitable combination thereof. In yet another example of the automated system 900, the composite material placement device 940 includes an automated fiber placement device 1302. In a further example, the automated fiber placement device 1302 is configured to lay at least one tow 1104 on a layup mandrel 942. In yet another example, the automated fiber placement device 1302 is configured to lay a course 1106 of tow 1105 on the layup mandrel 942. In yet another example of the automated system 900, the quality detection device 944 includes a shape measuring instrument 1502, a visual system 1504, or any other suitable quality detection device in any suitable combination thereof.

[0039] In yet another example of the automated system 900, a robotic manipulator 936 and a composite material placement device 940 are configured to lay up a layer 946 of composite material 902 for a composite workpiece 200 on a layup mandrel 942 in a fabrication cell 938, based on design data 926 for the layer 946. In this example, after the layup of the layer 946, a quality detection device 944 is configured to detect finished data 930 for the layer 946 on the layup mandrel 942. At least one analytical computing device 904 is configured to run a finished data analysis application program 920 and process the finished data 930 for the layer 946 to determine the finished fiber volume filling characteristics 932 of the layer 946 on the layup mandrel 942. At least one analytical computing device 904 is configured to run a predictive fiber volume filling rate application program 922 and to compare the finished fiber volume filling characteristics 932 with the planned fiber volume filling characteristics 928 based on design data 926 for the layer 946 in order to determine the predicted fiber volume filling rate 934 for the layer 946.

[0040] In a further example, layer 946 includes at least one of a ply 1102 of composite material 902, multiple tows 1105 of composite material 902, and multiple courses 1106 of the tows 1105 of composite material 902. In yet another further example, the planned fiber volume filling characteristics 928 take into account the planned overlap 1204 and planned gap 1202 for each layer 946, 950 of composite material 902 in the composite workpiece 200. In yet another further example, the finished data 930 is divided into a grid structure 1600 for the composite workpiece 200, which includes multiple data cells 1602 for each layer 946, 950 of the composite workpiece 200, and the finished data 930 includes grid location information 1404. In yet another example, the finished data 930 for layer 946 includes three-dimensional surface information 1402 representing the surface of layer 946 to capture the actual overlap 1204 and actual gap 1202 of the composite material 902 to layer 946. In yet another example, the finished fiber volume filling characteristics 932 for layer 946 take into account the measured overlap 1204 and measured gap 1202 of the composite material 902 to layer 946 within the composite workpiece 200.

[0041] In another further example, at least one analytical computing device 904 is configured to receive design data 926 for the layup of a composite material 902 from a design data storage device 914 via a network interface 906 and a communication network 908. In this example, at least one analytical computing device 904 is configured to run a design data analysis application program 918 and to process the design data 926 for the layer 946 of the layup in order to determine the planned fiber volume filling properties 928 of the layer 946.

[0042] In yet another further example, at least one analytical computing device 904 is configured to receive fiber volume fill rate requirements 952 for layup from a design data storage device 914 via a network interface 906 and a communication network 908. In this example, at least one analytical computing device 904 is configured to run a fiber volume fill rate risk application program 954 and to compare a predicted fiber volume fill rate 934 for layer 946 with the fiber volume fill rate requirements 952 in order to determine the risk probability 956 that the fiber volume fill rate requirements 952 for the composite workpiece 200 will not be achieved after the layup of layer 946.

[0043] In a further example, at least one analytical computing device 904 is configured to receive a risk threshold 958 for a risk probability 956 from a design data storage device 914 via a network interface 906 and a communication network 908, in order to classify the risk probability 956 as acceptable or unacceptable. In this example, at least one analytical computing device 904 is configured to run a fiber volume filling risk application program 954 and to compare the risk probability 956 after the layup of the layer 946 with the risk threshold 958 for the risk probability 956.

[0044] In a further example where the risk probability 956 exceeds the risk threshold 958, the risk probability 956 is unacceptable, and at least one analytical computing device 904 is configured to run a design data optimization application program 960 and optimize the design data 926 to form optimized design data 962 for the layup of at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200 in order to reduce the risk probability 956 of not achieving the fiber volume filling requirement 952 for the composite workpiece 200 after the layup of at least one subsequent layer 950. In this example, at least one analytical computing device 904 is configured to run a design data analysis application program 918 and process the optimized design data 962 for the second layer 1604 in order to determine the planned fiber volume filling characteristics 928 of the second layer 1604 of the layup. The robotic manipulator 936 and the composite material placement device 940 are configured to lay up a second layer 1604 of composite material 902 on top of a layer 946 on a layup mandrel 942, based on optimized design data 962.

[0045] In a further example, at least one analytical computing device 904 is configured to run a design data optimization application program 960 and to optimize the path plan for at least the rest of the composite workpiece 200 to form an optimized path plan 964 for the layup of at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200, in order to reduce the probability 956 of risk that the fiber volume filling requirement 952 for the composite workpiece 200 will not be met after the layup of at least one subsequent layer 950.

[0046] In yet another further example, at least one analytical computing device 904 is configured to run a design data optimization application program 960 and to optimize the fiber volume fill rate requirement 952 for at least the remaining portion of the composite workpiece 200 so as to form an optimized fiber volume fill rate requirement 966 for the layup of at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200, in order to reduce the probability 956 of risk that the fiber volume fill rate requirement 952 for the composite workpiece 200 will not be achieved after the layup of at least one subsequent layer 950.

[0047] In yet another example, at least one analytical computing device 904 is configured to run a design data optimization application program 960 and optimize numerical control programming for at least the rest of the composite workpiece 200 to form an optimized numerical control program 968 for the layup of at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200, in order to reduce the probability 956 of risk that the fiber volume filling requirement 952 for the composite workpiece 200 will not be met after the layup of at least one subsequent layer 950.

[0048] In yet another further example where the risk probability 956 does not exceed the risk threshold 958, the risk probability 956 is acceptable, and at least one analytical computing device 904 is configured to run a design data analysis application program 918 and process design data 926 for the second layer 1604 in order to determine the planned fiber volume filling characteristics 928 of the second layer 1604 of the layup. In this example, a robotic manipulator 936 and a composite material placement device 940 are configured to lay up the second layer 1604 of the composite material 902 on top of the layer 946 on the layup mandrel 942 based on the design data 926.

[0049] Referring generally to Figures 2, 9, 10, 11A–11C, 12A–12B, 14, and 16–22, this disclosure relates, as an example, to methods 1700, 1800, 1900, 2000, and 2200 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 2 provides an example of a composite workpiece 200. Figure 9 is a functional block diagram of an example of an automated system 900 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 10 is a block diagram showing an example of design data 926 used with the layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figures 11A–11C are functional diagrams showing examples of plies 1102, tows 1105, and courses 1106 of tows 1105 used with the layup of composite material 902 during the fabrication of a composite workpiece 200. Figures 12A and 12B are functional diagrams showing examples of gaps 1202 and overlaps 1204 between adjacent tows 1105, along with the layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200. Figure 14 is a block diagram showing an example of finished data 930 used in conjunction with the layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200. Figure 16 is a functional diagram showing an example of a grid structure 1600 for the composite workpiece 200 used in conjunction with the layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200. Figure 17 provides an example of a method 1700 for the layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200. Figure 18, in combination with Figure 17, provides an example of a method 1800 for the layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200. Figure 19, in combination with Figures 17 and 18, provides an example of method 1900 for layup and analysis of composite material 902 during the fabrication of composite workpiece 200. Figure 20, in combination with Figures 17, 18 and 19, provides an example of method 2000 for layup and analysis of composite material 902 during the fabrication of composite workpiece 200. Figure 21 provides an example of step 2002 for optimizing the design data 926 of Figure 20. Figure 22, in combination with Figures 17, 18 and 19, provides an example of method 2200 for layup and analysis of composite material 902 during the fabrication of composite workpiece 200.

[0050] Referring again to Figures 2, 9, 10, 11A-11C, 12A-12B, 14, 16 and 17, in one or more examples, a method 1700 (see Figure 17) for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200 includes a step 1706 of laying up one of several layers 946, 950 of composite material 902 for a composite workpiece 200 based on design data 926 for layer 946. In 1708, finished data 930 for layer 946 is detected using a quality detection device 944. In 1710, the finished data 930 for layer 946 is processed to determine the finished fiber volume filling characteristics 932 of layer 946. In step 1712, in order to determine the predicted fiber volume filling rate 934 for layer 946, the finished fiber volume filling characteristics 932 for layer 946 are compared with the planned fiber volume filling characteristics 928 based on the design data 926 for layer 946. In step 1714, the steps of detection 1708, processing 1710, and comparison 1712 are repeated for each subsequent layer 950 of a plurality of layers 946, 950. In step 1716, the predicted fiber volume filling rates 934 for the plurality of layers 946, 950 are processed to determine at least one through-thickness predicted fiber volume filling rate 970.

[0051] In another example of Method 1700, a layer 946 of composite material 902 is laid up on a layup mandrel 942 in a fabrication cell 938. In yet another example of Method 1700, the step 1708 of detecting finished data 930 is performed while the layer 946 is on the layup mandrel 942. In yet another example of Method 1700, the design data 926 for the layup includes layer construction information 1002. In yet another example of Method 1700, the design data 926 for the layup includes dimensional information 1004 for composite material 902, orientation information 1006 for composite material 902, dimensional information 1004 for composite workpiece 200, outline information 1008 for composite workpiece 200, or any other suitable design data for a layup of any suitable combination. In yet another example of Method 1700, the design data 926 for the layup includes layer location information 1010 for at least a portion of the design data 926. In yet another example of Method 1700, the composite workpiece 200 includes multiple zones 202, and the design data 926 for layup includes zone location information 1012 for at least a portion of the design data 926. In yet another example of Method 1700, each of the multiple layers 946, 950 includes at least one of the plies 1102 of the composite material 902, the multiple tows 1105 of the composite material 902, and the multiple courses 1106 of the tows 1105 of the composite material 902. In yet another example of Method 1700, the planned fiber volume filling characteristics 928 take into account the planned overlap 1204 and planned gap 1202 for each of the multiple layers 946, 950.

[0052] In another example of Method 1700, the finished data 930 for each of the multiple layers 946, 950 includes three-dimensional surface information 1402 representing the surface of the corresponding layer 946, 950 to capture the actual overlap 1204 and actual gap 1202 of the corresponding layer 946, 950. In yet another example of Method 1700, the finished data 930 is divided into a grid structure 1600 for a composite workpiece 200, which includes multiple data cells 1602 for each of the multiple layers 946, 950, and the finished data 930 includes grid location information 1404. In yet another example of Method 1700, the finished fiber volume filling characteristics 932 for each of the multiple layers 946, 950 take into account the measured overlap 1204 and measured gap 1202 for the corresponding layer 946, 950 of the multiple layers 946, 950. In yet another example, Method 1700 also includes step 1702 of receiving design data 926 for the layup of multiple layers 946, 950 of the composite material 902 in the composite workpiece 200. In 1704, the design data 926 for the multiple layers 946, 950 are processed to determine the planned fiber volume filling characteristics 928 for each layer 946, 950 individually and for the multiple layers 946, 950 together.

[0053] Referring again to Figures 9, 17, and 18, in one or more examples, a method 1800 (see Figure 18) for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200 includes method 1700 in Figure 17, followed by 1716 to 1802, where the fiber volume fill rate requirement 952 is received individually for each layer 946, 950 and collectively for multiple layers 946, 950. In 1804, after step 1706 of laying up each layer 946, 950, the predicted fiber volume fill rate 934 for each layer 946, 950 is individually compared with the fiber volume fill rate requirement 952 for the corresponding layer 946, 950 in order to determine the risk probability 956 of not achieving the fiber volume fill rate requirement 952 for the composite workpiece 200. In step 1806, after step 1706 of laying up each subsequent layer 950, the risk probability 956 for each layer 946, 950 is processed to determine the penetration thickness risk probability 972 for the current layer 1608 on the layup mandrel 942.

[0054] Referring again to Figures 9 and 17-19, in one or more examples, a method 1900 (see Figure 19) for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200 includes method 1700 in Figure 17 and method 1800 in Figure 18, followed by 1806-1902, where a risk threshold 958 for a risk probability 956 is received to classify the risk probability 956 as acceptable or unacceptable, individually for each layer 946, 950 and collectively for multiple layers 946, 950. In 1904, the risk probability 956 after step 1706 of laying up each layer 946, 950 is compared with a risk threshold 958 for the risk probability 956 in the corresponding layer 946, 950. In step 1706, after laying up each subsequent layer 950, the risk probability 956 for each layer 946,950 is processed to determine the penetration thickness risk probability 972 for the current layer 1608, and the penetration thickness risk probability 972 is compared with the corresponding risk threshold 958 for the current layer 1608 on the layup mandrel 942.

[0055] Referring again to Figures 9 and 17-21, in one or more examples, if the penetration thickness risk probability 972 for the current layer 1608 on the layup mandrel 942 exceeds the risk threshold 958, the penetration thickness risk probability 972 is unacceptable, and the method 2000 (see Figure 20) for layup and analysis of the composite material 902 during the fabrication of the composite workpiece 200 includes method 1700 in Figure 17, method 1800 in Figure 18, and method 1900 in Figure 19. In this example, method 2000 follows 1906-2002 in Figure 19, and to reduce the penetration thickness risk probability 972 that does not achieve the fiber volume filling requirement 952 for the composite workpiece 200 after step 1706 of laying up the subsequent layer 950, the design data 926 is optimized to form optimized design data 962 for layup of the subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200. In 2004, optimized design data 962 for the subsequent layer 950 of the layup is processed to determine the planned fiber volume filling properties 928 of the subsequent layer 950. In 2006, the next layer 1606 of the composite material 902 is laid up on top of the current layer 1608 on the layup mandrel 942 based on the optimized design data 962.

[0056] In another example of Method 2000, step 2002 of optimizing design data 926 includes step 2102 of optimizing the path plan for at least the rest of the composite workpiece 200 so as to form an optimized path plan 964 for laying up at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200, in order to reduce the probability 972 of through-thickness risk of not achieving the fiber volume filling requirement 952 for the composite workpiece 200 after step 2006 of laying up at least one subsequent layer 950. In yet another example of Method 2000, step 2002 of optimizing design data 926 includes step 2104 of optimizing the fiber volume fill rate requirement 952 for at least the remainder of the composite workpiece 200 so as to form an optimized fiber volume fill rate requirement 966 for the layup of at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200, in order to reduce the probability 972 of through thickness risk of not achieving the fiber volume fill rate requirement 952 for the composite workpiece 200 after step 2006 of laying up at least one subsequent layer 950. In yet another example of Method 2000, step 2002 of optimizing design data 926 includes step 2106 of optimizing the numerical control programming for at least the rest of the composite workpiece 200 so as to form an optimized numerical control program 968 for laying up at least one subsequent layer 950 of the composite material 902 during the fabrication of the composite workpiece 200, in order to reduce the probability 972 of through-thickness risk of not achieving the fiber volume filling requirement 952 for the composite workpiece 200 after step 2006 of laying up at least one subsequent layer 950.

[0057] Referring again to Figures 9 and 17-19 and 22, in one or more examples, if the penetration thickness risk probability 972 for the current layer 1608 on the layup mandrel 942 does not exceed the risk threshold 958, then the penetration thickness risk probability 972 is acceptable, and the method 2200 (see Figure 22) for layup and analysis of composite material 902 during the fabrication of the composite workpiece 200 includes method 1700 in Figure 17, method 1800 in Figure 18 and method 1900 in Figure 19. In this example, method 2200 continues from 1906 to 2202 in Figure 19, where design data 926 for the next layer 1606 of the layup is processed to determine the planned fiber volume filling characteristics 928 of the next layer 1606. In 2204, the next layer 1606 of the composite material 902 is laid up on the current layer 1608 on the layup mandrel 942 based on the design data 926.

[0058] Referring generally to Figures 2, 9, and 23, this disclosure relates, as an example, to a method 2300 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 2 provides an example of a composite workpiece 200. Figure 9 is a functional block diagram of another example of another automated system 900 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 23 provides an example of a method 2300 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200.

[0059] Referring again to Figures 2, 9 and 23, in one or more examples, a method 2300 (see Figure 23) for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200 includes step 2302 of laying up a layer 946 on a layup mandrel 942 based on design data 926. In 2304, finished data 930 is detected using a quality detection device 944. In 2306, the finished data 930 is processed to determine the finished fiber volume filling characteristics 932. In 2308, the finished fiber volume filling characteristics 932 are compared to the planned fiber volume filling characteristics 928 to determine the predicted fiber volume filling rate 934 for the layer 946.

[0060] Referring generally to Figures 2, 9, 16, and 24, this disclosure relates, as an example, to a method 2400 for optimizing design data 926 during the fabrication of a composite workpiece 200. Figure 2 provides an example of a composite workpiece 200. Figure 9 is a functional block diagram of another example of an automated system 900 for layup and analysis of composite material 902 during the fabrication of a composite workpiece 200. Figure 16 is a functional diagram showing an example of a grid structure 1600 for a composite workpiece 200 used in conjunction with layup and analysis of composite material 902 during the fabrication of the composite workpiece 200. Figure 24 provides an example of a method 2400 for optimizing design data 926 during the fabrication of a composite workpiece 200.

[0061] Referring again to Figures 2, 9, 16, and 24, in one or more examples, a method 2400 (see Figure 24) for optimizing design data 926 during the fabrication of a composite workpiece 200 includes the step 2402 of laying up a layer 946 on a layup mandrel 942 based on the design data 926. In 2404, finished data 930 is detected using a quality detection device 944. In 2406, the finished data 930 is processed to determine the finished fiber volume filling characteristics 932. In 2408, the finished fiber volume filling characteristics 932 are compared to the planned fiber volume filling characteristics 928 to determine the predicted fiber volume filling rate 934 for the layer 946. In 2410, in order to reduce the risk probability 956 of not achieving the fiber volume fill rate requirement 952 based at least partially on the predicted fiber volume fill rate 934, the design data 926 is optimized to form optimized design data 962 for at least one subsequent layer 950. In 2412, the second layer 1604 is laid up on top of the layer 946 on the layup mandrel 942 based on the optimized design data 962.

[0062] In another example of Method 2400, the optimized design data 962 includes an optimized path plan 964, an optimized fiber volume filling requirement 966, an optimized numerical control program 968, or any other suitable optimized design data in any suitable combination.

[0063] Examples of methods 300, 400, 500, 600, 800, 1700, 1800, 1900, 2000, 2200, 2300 for layup and analysis of composite material 902 during the fabrication of composite workpiece 200, automated systems 100, 900 for layup and analysis of composite material 902 during the fabrication of composite workpiece 200, and method 2400 for optimizing design data 926 during the fabrication of composite workpiece 200 may relate to or be used in the context of aircraft manufacturing. Although an example of an aircraft is described, the examples and principles disclosed herein may be applied to other products in the aerospace industry and other industries, such as other products in the automotive industry, space industry, construction industry and other design and manufacturing industries. Thus, in addition to aircraft, the examples and principles disclosed herein may be applied to the use of various products in the manufacture of various types of vehicles and the construction of various types of buildings.

[0064] For further details, refer to the accompanying drawings illustrating specific examples described herein. Other examples having different structures and functions will not deviate from the scope of this disclosure. The same reference numeral may refer to the same feature, element, or component in different drawings. Throughout this disclosure, several items may be referred to individually, several items collectively as such, and they may be referred to by the same reference numeral. Furthermore, as used herein, a feature, element, component, or step preceded by the words "one (a)" or "one (an)" should be understood not to exclusively mean multiple features, elements, components, or steps unless such exclusion is expressly stated.

[0065] Exemplary and non-exclusive examples of the subject matter of this disclosure are provided above, but are not necessarily claimed. Where the “Example” is used herein, it means that one or more forms, structures, elements, components, characteristics, and / or operating steps described in relation to that example are included in at least one aspect, embodiment, and / or embodiment of the subject matter of this disclosure. Thus, throughout this disclosure, the words “one example,” “another example,” “one or more examples,” and similar statements may, but not necessarily, refer to the same example. Furthermore, the subject matter characterizing any one example may, but not necessarily, include the subject matter characterizing any other example. Also, the subject matter characterizing any one example may, but not necessarily, be combined with the subject matter characterizing any other example.

[0066] As used herein, a system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a specified function is capable of actually performing the specified function without modification, rather than merely having the potential to perform the specified function after further modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function. As used herein, “configured to” refers to an existing characteristic of the system, apparatus, structure, article, element, component, or hardware that enables it to perform the specified function without further modification. For the purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as “configured to” perform a particular function may additionally or alternatively be described as “adapted to” and / or “operating to” perform that function.

[0067] Unless otherwise specified, terms such as “first,” “second,” and “third” are used herein solely as labels and are not intended to impose any order, arrangement, or hierarchical requirements on the items they refer to. Furthermore, a reference to, for example, an item “second” does not preclude the presence of, for example, an item “first” or a lower-numbered item, and / or, for example, an item “third” or a higher-numbered item.

[0068] As used herein, the phrase “at least one of” means, when used with a list of items, that one or more of the listed items may be used in various combinations, and that only one of each item in the list may be required. For example, “at least one of item A, item B, and item C” may not be limited to item A, or item A and item B. This example may also be limited to item A, item B, and item C, or item B and item C. In other examples, “at least one of” may not be limited to, for example, two of item A, one of item B, and ten of item C, or four of item B and seven of item C, or any other suitable combination. As used herein, the terms “and / or” and the “ / ” symbol include one or any combination of the related enumerated items.

[0069] As used herein, the terms “coupled,” “coupling,” and similar terms refer to two or more elements that are joined, connected, fixed, attached, linked, communicate with, or otherwise related to each other (e.g., mechanically, electrically, fluidly, optically, or electromagnetically). In various examples, elements may be related directly or indirectly. For example, element A may be directly related to element B. For another example, element A may be indirectly related to element B, for example, through another element C. It will be understood that not all relationships between various disclosed elements are necessarily represented. Therefore, other connections may exist that are not illustrated.

[0070] As used herein, the term “almost” refers to or represents a state that is close to the described state but not a perfect match, yet performs the desired function or achieves the desired result. For example, “almost” refers to a condition that is within a certain acceptable tolerance or precision, for example, a condition that is within 10% of the described condition. However, the term “almost” does not exclude conditions that perfectly match the described condition. As used herein, the term “substantially” refers to a described condition that essentially performs the desired function or achieves the desired result.

[0071] Figures 1, 2, 9, 10, 11A-11C, 12A-12B, and 13-16, referenced above, may represent functional elements, forms, or components, and do not necessarily imply a specific structure. Therefore, modifications, additions, and / or omissions may be made to the exemplified structures. Furthermore, those skilled in the art will understand that not all elements, features, and / or components described and illustrated in Figures 1, 2, 9, 10, 11A-11C, 12A-12B, and 13-16, referenced above, are necessarily included in all examples, and not all elements, features, and / or components described herein are necessarily shown in individual exemplary examples. Accordingly, some of the elements, features, and / or components described and illustrated in Figures 1, 2, 9, 10, 11A-11C, 12A-12B, and 13-16 can be combined in various ways without requiring the inclusion of other features, other drawings, and / or accompanying disclosures described and illustrated in Figures 1, 2, 9, 10, 11A-11C, 12A-12B, and 13-16, even if one or more such combinations are not expressly shown herein. Similarly, additional features, not limited to the examples presented, may be combined with some or all of the features illustrated and described herein. Unless otherwise specified, the schematic diagrams of the examples shown in Figures 1, 2, 9, 10, 11A-11C, 12A-12B, and 13-16, as referenced above, do not imply any structural limitations relating to the exemplary examples. Rather, it should be understood that while an exemplary structure is presented, that structure can be modified where appropriate. Therefore, modifications, additions, and / or omissions may be made to the exemplary structure.Furthermore, elements, features, and / or components that serve similar or at least substantially similar purposes are labeled with similar numbers in each of Figures 1, 2, 9, 10, 11A–11C, 12A–12B, and 13–16, and such elements, features, and / or components may not be described in detail herein with reference to each of Figures 1, 2, 9, 10, 11A–11C, 12A–12B, and 13–16. Similarly, not all elements, features, and / or components are labeled in each of Figures 1, 2, 9, 10, 11A–11C, 12A–12B, and 13–16, and the reference numerals associated with them may be used herein for consistency.

[0072] In Figures 3A–3B, 4–8, and 17–24 referenced above, blocks may represent operations, steps, and / or parts thereof, and the lines connecting the various blocks do not imply a specific order or dependency of the operations or parts thereof. It will be understood that not all dependencies between the various operations disclosed are necessarily represented. Figures 3A–3B, 4–8, and 17–24, and any accompanying disclosures describing the operations of the methods described herein, should not be construed as necessarily determining the order in which the operations are performed. Rather, while one exemplary order is shown, it should be understood that the order of operations may be modified where appropriate. Thus, modifications, additions, and / or omissions may be made to the illustrated operations, and certain operations may be performed in different orders or simultaneously. In addition, those skilled in the art will understand that not all described operations need to be performed.

[0073] Furthermore, whereever features, benefits, or similar terms are used throughout this specification, it is not meant that all features and benefits that may be realized in the examples disclosed herein should be, or are, included in any single example. Rather, any terms referring to features and benefits should be understood to mean that a particular feature, benefit, or characteristic described in relation to an example is included in at least one example. Accordingly, descriptions of features, benefits, and similar terms used throughout this disclosure may, but not necessarily, refer to the same example.

[0074] Examples of the subject matter disclosed herein can be described in relation to the aircraft manufacturing and maintenance methods 2500 shown in Figure 25, and the aircraft 2600 shown in Figure 26. In one or more examples, the disclosed automated systems 100, 900 for layup and analysis of composite materials 902 during the fabrication of a composite workpiece 200, and the method 2400 for optimizing design data 926 during the fabrication of the composite workpiece 200, may be used in aircraft manufacturing. Before production, the maintenance method 2500 may include the specification and design of the aircraft 2600 (block 2502) and material procurement (block 2504). During production, the manufacturing of components and subassemblies of the aircraft 2600 (block 2506) and system integration (block 2508) may be carried out. The aircraft 2600 may then be entered into service (block 2512) after certification and delivery (block 2510). During its service, aircraft 2600 may be scheduled for routine maintenance and inspection (block 2514). Routine maintenance and inspection may include modifications, reconfigurations, or modifications of one or more systems of aircraft 2600.

[0075] Each process of Maintenance and Inspection Method 2500 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, the system integrator may, not limited to, include any number of aircraft manufacturers and major system subcontractors; the third party may, not limited to, include any number of vendors, subcontractors, and suppliers; and the operator may be an airline, leasing company, military organization, service organization, etc.

[0076] As shown in Figure 26, an aircraft 2600 produced by service method 2500 may include a fuselage 2602 having multiple superstructure systems 2604 and internal systems 2606. Examples of superstructure systems 2604 include one or more of the propulsion system 2608, electrical system 2610, hydraulic system 2612, and environmental system 2614. Any number of other systems may be included. Although an aerospace example is illustrated, the principles disclosed herein can also be applied to other industries, such as the automotive industry. Thus, in addition to aircraft 2600, the principles disclosed herein may also be applied to other vehicles, such as land vehicles, sea vehicles, space vehicles, etc.

[0077] The disclosed methods 300, 400, 500, 600, 800, 1700, 1800, 1900, 2000, 2200, 2300 for layup and analysis of composite material 902 during the fabrication of composite workpiece 200, automated systems 100, 900 for layup and analysis of composite material 902 during the fabrication of composite workpiece 200, and method 2400 for optimizing design data 926 during the fabrication of composite workpiece 200 may be used in the fabrication of aircraft components. For example, components or subassemblies corresponding to the fabrication of components and subassemblies (block 2506) may be fabricated or manufactured in the same manner as components or subassemblies produced during the operation of aircraft 2600 (block 2512). Also, one or more examples of systems, methods, or combinations thereof may be used during the production phase (blocks 2506 and 2508), for example, by substantially accelerating the assembly of aircraft 2600 or reducing costs. Similarly, one or more examples of the implementation of a system or method, or combinations thereof, may be used, but not limited to, during the operation of aircraft 2600 (block 2512) and / or during maintenance and inspection (block 2514).

[0078] The forms, advantages, and characteristics described in one example may be combined in any suitable manner in one or more other examples. Those skilled in the art will recognize that the examples described herein may be implemented without having one or more of the specific features or advantages of a particular example. In other examples, additional features and advantages that may be recognized in a particular example may not be present in all examples. Furthermore, various examples of methods 300, 400, 500, 600, 800, 1700, 1800, 1900, 2000, 2200, 2300 for layup and analysis of composite material 902 during the fabrication of composite workpiece 200, automated systems 100, 900 for layup and analysis of composite material 902 during the fabrication of composite workpiece 200, and method 2400 for optimizing design data 926 during the fabrication of composite workpiece 200 are shown and described, and those skilled in the art will be able to recall modifications by reading this specification. This application includes such modifications and is limited only by the claims. [Explanation of Symbols]

[0079] 100 Automated Systems, 102 Automated Composite Laydown Filling Rate Analysis Device, 104 Manufacturing Equipment, 106 Real-time Quality Detection Hardware, 108 Real-time Defect Evaluation Device, 110 System Control Unit, 112 Programmed Machine Control Parameters, 114 Overlap and Gap Size / Location Analysis, 116 Through-Thickness Path Extraction, Alignment and Grid Module, 118 Requirements Grid Generation Module, 120 Plan-Time Filling Rate Analysis Module, 122 Measured Overlap / Gap Data Alignment, 124 Finish-Time Filling Rate Analysis, 126 Filling Rate Risk Output by Orientation and Through-Thickness, 128 Comparative Analysis of Finish-Time and Plan-Time Filling Rates, 130 Optimized Path Planning to Minimize Filling Rate Risk, 132 Automated Laydown of Composite Parts, 134 Improved Requirements for Plan-Time Filling Rate, 136 Optimized Numerical Control Programming Based on New Requirements, 138 Automated Layup of Composite Parts, 200 Composite Workpieces, 202 Zones, 602 Optimization, 900 Automated Systems, 902 Composite Materials, 904 Analytical Computing Devices, 906 Network Interfaces, 908 Communication Networks, 910 Processors, 912 Memory, 914 Design Data Storage Devices, 916 Application Program Storage Devices, 918 Design Data Analysis Application Programs, 920 Finished Data Analysis Application Programs, 922 Predictive Fiber Volume Filling Rate Application Programs, 924 Local Data Storage Devices, 926 Design Data, 928 Planned Fiber Volume Filling Characteristics, 930 Finished Data, 932 Finished Fiber Volume Filling Characteristics, 934 Predictive Fiber Volume Filling Rate, 936 Robot Manipulators, 938 Fabrication Cells, 940 Composite Material Placement Devices, 942 Layup Mandrels, 944 Quality Detection Devices, 946 Layers, 948 Remote Locations, 950 Subsequent Layers, 952 Fiber Volume Filling Rate Requirements, 954 Fiber Volume Filling Risk Application Programs, 956 Risk probability, 958 Risk threshold, 960 Design data optimization application program, 962 Optimized design data, 964 Optimized path planning, 966 Optimized fiber volume filling requirements, 968 Optimized numerical control program, 970972 Penetration Thickness Prediction Fiber Volume Filling Rate, 974 Penetration Thickness Risk Probability, 976 Penetration Thickness Completed Fiber Volume Filling Characteristics, 976 User Input Device, 978 User Display Device, 1002 Layer Construction Information, 1004 Dimensional Information, 1006 Orientation Information, 1008 Outline Information, 1010 Layer Location Information, 1012 Zone Location Information, 1102 Ply, 1104, 1105 Tow, 1106 Tow Course, 1202 Gap, 1204 Overlap, 1302 Automatic Fiber Placement Device, 1402 3D Surface Information, 1404 Grid Location Information, 1502 Shape Measuring Instrument, 1504 Visual System, 1600 Grid Structure, 1602 Data Cell, 1604 Second Layer, 1606 Next Layer, 1608 Current Layer, 2500 Service Method, Maintenance and Inspection Method, 2600 Aircraft, 2602 Airframe, 2604 Superstructure, 2606 Internal, 2608 Propulsion System, 2610 Electrical System, 2612 Hydraulic System, 2614 Environmental System

Claims

1. A method (300) for layup and analysis of composite material (902) during the fabrication of a composite workpiece (200), Step (306) of laying up a layer (946) of the composite material (902) for the composite workpiece (200) based on design data (926) for the layer (946), A step (308) of detecting completed data (930) for the layer (946) using a quality detection device (944), The steps include: (310) processing the completed data (930) for the layer (946) in order to determine the fiber volume filling characteristics (932) of the completed layer (946); In order to determine the predicted fiber volume filling rate (934) for the layer (946), the steps (312) are to compare the fiber volume filling characteristics (932) at completion with the planned fiber volume filling characteristics (928) based on the design data (926) for the layer (946) and Methods that include...

2. The method according to claim 1, wherein the layer (946) of the composite material (902) is laid up on a layup mandrel (942) in a fabrication cell (938), a second layer (1604) of the composite material (902) is laid up on the layer (946), and a subsequent layer (950) of the composite material (902) is laid up on the current layer (1608).

3. The method according to claim 1, wherein the step (308) of detecting the completed data (930) is performed while the layer (946) is on the layup mandrel (942).

4. Step (314) of laying up a subsequent layer (950) of the composite material (902) for the composite workpiece (200) based on the design data (926) for the subsequent layer (950), After the step (314) of laying up the corresponding subsequent layer (950) using a quality detection device (944), the step (316) of detecting completed data (930) for each subsequent layer (950), The process involves processing the completed data (930) for each of the subsequent layers (950) in order to determine the completed fiber volume filling characteristics (932) for each of the subsequent layers (950), (318) In order to determine the fiber volume filling characteristics (974) at the time of completion of the through-thickness, the steps (320) are to process the fiber volume filling characteristics (932) at the time of completion for each of the layers (946) and the subsequent layers (950) The method according to claim 1, further comprising (300).

5. The method according to claim 1, wherein the composite workpiece (200) comprises a plurality of zones (202), and the design data (926) for the layup includes zone location information (1012) for at least a portion of the design data (926).

6. The method according to claim 1, wherein the layer (946) includes at least one of a ply (1102) of the composite material (902), a plurality of tows (1105) of the composite material (902), and a plurality of courses (1106) of the tows (1105) of the composite material (902).

7. The method according to claim 1, wherein the completed data (930) is divided into a grid structure (1600) for the composite workpiece (200) which includes a plurality of data cells (1602) for each layer (946, 950) of the composite workpiece (200), and the completed data (930) includes grid location information (1404).

8. Step (302) of receiving design data (926) for the layup of the composite material (902), Step (304) to process the design data (926) for the layer (946) of the layup in order to determine the planned fiber volume filling characteristics (928) of the layer (946) and The method according to claim 1, further comprising (300).

9. The steps include receiving the fiber volume filling requirements (952) for the layup (402), In order to determine the risk probability (956) that the fiber volume filling rate requirement (952) for the composite workpiece (200) will not be met, the steps (404) are to compare the predicted fiber volume filling rate (934) for the layer (946) with the fiber volume filling rate requirement (952) and The method according to claim 1, further comprising (400).

10. The method according to claim 9, wherein the composite workpiece (200) comprises a plurality of layers (946, 950), and the fiber volume filling rate requirement (952) for the layup includes layer location information (1010) individually for each layer (946, 950) of the composite workpiece (200) and collectively for the plurality of layers (946, 950).

11. The steps include receiving a risk threshold (958) for the risk probability (956) in order to classify the risk probability (956) as acceptable or unacceptable (502), The step (504) is to compare the risk probability (956) with the risk threshold (958) for the risk probability (956) and The method according to claim 9, further comprising (500).

12. If the risk probability (956) exceeds the risk threshold (958), the risk probability (956) is unacceptable, and the method is In order to reduce the risk probability (956) of not achieving the fiber volume filling requirement (952) for the composite workpiece (200), the steps (602) of optimizing the design data (926) to form optimized design data (962) for the layup of at least one subsequent layer (950) of the composite material (902) during the manufacturing of the composite workpiece (200), Step (604) of processing the optimized design data (962) for the second layer (1604) of the layup to determine the planned fiber volume filling characteristics (928) of the second layer (1604), Step (606) of laying up a second layer (1604) of the composite material (902) on top of the layer (946) based on the optimized design data (962) The method according to claim 11, further comprising (600).

13. The step (602) of optimizing the design data (926) is as follows: Step (702) to optimize the path plan for at least the remainder of the composite workpiece (200) so as to form an optimized path plan (964) for the layup of at least one subsequent layer (950) of the composite material (902) during the manufacturing of the composite workpiece (200), in order to reduce the risk probability (956) of not achieving the fiber volume filling requirement (952) for the composite workpiece (200). The method according to claim 12, including the method described in claim 12.

14. The step (602) of optimizing the design data (926) is as follows: Step (704) to optimize the fiber volume fill rate requirement (952) for at least the remaining portion of the composite workpiece (200) so as to form an optimized fiber volume fill rate requirement (966) for the layup of at least one subsequent layer (950) of the composite material (902) during the manufacturing of the composite workpiece (200), in order to reduce the risk probability (956) of not achieving the fiber volume fill rate requirement (952) for the composite workpiece (200). The method according to claim 12, including the method described in claim 12.

15. The step (602) of optimizing the design data (926) is as follows: Step (706) to optimize the numerical control programming for at least the remainder of the composite workpiece (200) so as to form an optimized numerical control program (968) for the layup of at least one subsequent layer (950) of the composite material (902) during the manufacturing of the composite workpiece (200), in order to reduce the risk probability (956) of not achieving the fiber volume filling requirement (952) for the composite workpiece (200). The method according to claim 12, including the method described in claim 12.

16. If the risk probability (956) does not exceed the risk threshold (958), then the risk probability (956) is acceptable, and the method is The steps include (802) processing the design data (926) for the second layer (1604) of the layup to determine the planned fiber volume filling characteristics (928) of the second layer (1604), Step (804) of laying up the second layer (1604) of the composite material (902) on top of the layer (946) based on the design data (926) The method according to claim 11, further comprising (800).

17. An automated system (900) for layup and analysis of composite material (902) during the fabrication of a composite workpiece (200), An analytical computing device (904) that stores a design data analysis application program (918), a completed data analysis application program (920), and a predicted fiber volume filling rate application program (922), A robotic manipulator (936) located within a manufacturing cell (938) and operably communicating with at least one analytical computing device (904), comprising a composite material placement device (940), A layup mandrel (942) located within the manufacturing cell (938) lays up the composite material (902), A quality detection device (944) located within the manufacturing cell (938) and operably communicating with the at least one analytical computing device (904) and An automated system equipped with these features.

18. The at least one analytical computing device (904) is: A network interface (906) that communicates with a communication network (908) in an operable manner, The system comprises at least one processor (910) that operably communicates with a design data storage device (914) via the network interface (906) and the communication network (908), and a memory (912) associated with the at least one processor (910), At least one application program storage device (916) that operably communicates with the at least one processor (910) and stores the design data analysis application program (918), the completed data analysis application program (920), and the predicted fiber volume filling rate application program (922), and also stores one or more of the fiber volume filling risk application program (954) and the design data optimization application program (960), At least one local data storage device (924) that temporarily stores design data (926), planned fiber volume filling characteristics (928), completed data (930), completed fiber volume filling characteristics (932), and predicted fiber volume filling rate (934), and at least one local data storage device (924) that also temporarily stores one or more of the fiber volume filling rate requirements, risk probability, risk threshold, optimized path plan, optimized fiber volume filling rate requirements, and optimized numerical control program and The automated system according to claim 17, comprising:

19. The automated system according to claim 18, wherein the composite workpiece (200) comprises a plurality of zones (202), and the design data (926) for the layup includes zone location information (1012) for at least a portion of the design data (926).

20. The automated system according to claim 17, wherein the composite material placement device (940) comprises an automated fiber placement device (1302).

21. The automated system according to claim 17, wherein the quality detection device (944) comprises at least one of a shape measuring instrument (1502) and a vision system (1504).

22. The robotic manipulator (936) and the composite material placement device (940) are configured to lay up a layer (946) of the composite material (902) for the composite workpiece (200) on the layup mandrel (942) in the fabrication cell (938) based on design data (926) for the layer (946). After the layup of the layer (946), the quality detection device (944) is configured to detect completed data (930) for the layer (946) on the layup mandrel (942). The at least one analytical computing device (904) is configured to execute the finished data analysis application program (920) and to process the finished data (930) for the layer (946) in order to determine the finished fiber volume filling characteristics (932) of the layer (946) on the layup mandrel (942), The automated system according to claim 17, wherein the at least one analytical computing device (904) is configured to execute the predicted fiber volume filling rate application program (922) and to compare the finished fiber volume filling characteristics (932) with the planned fiber volume filling characteristics (928) based on the design data (926) for the layer (946) in order to determine the predicted fiber volume filling rate (934) for the layer (946).

23. The automated system according to claim 22, wherein the completed data (930) is divided into a grid structure (1600) for the composite workpiece (200) which includes a plurality of data cells (1602) for each layer (946, 950) of the composite workpiece (200), and the completed data (930) includes grid location information (1404).

24. The at least one analytical computing device (904) is configured to receive design data (926) for the layup of the composite material (902) from a design data storage device (914) via a network interface (906) and a communication network (908). The automated system according to claim 22, wherein the at least one analytical computing device (904) is configured to run the design data analysis application program (918) and to process the design data (926) for the layer (946) of the layup in order to determine the planned fiber volume filling characteristics (928) of the layer (946).

25. The at least one analytical computing device (904) is configured to receive fiber volume filling requirements (952) for the layup from a design data storage device (914) via a network interface (906) and a communication network (908). The automated system according to claim 22, wherein the at least one analytical computing device (904) is configured to run a fiber volume fill risk application program (954) and to compare the predicted fiber volume fill rate (934) for the layer (946) with the fiber volume fill rate requirement (952) in order to determine the probability (956) of risk that the fiber volume fill rate requirement (952) for the composite workpiece (200) will not be achieved after the layup of the layer (946).

26. The at least one analytical computing device (904) is configured to receive a risk threshold (958) for the risk probability (956) from a design data storage device (914) via a network interface (906) and a communication network (908) in order to classify the risk probability (956) as acceptable or unacceptable. The automated system according to claim 25, wherein the at least one analytical computing device (904) is configured to run the fiber volume filling risk application program (954) and to compare the risk probability (956) after the layup of the layer (946) with the risk threshold (958) for the risk probability (956).

27. If the risk probability (956) exceeds the risk threshold (958), then the risk probability (956) is unacceptable. The at least one analytical computing device (904) is configured to run the design data optimization application program (960) and to optimize the design data (926) to form optimized design data (962) for the layup of the at least one subsequent layer (950) of the composite material (902) during the fabrication of the composite workpiece (200) in order to reduce the risk probability (956) of not achieving the fiber volume filling requirement (952) for the composite workpiece (200) after the layup of the at least one subsequent layer (950). The at least one analytical computing device (904) is configured to execute the design data analysis application program (918) and to process the optimized design data (962) for the second layer (1604) in order to determine the planned fiber volume filling characteristics (928) of the second layer (1604) of the layup. The automated system according to claim 26, wherein the robotic manipulator (936) and the composite material placement device (940) are configured to lay up a second layer (1604) of the composite material (902) on the layer (946) on the layup mandrel (942) based on the optimized design data (962).

28. The automated system according to claim 27, wherein the at least one analytical computing device (904) runs the design data optimization application program (960) and is configured to optimize the path plan for at least the remaining portion of the composite workpiece (200) to form an optimized path plan (964) for the layup of the at least one subsequent layer (950) of the composite material (902) during the fabrication of the composite workpiece (200), in order to reduce the risk probability (956) of not achieving the fiber volume filling requirement (952) for the composite workpiece (200) after the layup of the at least one subsequent layer (950).

29. The automated system according to claim 27, wherein the at least one analytical computing device (904) runs the design data optimization application program (960) and is configured to optimize the fiber volume fill rate requirement (952) for at least the remaining portion of the composite workpiece (200) to form an optimized fiber volume fill rate requirement (966) for the layup of the at least one subsequent layer (950) of the composite material (902) during the fabrication of the composite workpiece (200), in order to reduce the risk probability (956) of not achieving the fiber volume fill rate requirement (952) for the composite workpiece (200) after the layup of the at least one subsequent layer (950).

30. The automated system according to claim 27, wherein the at least one analytical computing device (904) runs the design data optimization application program (960) and is configured to optimize numerical control programming for at least the rest of the composite workpiece (200) to reduce the risk probability (956) of not achieving the fiber volume filling requirement (952) for the composite workpiece (200) after the layup of the at least one subsequent layer (950), by forming an optimized numerical control program (968) for the layup of the at least one subsequent layer (950) of the composite material (902) during the fabrication of the composite workpiece (200).

31. If the risk probability (956) does not exceed the risk threshold (958), then the risk probability (956) is acceptable. The at least one analytical computing device (904) is configured to execute the design data analysis application program (918) and to process the design data (926) for the second layer (1604) in order to determine the planned fiber volume filling characteristics (928) of the second layer (1604) of the layup. The automated system according to claim 26, wherein the robotic manipulator (936) and the composite material placement device (940) are configured to lay up the second layer (1604) of the composite material (902) on the layer (946) on the layup mandrel (942) based on the design data (926).

32. A method (1700) for layup and analysis of composite material (902) during the fabrication of a composite workpiece (200), Step (1706) of laying up one of the multiple layers (946, 950) of the composite material (902) for the composite workpiece (200) based on design data (926) for the layer (946), A step (1708) of detecting completed data (930) for the layer (946) using a quality detection device (944), The steps include: (1710) processing the completed data (930) for the layer (946) in order to determine the fiber volume filling characteristics (932) of the completed layer (946); In order to determine the predicted fiber volume filling rate (934) for the layer (946), the steps (1712) are to compare the completed fiber volume filling characteristics (932) for the layer (946) with the planned fiber volume filling characteristics (928) based on the design data (926) for the layer (946), For each subsequent layer (950) among the plurality of layers (946, 950), the step (1714) of repeating the layup step (1706), the detection step (1708), the processing step (1710), and the comparison step (1712), Step (1716) to process the predicted fiber volume filling rate (934) for the plurality of layers (946, 950) in order to determine the predicted fiber volume filling rate (970) for at least one through thickness, and Methods that include...

33. The method according to claim 32, wherein the composite workpiece (200) comprises a plurality of zones (202), and the design data (926) for the layup includes zone location information (1012) for at least a portion of the design data (926).

34. The completed data (930) is one of the layers (946, 950) The composite workpiece (200) includes multiple data cells (1602) for 946, 950) The method according to claim 32, wherein the data is divided into a grid structure (1600), and the completed data (930) includes grid location information (1404).

35. Step (1702) of receiving design data (926) for the layup of multiple layers (946, 950) of the composite material (902) in the composite workpiece (200), Step (1704) of processing the design data (926) for the plurality of layers (946, 950) in order to determine the planned fiber volume filling characteristics (928) for each layer (946, 950) individually and for the plurality of layers (946, 950) together. The method according to claim 32, further comprising (1700).

36. Step (1802) of receiving fiber volume filling requirements (952) individually for each layer (946, 950) and collectively for the multiple layers (946, 950), After the step (1706) of laying up each layer (946, 950), the step (1804) is to individually compare the predicted fiber volume fill rate (934) for each layer (946, 950) with the fiber volume fill rate requirement (952) for the corresponding layer (946, 950) in order to determine the risk probability (956) of not achieving the fiber volume fill rate requirement (952) for the composite workpiece (200), After the step (1706) of laying up each subsequent layer (950), the step (1806) of processing the risk probabilities (956) for each layer (946, 950) in order to determine the penetration thickness risk probability (972) for the current layer (1608) on the layup mandrel (942) and The method according to claim 32, further comprising (1800).

37. Step (1902) of receiving a risk threshold (958) for the risk probability (956) in order to classify the risk probability (956) as acceptable or unacceptable, individually for each layer (946, 950) and collectively for multiple layers (946, 950), Step (1904) of comparing the risk probability (956) after the step (1706) of laying up each layer (946, 950) with the risk threshold (958) for the risk probability (956) in the corresponding layer (946, 950), After the step (1706) of laying up each subsequent layer (950), the steps of processing (1906) the risk probabilities (956) for each layer (946, 950) in order to determine the penetration thickness risk probability (972) for the current layer (1608), and comparing the penetration thickness risk probability (972) with the corresponding risk threshold (958) for the current layer (1608) on the layup mandrel (942) and The method according to claim 36, further comprising (1900).

38. If the penetration thickness risk probability (972) for the current layer (1608) on the layup mandrel (942) exceeds the risk threshold (958), then the penetration thickness risk probability (972) is unacceptable, and the method In order to reduce the probability (972) of the risk of through-thickness not achieving the fiber volume filling requirement (952) for the composite workpiece (200) after the step (1706) of laying up the subsequent layer (950), the step (2002) of optimizing the design data (926) to form optimized design data (962) for laying up the subsequent layer (950) of the composite material (902) during the fabrication of the composite workpiece (200), The steps include (2004) processing the optimized design data (962) for the subsequent layer (950) of the layup in order to determine the planned fiber volume filling characteristics (928) of the subsequent layer (950), Step (2006) of laying up the next layer (1606) of the composite material (902) on the current layer (1608) on the layup mandrel (942) based on the optimized design data (962) and The method according to claim 37, further comprising (2000).

39. The step (2002) of optimizing the design data (926) is as follows: Step (2102) to optimize the path plan for at least the remaining portion of the composite workpiece (200) so as to form an optimized path plan (964) for the layup of at least one subsequent layer (950) of the composite material (902) during the fabrication of the composite workpiece (200) in order to reduce the probability (972) of the through thickness risk of not achieving the fiber volume filling requirement (952) for the composite workpiece (200) after the step (2006) of laying up the at least one subsequent layer (950). The method according to claim 38, including the method described in claim 38.

40. The step (2002) of optimizing the design data (926) is as follows: Step (2104) to optimize the fiber volume fill rate requirement (952) for at least the remaining portion of the composite workpiece (200) so as to form an optimized fiber volume fill rate requirement (966) for the layup of at least one subsequent layer (950) of the composite material (902) during the fabrication of the composite workpiece (200) in order to reduce the probability (972) of the risk of through thickness not achieving the fiber volume fill rate requirement (952) for the composite workpiece (200) after the layup step (2006) of the at least one subsequent layer (950) The method according to claim 38, including the method described in claim 38.

41. The step (2002) of optimizing the design data (926) is as follows: Step (2106) to optimize the numerical control programming for at least the remainder of the composite workpiece (200) so as to form an optimized numerical control program (968) for the layup of at least one subsequent layer (950) of the composite material (902) during the fabrication of the composite workpiece (200) in order to reduce the probability (972) of the through-thickness risk of not achieving the fiber volume filling requirement (952) for the composite workpiece (200) after the step (2006) of laying up the at least one subsequent layer (950) The method according to claim 38, including the method described in claim 38.

42. If the penetration thickness risk probability (972) for the current layer (1608) on the layup mandrel (942) does not exceed the risk threshold (958), then the penetration thickness risk probability (972) is acceptable, and the method is The steps include processing the design data (926) for the next layer (1606) in order to determine the planned fiber volume filling characteristics (928) of the next layer (1606) of the layup (2202), Step (2204) of laying up the next layer (1606) of the composite material (902) on the current layer (1608) on the layup mandrel (942) based on the design data (926) and The method according to claim 37, further comprising (2200).

43. A method (2300) for layup and analysis of composite material (902) during the fabrication of a composite workpiece (200), Step (2302) of laying up the layer (946) on the layup mandrel (942) based on the design data (926), A step (2304) of detecting finished data (930) using a quality detection device (944), The steps include: processing the completed data (930) in order to determine the fiber volume filling characteristics (932) at completion (2306); In order to determine the predicted fiber volume filling rate (934) for the layer (946), the steps (2308) are to compare the fiber volume filling characteristics (932) at completion with the planned fiber volume filling characteristics (928) and Methods that include...

44. An automated system (900) for layup and analysis of composite material (902) during the fabrication of a composite workpiece (200), An analytical computing device (904) that stores a design data analysis application program (918), a completed data analysis application program (920), and a predicted fiber volume filling rate application program (922), A composite material placement device (940) that communicates operably with the aforementioned analytical computing device (904), A layup mandrel (942) for laying up the composite material (902), A quality detection device (944) that communicates with the aforementioned analytical computing device (904) in an operable manner. An automated system equipped with these features.

45. A method (2400) for optimizing design data (926) during the manufacturing of a composite workpiece (200), Step (2402) of laying up the layer (946) on the layup mandrel (942) based on the design data (926), A step (2404) of detecting finished data (930) using a quality detection device (944), The steps include: processing the completed data (930) (2406) in order to determine the fiber volume filling characteristics (932) at completion; In order to determine the predicted fiber volume filling rate (934) for the layer (946), the steps include: (2408) comparing the fiber volume filling characteristics (932) at completion with the planned fiber volume filling characteristics (928); Step (2410) of optimizing the design data (926) to form optimized design data (962) for at least one subsequent layer (950) in order to reduce the risk probability (956) of not achieving the fiber volume filling rate requirement (952), based at least in part on the predicted fiber volume filling rate (934), Step (2412) of laying up a second layer (1604) on the layer (946) on the layup mandrel (942) based on the optimized design data (962) and Methods that include...

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