Composite Structure Warpage Control System

Abstract

To provide a method, an apparatus, and a system for managing composite parts.SOLUTION: The acceptable level of warpage for composite parts is identified. The warpage of the composite part is the change in the composite part during manufacturing that deviates from the design specifications of the composite part. The orientation is selected to form the selected orientation in the stacking order of the plies of the composite part which results in a composite part with an acceptable level of warpage and desired strength. The composite part is manufactured using the selected orientation.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present disclosure relates generally to manufacturing, and more particularly to manufacturing of composite parts. More specifically, the present disclosure relates to methods, apparatus and systems for controlling warpage during composite part manufacturing. [Background technology]

[0002] Warpage often occurs during the manufacture of composite parts. In aircraft, composite parts may include, for example, skin panels, wings, stabilizer panels, and other components. For example, these types of composite panels may be reinforced with stiffening structures to reduce or avoid bending or buckling of the structures when loads are applied to these types of structures. Stiffening structures, such as stringers, may be formed on the composite panels or other composite structures. The use of these components to form stiffened composite parts often results in warpage, where the manufactured part has dimensions that deviate from the part's design specifications. Composite part warpage has been dismissed as an acceptable manufacturing issue.

[0003] The warpage can cause composite parts to not fit as desired with other composite parts when assembling aircraft components, and as a result, gaps can exist when the parts are placed together for assembly.

[0004] In these situations, shims can be used. A shim is a structure used to align parts. A shim can be, for example, a washer, a wedge, a piece of material, or other structure that fills a gap between two parts where the gap results from one or more warps in the parts.

[0005] However, using shims can be time consuming and increase manufacturing costs; for example, gaps between parts must be identified and measured. In some cases, warping can make the gap small enough that it can be closed when the parts are connected together. In these situations, shims are not necessary.

[0006] When the gap is too large, a shim is manufactured to fit the gap. In some cases, the shape of the gap can be complex, which requires more time and effort to create a shim to fit the gap. Then, workers install the shim into the gap.

[0007] This process can be time consuming and expensive, especially when a large number of shims, such as hundreds or thousands of shims, are installed as part of the aircraft manufacturing process. Additionally, the use of shims can also add weight to the aircraft.

[0008] It would therefore be desirable to have a method and apparatus that takes into account at least some of the above problems, as well as possible other problems. For example, it would be desirable to have a method and apparatus that overcomes the technical problems of manufacturing composite parts having dimensions that deviate from the composite part specifications. Summary of the Invention

[0009] An embodiment of the present disclosure provides a method for managing a composite part. An acceptable level of warpage is identified for the composite part. Warpage of the composite part is a variation of the composite part during manufacturing that deviates from the design specifications of the composite part. An orientation is selected for the plies of the composite part in a stacking sequence, and manufacturing the composite part using the selected orientation produces the selected orientation such that a composite part having an acceptable level of warpage and a desired strength is obtained.

[0010] Another embodiment of the present disclosure provides a composite part system comprising a computer system and a composite part designer of the computer system. The composite part designer is configured to identify an acceptable level of warpage of the composite part. Warpage is a variation of the composite part during manufacturing that deviates from a design specification of the composite part. The composite part designer selects an orientation in the stacking sequence for plies of the composite part to form the selected orientation in the stacking sequence such that manufacturing the composite part using the selected orientation in the stacking sequence results in a composite part having an acceptable level of warpage and a desired strength.

[0011] Yet another embodiment of the present disclosure provides a product management system that includes fabrication equipment and a controller in communication with the fabrication equipment, the controller configured to control the fabrication equipment to manufacture a composite part using a part design selected for a stacking sequence for plies of the composite part that results in a composite part having an acceptable level of warpage and a desired strength, where warpage is a change in the composite part during fabrication that deviates from a design specification of the composite part.

[0012] These features and functions may be realized alone in various embodiments of the present disclosure or may be combined in further embodiments, the details of which can be seen in further detail with reference to the following description and drawings.

[0013] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims, however the illustrative embodiments, together with further objects and features thereof, preferred modes of use, will be best understood by reference to the following detailed description of the illustrative embodiments of the present disclosure taken in conjunction with the accompanying drawings. [Brief description of the drawings]

[0014] [Figure 1] FIG. 1 is an illustration of a composite part environment in accordance with an illustrative embodiment. [Diagram 2] FIG. 1 is an illustration of a block diagram of a user interface system for designing a composite part in accordance with an illustrative embodiment. [Diagram 3] 11 is an illustration of results displayed in a graphical user interface in accordance with an illustrative embodiment. [Figure 4] 11 is an illustration of results displayed in a graphical user interface in accordance with an illustrative embodiment. [Diagram 5] 11 is an illustration of results displayed in a graphical user interface in accordance with an illustrative embodiment. [Figure 6] 11 is an illustration of results displayed in a graphical user interface in accordance with an illustrative embodiment. [Figure 7]FIG. 10 is an illustration of a flowchart of a process for managing composite parts in accordance with an illustrative embodiment. [Figure 8] FIG. 10 is an illustration of a flowchart of a process for selecting a ply orientation for a composite part in accordance with an illustrative embodiment; [Figure 9] FIG. 10 is an illustration of a flowchart of a process for selecting a ply orientation for a composite part in accordance with an illustrative embodiment; [Figure 10] FIG. 11 is an illustration of a flowchart of a process for displaying results from an analysis of ply orientation in accordance with an illustrative embodiment; [Figure 11] FIG. 1 is an illustration of a flowchart of a process for manufacturing a composite part in accordance with an illustrative embodiment. [Figure 12] 1 is a block diagram of a data processing system in accordance with an illustrative embodiment; [Figure 13] FIG. 1 is an illustration of an aircraft manufacturing and service method in accordance with an illustrative embodiment. [Figure 14] FIG. 1 is a block diagram of an aircraft in which an illustrative embodiment may be implemented. [Figure 15] FIG. 1 is a block diagram of an illustrated product management system in accordance with an exemplary embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that currently, warping of a panel with a balanced, symmetrical layup is believed to be an inherent behavior of the composite material and is unrelated to the in-plane properties of the laminate. The illustrative embodiments recognize and take into account that currently, warping is not considered a predictable defect.

[0016] The illustrative embodiments recognize and take into account that current design processes do not use the level of warpage as a variable. The illustrative embodiments recognize and take into account that it would be desirable for the current design process to focus on providing desired performance of a composite structure, such as a lower wing panel, regardless of possible warpage. For example, the illustrative embodiments recognize and take into account that a desired performance can be the elimination of tears from a composite part, such as an aircraft wing lower skin panel.

[0017] Thus, the illustrative embodiments provide methods, apparatus, and systems for designing and manufacturing a composite part that achieves a desired level of warpage and maintains a desired performance of the composite part. For example, the illustrative embodiments manage a composite part. An acceptable level of warpage is identified for the composite part. Warpage of the composite part is a variation in the composite part during manufacturing that deviates from the design specifications of the composite part. An orientation in the stacking sequence is selected for the plies of the composite part, and manufacturing the composite part using the selected orientation produces the selected orientation such that a composite part with an acceptable level of warpage and a desired strength is obtained.

[0018] With reference to the drawings, and in particular to FIG. 1 , an example of a composite part environment is depicted in accordance with an illustrative embodiment. Composite part environment 100 is an environment in which a composite part 102 is designed for use in a product 104, such as an aircraft 106. Composite part 102 can take a number of different forms. For example, composite part 102 can be one of a skin panel, a fairing, an engine housing, a stringer, a door, a wing, a panel, and a number of other suitable types of parts that can be used in product 104, and in particular aircraft 106.

[0019] In this illustrative example, the design 108 of the composite part 102 is created by a composite part designer 110 in a part manager 111 of a computer system 112. As shown, the composite part designer 110 may be implemented in software, hardware, firmware, or a combination thereof. If software is used, the operations performed by the composite part designer 110 may be implemented as program code configured to run on hardware, such as a processor unit. If firmware is used, the operations performed by the composite part designer 110 may be implemented in program code and data to run on a processor unit and stored in persistent storage. If hardware is used, the hardware may include circuitry operative to perform the operations in the composite part designer 110.

[0020] In an exemplary embodiment, the hardware may take the form of at least one selected from a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or any other suitable type of hardware configured to perform certain operations. With a programmable logic device, the device may be configured to perform certain operations. The device may be reconfigured later or may be permanently configured to perform certain operations. Programmable logic devices include, for example, programmable logic arrays, programmable array logic, field programmable logic arrays, field programmable gate arrays, and other suitable hardware devices. Additionally, these processes may be implemented in organic components embedded in inorganic components, and may be composed entirely of non-human organic components. For example, these processes may be implemented as circuits in organic semiconductors.

[0021] Computer system 112 is a physical hardware system and includes one or more data processing systems. When there is more than one data processing system in computer system 112, these data processing systems communicate with each other using a communication medium. The communication medium may be a network. The data processing system may be selected from at least one of a computer, a server computer, a tablet computer, or any other suitable data processing system.

[0022] As used herein, the phrase "at least one of" when used with enumerated items means that various combinations of one or more of the enumerated items may be used and that only one of each enumerated item may be required. In other words, "at least one of" means that any combination of items and any number of items from the enumeration may be used, but not all of the enumerated items are required. An item may be a specific object, article, or category.

[0023] For example, and without limitation, "at least one of item A, item B, and item C" may include "item A," "item A and item B," or "item B." This example could also include "item A, item B, and item C," or "item B and item C." Combinations of any of these items may of course also be present. In one exemplary embodiment, "at least one of" may be, by way of example and without limitation, "2 item A, 1 item B, and 10 item C," "4 item B, and 7 item C," or any other suitable combination.

[0024] As shown, composite part designer 110 operates to manage composite part 102. Managing composite part 102 with composite part designer 110 includes specifying a tolerance level 114 of warpage 116 of composite part 102. Warpage 116 of composite part 102 is a variation of composite part 102 during manufacturing that deviates from design specifications 119 of composite part 102. In an exemplary embodiment, design specifications 119 specify characteristics of composite part 102 including at least one of dimensions, strength, tolerances, or other characteristics for composite part 102.

[0025] In this illustrative example, composite part designer 110 selects an orientation 118 for stacking sequence 120 of plies 122 of composite part 102 to form selected orientation 126 in stacking sequence 120. Manufacturing composite part 102 using selected orientation 126 in stacking sequence 120 results in composite part 102 having acceptable level 114 of warpage 116 and desired strength 124 to form selected orientation 126.

[0026] Warpage 116 is treated as a variable by composite part designer 110 when selecting orientation 118. The selection of orientation 118 is made such that composite part 102 has both an acceptable level 114 of warpage 116 and a desired strength 124. In this illustrative example, desired strength 124 may be based on design specifications 119. The specifications may specify a margin of safety that is desired for composite part 102.

[0027] In an example embodiment, the composite part designer 110 may select an orientation 118 for the plies 122 of the composite part 102 that results in the composite part 102 having an acceptable level 114 of warpage 116 and a desired strength 124, and may form the selected orientation 126 in a number of different ways. For example, the composite part designer 110 may select a candidate orientation 128 for the stacking sequence 120 of the plies 122. The composite part designer 110 may perform a stress analysis 130 of the composite part 102 using the candidate orientation 128 for the stacking sequence 120 of the plies 122. As shown, the stress analysis 130 includes a simulation of one or more types of forces that may be applied to the composite part 102. For example, the simulation may be a set of loads applied to the composite part 102. The other forces may include frictional forces, tension forces, or other suitable types of forces.

[0028] In an exemplary embodiment, the stress analysis 130 may take the form of a laminate analysis 131. The laminate analysis 131 may be implemented using currently used analytical algorithms that may be used to analyze the composite part 102. These algorithms may implement classical laminate theory, in which engineering and physical properties of the plies are developed based on the fiber angle relative to the primary load direction. The properties are summed in a specific direction over the thickness of the ply and divided by the total thickness. The laminate analysis 131 may be performed on the composite part design 150 to determine properties such as strength, damage tolerance, or other properties of the composite part 102 manufactured using the composite part design 150. The laminate analysis 131 may be used to calculate properties of a laminate, such as a composite part 102 having plies 122 with orientation 118 in stacking sequence 120.

[0029] In this exemplary embodiment, one of the characteristics of composite part 102 is the amount or level of warpage 116. The amount of warpage 116 can be determined by layup analysis 131 using stack sequence 120, including orientation 118 of plies 122, in addition to other information such as dimensions, material type, or other information required to analyze design 108. In an exemplary embodiment, layup analysis 131 calculates warpage data such as αY and αX, and normalized warpage (αY / αX), as shown in FIG. 4 and in the description of FIG. 4 below.

[0030] When the results from the stress analysis 130 indicate that the composite part 102 has an acceptable level 114 of warpage 116 and the desired strength 124 for the composite part 102, the composite part designer 110 uses the candidate orientation 128 for the stack sequence 120 as the selected orientation 126.

[0031] When a stress analysis 130 performed on the composite part 102 with the candidate orientation 128 indicates that the composite part 102 does not have the desired strength 124, the composite part designer 110 may select a new orientation 132 for the stack sequence 120. By changing the orientation in the stack sequence 120, the position of the ply 122 may be changed to a different position in the stack sequence 120.

[0032] The composite part designer 110 performs a stress analysis 130 of the composite part 102 using the new orientation 132 for the stacking sequence 120 of the plies 122 as the candidate orientation 128. The composite part designer 110 iteratively selects the new orientation 132 as the candidate orientation 128 and performs a stress analysis 130 of the composite part 102 using the candidate orientation 128 for the stacking sequence 120 of the plies 122 until the desired strength 124 is present in the composite part 102.

[0033] The selected orientation 126 may comprise at least one of 90 degree plies, +45 degree plies, -45 degree plies, or 0 degree plies. For example, the selected orientation 126 may comprise 90 degree plies, +45 degree plies, -45 degree plies, and 0 degree plies. In another exemplary embodiment, the selected orientation 126 may include at least 10 percent of the plies having a 90 degree orientation. In another exemplary embodiment, the selected orientation 126 may include at least 12.5 percent to 20 percent of the plies having a 90 degree orientation. In yet another exemplary embodiment, the selected orientation 126 may include 40 percent to 50 percent of the plies having a 45 degree orientation. In this example, the 45 degree orientation may be a +45 degree orientation, a -45 degree orientation, or a combination thereof.

[0034] In an example embodiment, the degrees of the different orientations may be based on a reference axis. For example, the degrees may be relative to a part axis of the composite part 102. In another example, the degrees of the ply 122 may be relative to a tool head of a machine, such as an automated tape laying machine or other automated tool.

[0035] The illustration of several plies in these orientations is provided merely as an illustrative example and is not intended to limit the manner in which several plies in different orientations may be selected. These orientations and other orientations may be used for the selected orientation 126 such that there is an acceptable level 114 of warp 116 and there is a desired strength 124 for the composite part 102. Furthermore, the location of the different orientations forming the stack sequence 120 may be a third variable in addition to the acceptable level 114 of warp 116 and the desired strength 124.

[0036] In an example embodiment, the selection of at least one of the candidate orientations 128 or the new orientation 132 may be made by the composite part designer 110 in a number of different ways. The selection may be made using input 134 received from at least one of an operator 136 or an artificial intelligence system 138.

[0037] In this depicted example, the workforce 136 are personnel designing composite parts 102 for use in the aircraft 106. The artificial intelligence system 138 is a system that has intelligent activity and can be based on the functions of the human brain.

[0038] As shown, the artificial intelligence system 138 includes at least one of an artificial neural network, a cognitive system, a Bayesian network, fuzzy logic, an expert system, a natural language system, or other suitable system. Machine learning is used to train the artificial intelligence system. Machine learning involves inputting data into a process that allows the process to adjust and improve the capabilities of the artificial intelligence system.

[0039] A cognitive system is a computing system that mimics the functions of the human brain. An example of a cognitive system may be IBM Watson, available from International Business Machines Corporation.

[0040] In this exemplary embodiment, part manager 111 may also include a controller 140 of computer system 112. As shown, controller 140 is configured to control the production of composite part 102 in product management system 142 using selected orientation 126. In essence, composite part 102 may be produced in product management system 142 using selected orientation 126.

[0041] The selected orientation 126 for the stack sequence 120 allows the composite part designer 110 to generate a composite part design 150. The composite part design 150 is a design that can be used by the controller 140 to manufacture the composite part 102 such that the composite part 102 has an acceptable level 114 of warpage 116 and a desired strength 124. The design may be, for example, a computer-aided design model, a computer-aided manufacturing model, a computer numerically controlled (CNC) program, or other type of model.

[0042] In an exemplary embodiment, composite part design 150 is in contrast to design 108. Design 108 includes design specifications 119. Design specifications 119 include a layup of plies 122 with an initial stacking sequence and orientations of plies 122 in the initial stacking sequence. These orientations can be varied to produce the selected orientations 126 for stacking sequence 120 that result in an acceptable level 114 of warpage 116 and desired strength 124 for composite part 102 manufactured using the selected orientations 126 for stacking sequence 120.

[0043] For example, controller 140 may use composite part design 150 including selected orientations 126 for stacking sequence 120 of plies 122 of composite part 102 to manufacture composite part 102. Controller 140 may control operation of ply layup system 144 to lay up plies 122 of composite part 102 using selected orientations 126 of composite part design 150 to form composite layup 146. In this illustrative embodiment, ply layup system 144 may be, for example, at least one of an automated fiber placement machine, a tape laying machine, or other suitable hardware equipment operable to lay up plies 122 in selected orientations 126 in forming composite layup 146.

[0044] In exemplary embodiments, the control of one or more machines of the ply layup system 144 may be formed using a program. For example, when an automated fiber placement machine is used, the machine may be a computer numerically controlled (CNC) automated fiber placement machine. The CNC program may be generated from a design of the part, such as a computer aided design. The program may be executed by the controller 140 to control the operation of the automated fiber placement machine. The controller 140 may be part of the automated fiber placement machine in some exemplary embodiments.

[0045] Additionally, the controller 140 can control a curing system 148 to cure the composite layup 146 to form the composite part 102. As shown, the curing system 148 can be at least one of a curing oven, an autoclave, a curing lamp system, or other suitable hardware equipment capable of curing the composite layup 146 to form the composite part 102.

[0046] In this illustrative embodiment, part manager 111 is part of composite part system 115. At least one of ply layup system 144 or curing system 148 may also be part of composite part system 115.

[0047] 2, a block diagram of a user interface system for designing a composite part is shown in accordance with an exemplary embodiment. In an exemplary embodiment, the same reference numbers may be used in multiple figures, and thus the repeated use of a reference number in different figures indicates the same element in the different figures.

[0048] In the exemplary embodiment, user interface system 200 provides an interface for workers 136 to interact with at least one of composite part designer 110 or controller 140 of computer system 112 in FIG.

[0049] As shown, the user interface system 200 includes a display system 202 and an input system 204. These components may be connected to the computer system 112 or may be considered part of the computer system 112.

[0050] In this exemplary embodiment, display system 202 is a physical hardware system and includes one or more display devices capable of displaying graphical user interface 206. The display devices may include at least one of a light emitting diode (LED) display, a liquid crystal display (LCD), an organic light emitting diode (OLED) display, a computer monitor, a projector, a flat panel display, a heads up display (HUD), or other suitable device capable of outputting information for visually presenting information.

[0051] As shown, display system 202 is configured to display a graphical user interface 206. Work personnel 136 are personnel who can interact with graphical user interface 206 through user input 208 generated by input system 204 of computer system 112. Input system 204 is a physical hardware system and may be selected from at least one of a mouse, a keyboard, a trackball, a touch screen, a stylus, a motion sensing input device, a cyberglove, or any other suitable type of input device.

[0052] For example, work personnel 136 may use graphical user interface 206 to select or create composite part design 150 for composite part 102. In the illustrative example, work personnel 136 may generate user input 208 to select tolerance level 114 of warpage 116 and desired strength 124 for composite part 102, the latter three of which are shown in block form in FIG.

[0053] User input 208 may be generated to specify a selected orientation 126 for the stacking sequence 120 of plies 122 to form composite part design 150. Composite part design 150 is a design used by controller 140 to manufacture composite part 102.

[0054] As shown, composite part design 150 includes stacking sequence 120 of plies 122 that form composite part 102. In this illustrative example, stacking sequence 120 may be obtained from design 108 of composite part 102 in Figure 1.

[0055] In this exemplary embodiment, operator personnel 136 may select candidate orientations 128. As shown, user input 208 may also select which plies in stack sequence 120 have a particular orientation. In essence, operator personnel 136 may maintain the same percentage of candidate orientations 128, but change which plies in stack sequence 120 have a particular orientation.

[0056] As shown, the sets of candidate orientations 128 can be displayed as ply percentage envelopes 220 in the graphical user interface 206. The set of candidate orientations 128 are the ply percentages in this example embodiment. For example, the set of candidate orientations can be 35 / 50 / 15, where in the stack sequence 120, 35 is the percentage of plies 122 that have a 0 degree orientation, 50 is the percentage of plies 122 that have a + / - 45 degree orientation, and 15 is the percentage of plies 122 that have a 90 degree orientation.

[0057] These ply percentage envelopes can be the percentage of plies at different orientations. These percentages can be specific variables or ranges, such as 0 degree plies, + / - 45 degree plies, and 90 degree plies. In this exemplary embodiment, the + / - 45 degree plies are an equal percentage of +45 degree plies and -45 degree plies. For example, selecting 30 percent of the + / - 45 degree plies means that 15 percent of the plies are +45 degrees and 15 percent of the plies are -45 degrees.

[0058] Selection of a ply percentage envelope of ply percentage envelope 220 results in a set of candidate orientations 128 of stack sequence 120 being sent to user input 208 to composite part designer 110 .

[0059] Composite part designer 110 may perform stress analysis 130 using the set of candidate orientations 128 of stack sequence 120 to generate results 210. Results 210 may include data or information about at least one of strength, margin of safety, warpage, build efficiency, or other information about composite part 102 having candidate orientations 128 of stack sequence 120 of composite part 102.

[0060] The stress analysis 130, in this illustrative example, is in the form of a laminate analysis 131. The laminate analysis 131 can receive structural loads 222 for performing an analysis of a set of candidate orientations 128 selected by user input 208.

[0061] In this illustrative example, results 210 may be displayed in graphical user interface 206 for viewing by operations personnel 136. Results 210 may be displayed in a number of different ways. For example, results 210 may be displayed using line graphs, bar graphs, text, raw simulation data, or any other suitable type of display.

[0062] Additionally, composite part designer 110 may also display stack sequence 120 and other suitable information regarding design 108 of composite part 102. For example, a visualization of composite part 102 including warpage 116 may be displayed, and a visualization of composite part 102 without warpage 116 according to design 108 may be displayed.

[0063] Based on the results 210 displayed in the graphical user interface 206, the operator 136 can select a new orientation 132 for use as the candidate orientation 128 through selection of a ply percentage envelope 220 displayed in the graphical user interface 206. A layup analysis 131 can be performed with the updated candidate orientation. This process can be performed iteratively until the candidate orientation 128 provides the desired results in acceptable levels 114 of warpage 116 and the desired strength 124.

[0064] In some example embodiments, a plurality of sets of candidate orientations 128 may provide an acceptable level 114 of bow 116 and a desired strength 124. In this context, the set of candidate orientations 128 may be selected based on various factors. These other factors may include at least one of cost, difficulty of manufacture, maximum strength, minimum bow, or other suitable factors.

[0065] For example, some of the sets of candidate orientations 128 may provide both an acceptable level 114 of warp 116 and a desired strength 124. However, some of the sets of candidate orientations 128 may provide a low level of warp 116 even if all of the warp 116 is within the acceptable level 114. In essence, the acceptable level 114 of warp 116 may be a threshold for a maximum level of warp 116 that is acceptable.

[0066] As another example, some of the sets of candidate orientations 128 may provide a higher level of strength, even if all of the sets of candidate orientations 128 provide the desired strength 124. In essence, the desired strength 124 may be a minimum or threshold level of strength for the composite part 102.

[0067] Additionally, the results 210 displayed in the graphical user interface 206 may also include suggestions for ply percentage envelopes 220 that meet the tolerance levels 114 of warpage 116 and the desired strength 124. These suggestions and results 210 may be generated by at least one of the laminate analysis 131 or the artificial intelligence system 138. The operator 136 may generate a user input 208 that selects one of the suggested ones of the ply percentage envelopes 220. The selection results in the selected ply percentage envelope being used in the composite part design 150.

[0068] The illustration of the ply percentage envelope 220 in the graphical user interface 206 is presented as one way in which the operator 136 may select a candidate orientation 128 from the analysis. This illustration is not intended to limit the manner in which the candidate orientation 128 may be selected. In yet another exemplary embodiment, the operator 136 may enter a candidate orientation 128 in the stack sequence 120 in the graphical user interface 206 instead of selecting a ply percentage envelope from the ply percentage envelope 220. In yet another exemplary embodiment, the artificial intelligence system 138 may select a candidate orientation 128 without the necessary user input 208 generated by the operator 136.

[0069] In one exemplary embodiment, there are one or more technical solutions that overcome a technical problem involving manufacturing a composite part having dimensions that deviate from the composite part specifications. In particular, the exemplary embodiment includes one or more technical solutions that reduce the number of shims installed in an object, such as an aircraft. As a result, in the exemplary embodiment, the one or more technical solutions may provide a technical effect of reducing gaps between composite parts being assembled. In the exemplary embodiment, the number of shims manufactured and installed may be reduced by using composite parts with fewer gaps that require shims.

[0070] Computer system 112 may be configured to perform at least one of the steps, processes, or operations described in various exemplary embodiments using software, hardware, firmware, or a combination thereof. As a result, computer system 112 operates as a special-purpose computer system that enables composite part designer 110 of computer system 112 to treat warpage 116 as a variable and generate composite part designs that can be used to manufacture composite parts having an acceptable level 114 of warpage 116 and a desired strength 124. In particular, composite part designer 110 transforms computer system 112 into a special-purpose computer system as compared to general computer systems currently available that do not include composite part designer 110.

[0071] In an exemplary embodiment, the use of the composite part designer 110 in the computer system 112 is integrated with a composite part management implementation that enhances the performance of the computer system 112 in controlling composite part manufacturing in a product management system. In essence, the composite part design 150 in the computer system 112 is directed to a process implementation integrated into the composite part design 150 in the computer system 112 that selects an orientation 118 for the stacking sequence 120 of the plies 122. In this exemplary embodiment, the orientation 118 can be selected to form the selected orientation 126 for the stacking sequence 120. The stacking sequence 120 having the selected orientation 126 can be used to implement the composite part design 150 that can be used to manufacture the composite part 102. Manufacturing the composite part 102 using the composite part design 150 can result in a composite part 102 having desired characteristics, such as an acceptable level 114 of warpage 116 and a desired strength 124.

[0072] The illustration of the composite component environment 100 in FIG. 1 is not intended to imply physical or architectural limitations to the manner in which an example embodiment may be implemented. Other components in addition to or in place of the illustrated components may be used. Some components may be unnecessary. Also, blocks are presented to illustrate some functional components. When implemented in an example embodiment, one or more of these blocks may be combined, divided, or combined and divided into different blocks.

[0073] Although the exemplary embodiment is described with respect to aircraft 106, other exemplary embodiments may be applied to other types of platforms. The platform may be, for example, a mobile platform, a stationary platform, a land-based structure, a water-based structure, and a space-based structure. More specifically, the platform may be a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, a building, or any other suitable platform that uses composite parts.

[0074] 3-6 are examples of one embodiment of the graphical user interface 206 displayed on the display system 202 to the work personnel 136. The work personnel 136 can generate user input 208 using the input system 204 to interact with the graphical user interface 206 and select a candidate orientation 128. Additionally, these figures illustrate various forms that the results 210 of FIG. 2 can take when displayed to the work personnel 136. The display of the graphical user interface 206 can be performed by the composite part designer 110.

[0075] 3, an illustration of results displayed in a graphical user interface 300 is shown in accordance with an exemplary embodiment, where the graphical user interface 300 is an example of one embodiment of the graphical user interface 206 for displaying the results 210 of FIG.

[0076] In this example, table 302 illustrates the characteristics of various ply percentage envelopes. As shown, column 304 illustrates various types of ply percentage envelopes.

[0077] In this exemplary embodiment, the membrane in column 304 is a composite part that includes layers of plies that all have the same orientation, such as 0 degrees. In the other rows, the ply percentage envelopes show the percentage of plies that have orientations in the following order: 0 degrees, + / - 45 degrees, and 90 degrees. In this exemplary embodiment, the "+ / -" degrees means that the percentage of 45 degree plies is evenly distributed between -45 degrees and +45 degrees.

[0078] As shown, column 306 contains values ​​of the elastic modulus in the x-direction and column 308 contains values ​​of the elastic modulus in the y-direction. Column 310 contains values ​​of the Poisson's ratio, where Vxy represents the strain of a laminate having a y-direction plane XY caused by a load in the x-direction. As shown in column 312, Vyx is the Poisson's ratio when a strain in the x-direction is caused by a load in the y-direction in the XY plane.

[0079] In table 302, column 314 contains the value of Poisson's ratio divided by the elastic modulus in the x-direction. The values ​​in this column are obtained from the generalized Hooke's law, a law of application for orthotropic materials including composites, in conjunction with an application of Betti's law. This information means that the elastic properties control the strength contribution of a given lamina in a given orientation within the context of a laminate, independent of the shear modulus Gxy.

[0080] Column 316 includes layup efficiency values. As can be seen, the thin film in row 305 has the highest efficiency. The efficiency takes into account factors such as camber, ply orientation, ply percentage, and other factors.

[0081] In this illustrative example, graphical indicator 318 identifies recommended ply percentage envelopes. In this example, the recommended ply percentage envelopes are illustrated by graphical indicator 318 including 37 / 45 / 18, 40 / 40 / 20, and 40 / 45 / 15.

[0082] Bar graph 320 illustrates the laminate effect of a composite part having a different ply percentage envelope compared to a thin film. Bar graph 320 graphically illustrates the values ​​in column 316 of graphical user interface 300.

[0083] 4, a diagram of results displayed in a graphical user interface is shown in accordance with an exemplary embodiment, in which graphical user interface 400 is an example of one embodiment of graphical user interface 206 for displaying results 210 of FIG.

[0084] In this example, a line graph 402 illustrates a comparison of the effect of ply percentages on the warpage of a composite part, such as a panel. As shown, the x-axis 403 illustrates the ply percentage envelopes and the y-axis 401 illustrates the normalized warpage. Normalized warpage is warpage normalized to one of the ply percentage envelopes so that the ply percentage envelopes can be compared to one another. In this illustrative example, the ply percentage envelope 37 / 45 / 18 is selected because it is the composite part layup with the lowest warpage.

[0085] In this exemplary embodiment, line 404 is the normalized warpage. Line 406 is the percentage of 0 degree plies and 90 degree plies, and line 408 shows the percentage of + / - 45 degree plies for different ply percentage envelopes. Line 406 shows the effect of + / - 45 plies on the warpage of the composite part.

[0086] The graphical indicator 410 identifies an efficient layup range that includes the following ply percentage envelopes: 35 / 50 / 15, 37 / 45 / 18, and 40 / 40 / 20. These ply percentage envelopes result in the following order of percentages: 0 degree plies, + / - 45 degree plies, and 90 degree plies.

[0087] As shown, a graphical indicator 410 displayed in the graphical user interface 400 indicates a suitable or recommended ply percentage envelope.

[0088] 5, a diagram of results displayed in a graphical user interface is shown according to an exemplary embodiment, where graphical user interface 500 is an example of one embodiment of graphical user interface 206 for displaying results 210 of FIG.

[0089] As shown, a line graph 502 depicts laminate efficiency versus Poisson mismatch ratio. In this example, the x-axis 501 represents ply fraction envelope and the y-axis 503 represents laminate efficiency versus Poisson mismatch ratio.

[0090] In this illustrative example, line 504 of line graph 502 shows the laminate efficiency of a composite part using different ply percentage envelopes. The laminate efficiency indicates the efficiency of a composite part manufactured using a particular ply percentage envelope. In this illustrative example, the maximum efficiency is considered to be a ply with a 0 degree orientation. This type of composite part has a controlled efficiency of 1.0.

[0091] Line 506 of line graph 502 shows the mismatch of Poisson's ratio for different ply fraction envelopes. As can be seen from line graph 502, there is a direct correlation between laminate efficiency and Poisson's ratio mismatch. The lower the Poisson's ratio mismatch, the higher the laminate efficiency. For example, a Poisson's ratio of 0.34 for an individual ply is desirable. This value is selected so that the plies do not overstretch to reduce the possibility of premature delamination or adhesion failure. A Poisson's ratio less than 0.34 can reduce or eliminate problems such as delamination and adhesion failure. Reducing the Poisson's ratio reduces the mechanical residual stresses in the composite part.

[0092] In this exemplary embodiment, graphical indicator 508 identifies recommended percentage envelopes for use in the composite part. In this exemplary embodiment, graphical indicator 508 recommends the following ply percentage envelopes: 35 / 50 / 15, 37 / 45 / 18, and 40 / 40 / 20. These ply percentage envelopes result in the following order of percentages: 0 degree plies, + / - 45 degree plies, and 90 degree plies.

[0093] 6, a diagram of results displayed in a graphical user interface 600 is shown in accordance with an exemplary embodiment, where the graphical user interface 600 is an example of one embodiment of the graphical user interface 206 for displaying the results 210 of FIG.

[0094] As shown, a line graph 602 shows laminate strength versus warpage, in this example, the x-axis 601 shows the ply percentage envelope, and the y-axis 603 shows the percentage of warpage versus laminate efficiency.

[0095] In line graph 602, line 604 represents normalized warpage. Warpage can be normalized using the ply percentage envelope that has the lowest amount of warpage.

[0096] Line 606 represents the laminate efficiency. In this example, a composite part with a ply oriented at 0 degrees has a defect of 1.0 because the load is placed along the ply. Other plies such as + / - 45 degrees and 90 degrees have lower levels of efficiency compared to the 0 degree ply.

[0097] As shown, the graphical indicator 608 identifies the ply percentage envelopes that are recommended for use. In this exemplary embodiment, the graphical indicator 608 identifies the following ply percentage envelopes: 35 / 50 / 15, 37 / 45 / 18, and 40 / 40 / 20. These ply percentage envelopes result in the following order of percentages: 0 degree ply, + / - 45 degree ply, and 90 degree ply.

[0098] The graphical user interface diagrams of Figures 3-6 are provided for purposes of illustrating how the graphical user interface 206 shown in block form in Figure 2 may be implemented. For example, other types of graphical displays may use other types of charts. For example, scatter plots, waterfall charts, area charts, or other types of graphs or charts may be used in addition to or instead of those shown in these figures. As another example, the graphical indicators may include at least one of animation, text, icons, images, or other suitable types of graphical indicators that may draw the attention of operational personnel to a particular ply percentage or other information displayed in the graphical user interface.

[0099] Further, other ply percentages may be used in addition to or instead of those shown. Further, while the orientations are shown as 0 degrees, +45 degrees, -45 degrees, and 90 degrees, other orientations may be used in addition to or instead of those shown, such as, for example, 30 degrees, 60 degrees, or some other suitable orientation. Some ply percentage envelopes may include only two orientations rather than three sections as shown in the exemplary embodiment.

[0100] 7, a flowchart of a process for managing composite parts is shown in accordance with an example embodiment. The process of FIG. 7 may be implemented in hardware, software, or both. When implemented in software, the process may take the form of program code executed by one or more processor units located in one or more hardware devices in one or more computer systems. For example, the process may be implemented in part manager 111 of computer system 112 of FIG. 1. Managing composite parts includes at least one of designing composite parts, manufacturing composite parts, or both designing and manufacturing composite parts.

[0101] The process begins by identifying an acceptable level of composite part warpage (step 700). Composite part warpage is the variation in a composite part during manufacturing that deviates from the composite part's design specifications. In this example, warpage is a variable that can be selected when determining ply orientation.

[0102] The process selects an orientation for the plies of the composite part in a stacking sequence that results in a composite part having an acceptable level of warpage and a desired strength, forming the selected orientation (step 702). The process then ends. The composite part can be manufactured using the selected orientation.

[0103] With reference now to Figure 8, a flowchart of a process for selecting a ply orientation for a composite part is depicted in accordance with an illustrative embodiment. The process of Figure 8 is an example of one way in which operation 702 of Figure 7 may be implemented.

[0104] The process begins by selecting a candidate orientation for the stacking order for the plies (step 800). The process performs a stress analysis of the composite part using the candidate orientation for the stacking order for the plies (step 802). The process uses the candidate orientation for the stacking order as the selected orientation when the stress analysis indicates that the composite part has strength that meets the desired strength of the composite part (step 804). The process then ends.

[0105] With reference now to Figure 9, a flowchart of a process for selecting a ply orientation for a composite part is depicted in accordance with an illustrative embodiment. The process of Figure 9 is an example of one way in which operation 702 of Figure 7 may be implemented.

[0106] The process begins by selecting candidate orientations for the plies in the stacking order (step 900). Step 900 may be performed by receiving user input selecting the candidate orientations. For example, user input may be received made to a graphical user interface selecting a set of candidate orientations to be displayed in the graphical user interface. The sets of candidate orientations may be ply percentage envelopes. Each ply percentage envelope is a set of candidate orientations.

[0107] The process performs a stress analysis of the composite part using the candidate orientations for the plies in the stacking order (step 902). The process determines whether the composite part has a strength that meets a desired strength of the composite part from the results of the stress analysis (step 904).

[0108] If the stress analysis indicates that the composite part with the candidate orientation has strength that meets the desired strength, the process uses the candidate orientation in the stacking order as the selected orientation (operation 906). The process then ends.

[0109] Referring again to step 904, if the stress analysis indicates that the composite part with the candidate orientation does not have the strength to meet the desired strength of the composite part, the process then selects a new orientation for the candidate orientation in the stacking order, step 908. The process returns to step 902 to perform a stress analysis of the composite part using the candidate orientation for the plies in the stacking order.

[0110] With reference to Figure 10, an illustration of a flow chart of a process for displaying results from analytically analyzing ply orientation is depicted in accordance with an example embodiment. The process of Figure 11 may be implemented in hardware, software, or both. When implemented in software, the process may take the form of program code executed by one or more processor units located in one or more hardware devices in one or more computer systems.

[0111] For example, the process may be implemented in part manager 111 of computer system 112 of Figure 1. More specifically, the process may be implemented in composite part designer 110 for displaying results 210 in graphical user interface 206 on display system 202 of Figure 2.

[0112] The process begins by identifying a composite part design that includes stacking sequences and candidate orientations for the plies that will be used to form the composite part (step 1000). The process performs a stress analysis using the composite part design (step 1002).

[0113] The process receives results from the stress analysis (operation 1004). In this example embodiment, the results can include information selected from at least one of: warpage level, intensity, rate of orientation, percentage of orientation, set of candidate orientations, or a graphical indicator identifying the best set of candidate orientations or a range of sets of candidate orientations.

[0114] The process displays the results on a graphical user interface of a display system (step 1006). The process also displays the candidate orientations in the stacking order (step 1008).

[0115] A determination is made as to whether user input is received to accept the candidate orientation (step 1010). If user input is received to accept the candidate orientation, the candidate orientation is used as the selected orientation for the stack order of the composite part design (step 1012). The process then ends.

[0116] Referring again to step 1010, if no user input is received to accept the candidate orientation, the process receives user input to select a new orientation as the candidate orientation (step 1014). The process then returns to step 1002.

[0117] 11, an illustration of a flow chart of a process for manufacturing a composite part is depicted in accordance with an example embodiment. The process of FIG. 11 may be implemented in hardware, software, or both. When implemented in software, the process may take the form of program code executed by one or more processor units located in one or more hardware devices in one or more computer systems. For example, the process may be implemented in part manager 111 of computer system 112 of FIG. 1. Managing the composite part includes at least one of designing the composite part, manufacturing the composite part, or both designing and manufacturing the composite part.

[0118] The process begins by identifying a composite part for manufacture, step 1100. The process identifies a composite part design for the composite part, the composite part design including a selected ply orientation in the stack order of the composite part, step 1102. In this illustrative example, the orientation is selected such that the manufactured composite part has an acceptable level of warpage and a desired strength.

[0119] The process controls operation of a ply layup system to lay up the plies using a stacking sequence with the selected orientation to form a composite layup (step 1104). The composite layup is in an uncured form of the composite part. The process controls a curing system to cure the composite layup to form the composite part (step 1106). The process then terminates.

[0120] The illustrated flow diagrams and block diagrams of various embodiments show the structure, functions, and steps of some possible implementations of the apparatus and methods in the exemplary embodiments. In this regard, each block in the flow diagrams or block diagrams may represent at least one of a module, a segment, a function, or a portion of a process or step. For example, one or more blocks may be implemented as program code, hardware, or a combination of program code and hardware. If implemented in hardware, the hardware may take the form of, for example, an integrated circuit that is manufactured or configured to perform one or more steps of the flow charts or block diagrams. If implemented as a combination of program code and hardware, the embodiment may take the form of firmware. Each block in the flow charts or block diagrams may be implemented using dedicated hardware and a dedicated hardware system that performs various steps or combinations of the program code executed by the dedicated hardware.

[0121] In some alternative implementations of the exemplary embodiments, one or more functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be performed substantially simultaneously, or the blocks may sometimes be performed in the reverse order, depending on the functionality involved. Also, other blocks may be added in addition to the blocks depicted in the flowcharts or block diagrams.

[0122] 12, a block diagram of a data processing system is shown in accordance with an exemplary embodiment. Data processing system 1200 may be used to implement one or more of computer system 112 in FIG. 1. In this exemplary example, data processing system 1200 includes a communications framework 1202 that provides communications between a processor unit 1204, a memory 1206, a persistent storage device 1208, a communications unit 1210, an input / output (I / O) unit 1212, and a display 1214. In this example, communications framework 1202 takes the form of a bus system.

[0123] Processor unit 1204 is responsible for executing instructions for software that is loaded into memory 1206. Processor unit 1204 includes one or more processors. For example, processor unit 1204 may be selected from among at least one of a central processing unit (CPU), a graphics processing unit (GPU), a physical processing unit (PPU), a digital signal processor (DSP), a network processor, or other suitable types of processor.

[0124] Memory 1206 and persistent storage 1208 are examples of storage device 1216. A storage device is any hardware capable of storing information, such as, by way of example and not limitation, data, program code in a functional form, and / or other suitable information, on a temporary, persistent, or both temporary and persistent basis. Storage device 1216, in these examples, may also be referred to as a computer-readable storage device. Memory 1206, in these examples, may be, for example, a random access memory or any other suitable volatile or non-volatile storage device. Persistent storage 1208 may take various forms, depending on the particular implementation.

[0125] For example, persistent storage 1208 may contain one or more components or devices. For example, persistent storage 1208 may be a hard drive, a solid-state drive (SSD), a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The medium used by persistent storage 1208 may also be removable. For example, persistent storage 1208 may be a removable hard drive.

[0126] In these illustrative examples, communications unit 1210 provides for communication with other data processing systems or devices. In these illustrative examples, communications unit 1210 is a network interface card.

[0127] Input / output unit 1212 allows for input and output of data to and from other devices that may be connected to data processing system 1200. For example, input / output unit 1212 may provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, input / output unit 1212 may send output to a printer. Display 1214 provides a mechanism for displaying information to a user.

[0128] Instructions for at least one of the operating system, applications, or programs may be present in storage 1216, which is in communication with processor unit 1204 via communications framework 1202. The processes of the different embodiments may be performed by processor unit 1204 using computer-executable instructions, which may be present in a memory, such as memory 1206.

[0129] These instructions are referred to as program code, computer usable program code, or computer readable program code, which may be read and executed by a processor in processor unit 1204. In different embodiments, the program code may be embodied on different physical or computer readable storage media, such as memory 1206 or persistent storage 1208.

[0130] Program code 1218 may be located in a functional form on computer readable media 1220, which is selectively removable, and loaded onto or transferred to data processing system 1200 for execution by processor unit 1204. Program code 1218 and computer readable media 1220, in these examples, form computer program product 1222. In an exemplary embodiment, computer readable media 1220 is computer readable storage medium 1224.

[0131] In these examples, computer-readable storage media 1224 is a physical or tangible storage device used to store program code 1218, rather than a medium that propagates or transmits program code 1218.

[0132] In an alternative aspect, program code 1218 may be transferred to data processing system 1200 using a computer readable signal medium. The computer readable signal medium may be, for example, a propagated data signal containing program code 1218. For example, the computer readable signal medium may be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals may be transmitted over a connection, such as a wireless connection, an optical fiber cable, a coaxial cable, a wire, or any other suitable type of connection.

[0133] The different components illustrated for data processing system 1200 are not meant to provide architectural limitations to the manner in which different embodiments may be implemented. In some illustrative examples, one or more of the components may be incorporated into or otherwise form a part of another component. For example, in some illustrative examples, memory 1206, or portions thereof, may be integrated into processor unit 1204. Different illustrative embodiments may be implemented in a data processing system that includes additional or alternative components to those illustrated for data processing system 1200. Other components illustrated in FIG. 12 may differ from the illustrated illustrative examples. Different embodiments may be implemented using any hardware device or system capable of executing program code 1218.

[0134] An example embodiment of the disclosure may be described in light of aircraft manufacturing and service method 1300 shown in Figure 13 and aircraft 1400 shown in Figure 14. With reference initially to Figure 13, an aircraft manufacturing and service method is illustrated in accordance with an example embodiment. During pre-production, aircraft manufacturing and service method 1300 may include specification and design 1302 of the aircraft 1400 in Figure 14, and material procurement 1304.

[0135] During production, component and subassembly manufacturing 1306 and system integration 1308 of the aircraft 1400 of Figure 14 occurs. The aircraft 1400 of Figure 14 may then undergo certification and delivery 1310 for placement in service 1312. While in service 1312 by a customer, the aircraft 1400 of Figure 14 is scheduled for routine maintenance and service 1314, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

[0136] Each process of aircraft manufacturing and service method 1300 may be performed or carried out by a system integrator, a third party, an entity, or some combination thereof. In these examples, an entity may be a customer. As used herein, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an entity may be an airline, a leasing company, a military entity, a service organization, etc.

[0137] 14 , a diagram of an aircraft in which an illustrative embodiment may be implemented is shown. In this example, the aircraft 1400 may be manufactured by the aircraft manufacturing and service method 1300 of FIG. 13 and may include an airframe 1402 having a number of systems 1404 and an interior 1406. Example systems 1404 include one or more of a propulsion system 1408, an electrical system 1410, a hydraulic system 1412, and an environmental system 1414. Any number of other systems may be included. Although an aerospace example is shown, various illustrative embodiments may be applied to other industries, such as the automotive industry.

[0138] Apparatus and methods embodied herein may be employed during at least one stage of aircraft manufacturing and service method 1300 in Figure 13.

[0139] In one illustrative example, the components or subassemblies produced in component and subassembly manufacturing 1306 of FIG. 13 may be fabricated or manufactured in a similar manner as the components or subassemblies produced while the aircraft 1400 is in service 1312 of FIG. 13. In yet another example, one or more of the equipment embodiments, method embodiments, or a combination thereof may be utilized during the manufacturing stages of the components and subassemblies manufacturing 1306 of FIG. 13 as well as during system integration 1308 of FIG. One or more of the equipment embodiments, method embodiments, or a combination thereof may be utilized while the aircraft 1400 is in service 1312 of FIG. 13, during maintenance and service 1314 of FIG. 13, or both. Any number of the different illustrative embodiments may be utilized to significantly increase the efficiency of assembly of the aircraft 1400, reduce the cost of the aircraft 1400, or both to significantly increase the efficiency of assembly of the aircraft 1400 and reduce the cost of the aircraft 1400.

[0140] For example, the use of composite parts manufactured in accordance with illustrative embodiments may reduce the number of shims required to assemble aircraft 1400. As a result, the amount of time and expense required for at least one of component and subassembly manufacturing 1306 or system integration 1308 may be reduced due to a reduced need to manufacture and install shims as part of assembled components to form aircraft 1400.

[0141] Similar time cost savings can occur during maintenance and repair 1314 by reducing the number of shims that need to be manufactured and installed when replacing parts to add parts during at least one of routine maintenance, refurbishment, reconfiguration, modification, or other maintenance.

[0142] 15, an illustration of a block diagram of a product management system is shown in accordance with an illustrative embodiment. Product management system 1500 is a physical hardware system. In this example, product management system 1500 includes at least one of a manufacturing system 1502 or a maintenance system 1504.

[0143] Manufacturing system 1502 is configured to manufacture a product, such as aircraft 1400 in Figure 14. As shown, manufacturing system 1502 includes manufacturing equipment 1506. Manufacturing equipment 1506 includes at least one of fabrication equipment 1508 or assembly equipment 1510.

[0144] Fabrication equipment 1508 is equipment used to fabricate components for parts used to form aircraft 1400 in FIG. 14. For example, fabrication equipment 1508 may include machines and tools. These machines and tools may be at least one of drills, hydraulic presses, furnaces, dies, composite tape racks, vacuum systems, lathes, or other suitable types of equipment. Fabrication equipment 1508 may be used to fabricate at least one of metal parts, composite parts, semiconductors, circuits, fasteners, ribs, skins, spars, antennas, or other suitable types of parts.

[0145] Assembly equipment 1510 is equipment used to assemble parts that form aircraft 1400 of FIG. 14. In particular, assembly equipment 1510 may be used to assemble components and parts that form aircraft 1400 of FIG. 14. Assembly equipment 1510 may also include machines and tools. Such machines and tools may be at least one of a robotic arm, a crawler, a fastener installation system, a rail-based drilling system, or a robot. Assembly equipment 1510 may be used to assemble parts such as seats, horizontal stabilizers, wings, engines, engine housings, landing gear systems, and other parts for aircraft 1400 of FIG. 14.

[0146] In this illustrative example, maintenance system 1504 may include maintenance equipment 1512. Maintenance equipment 1512 may include any equipment necessary to perform maintenance on aircraft 1400, FIG. 14. Maintenance equipment 1512 may include tools for performing various operations on parts of aircraft 1400, FIG. 14. These operations may include at least one of disassembling a part, refurbishing a part, inspecting a part, reworking a part, manufacturing a replacement part, or other operations to perform maintenance on aircraft 1400, FIG. 14. These operations may be routine maintenance, inspections, upgrades, refurbishing, or other types of maintenance operations.

[0147] In an example embodiment, the maintenance equipment 1512 may include ultrasonic inspection devices, x-ray imaging systems, vision systems, drills, crawlers, and other suitable devices. In some cases, the maintenance equipment 1512 may include fabrication equipment 1508, assembly equipment 1510, or both, for producing and assembling parts that may be required for maintenance.

[0148] The product management system 1500 also includes a control system 1514. The control system 1514 is a hardware system and may also include software or other types of components. The control system 1514 is configured to control operations of at least one of the manufacturing system 1502 or the maintenance system 1504. In particular, the control system 1514 may control operations of at least one of the production equipment 1508, the assembly equipment 1510, or the maintenance equipment 1512.

[0149] In this exemplary embodiment, control system 1514 may include controller 140 in Figure 1. In this exemplary embodiment, controller 140 may receive composite part design 150 from composite part designer 110 and control operation of fabrication equipment 1508 to manufacture composite part 102. In this exemplary embodiment, fabrication equipment 1508 may include ply layup system 144 and curing system 148.

[0150] The hardware of control system 1514 may be implemented using hardware, which may include computers, circuits, networks, and other types of equipment. The control may take the form of direct control of manufacturing equipment 1506. For example, robots, computer-controlled machines, and other equipment may be controlled by control system 1514. In other illustrative examples, control system 1514 may manage operations performed by personnel 1516 in the manufacture or maintenance of aircraft 1400. For example, control system 1514 may assign tasks, provide instructions, display models, or perform other operations to manage operations performed by personnel 1516. As shown in these illustrative examples, controller 140 of FIG. 1 may be implemented in control system 1514 to manage at least one of the manufacture or maintenance of aircraft 1400 of FIG. 14.

[0151] In various illustrative examples, operations personnel 1516 may operate or interact with at least one of production equipment 1506, maintenance equipment 1512, or control system 1514. This interaction may occur to produce aircraft 1400 in Figure 14.

[0152] Of course, product management system 1500 may be configured to manage other products besides aircraft 1400 of Figure 14. Although product management system 1500 is described with respect to manufacturing in the aerospace industry, product management system 1500 may be configured to manage products in other industries. For example, product management system 1500 may be configured to manufacture products in the automotive industry, as well as any other suitable industry.

[0153] Thus, the illustrative embodiments provide a method, apparatus, and system for managing a composite part. An acceptable level of warpage is identified for the composite part. Warpage of the composite part is a variation of the composite part during manufacturing that deviates from the design specifications of the composite part. An orientation is selected for the plies of the composite part in the stacking sequence to form the selected orientation in the stacking sequence such that manufacturing the composite part using the selected orientation in the stacking sequence results in a composite part having an acceptable level of warpage and a desired strength.

[0154] In the exemplary embodiments, there are one or more technical solutions that overcome a technical problem including manufacturing a composite part having dimensions that deviate from the composite part specifications. In particular, the exemplary embodiments include one or more technical solutions that reduce the number of shims installed in an object, such as an aircraft. As a result, in the exemplary embodiments, the one or more technical solutions may provide a technical effect of reducing gaps between composite parts being assembled. In the exemplary embodiments, the number of shims manufactured and installed may be reduced by using composite parts with fewer gaps that require shims.

[0155] The description of various exemplary embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or to be limited to the embodiments in the form disclosed. Components that perform operations or steps are described by way of various examples. In the exemplary examples, the components may be configured to perform the described operations or tasks. For example, the components may have a structural configuration or design that provides the components with the capability to perform the operations or tasks described as being performed by the components in the exemplary examples.

[0156] Additionally, the disclosure includes embodiments according to the following provisions:

[0157] Clause 1. A method for managing a composite part (104), comprising: identifying an acceptable level (114) of warpage (116) of the composite part (104), which is a variation of the composite part (104) during manufacture that deviates from a design specification (119) of the composite part (104); selecting an orientation (118) for the stacking sequence (120) of plies (122) of the composite part (104) to form the selected orientation (126) for the stacking sequence (120) such that manufacturing the composite part (104) using the selected orientation (126) for the stacking sequence (120) results in a composite part (104) having an acceptable level (114) of warpage (116) and a desired strength (124); The method includes:

[0158] Clause 2. Selecting an orientation (118) for a stacking sequence (120) of plies (122) of a composite part (104) to form the selected orientation (126) for the stacking sequence (120) such that manufacturing the composite part (104) using the selected orientation (126) for the stacking sequence (120) results in a composite part (104) having an acceptable level (114) of warpage (116) and a desired strength (124); selecting a candidate orientation (128) for the stacking order (120) of the plies (122); performing a stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking order (120) of the plies (122); using the candidate orientation (128) for the stacking sequence (120) as the selected orientation (126) when the stress analysis (130) indicates that the composite part (104) has the desired strength (124) of the composite part (104). 2. The method according to claim 1, comprising:

[0159] Clause 3. Selecting an orientation (118) for a stacking sequence (120) of plies (122) of a composite part (104) to form the selected orientation (126) for the stacking sequence (120) such that manufacturing the composite part (104) using the selected orientation (126) for the stacking sequence (120) results in a composite part (104) having an acceptable level (114) of warpage (116) and a desired strength (124); selecting a new orientation (132) for the candidate orientation (128) in the stacking sequence (120) when a stress analysis (130) of the composite part (104) having the candidate orientation (128) indicates that the composite part (104) does not have a desired strength (124); performing a stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking order (120) of the plies (122); and iteratively selecting a new orientation (132) and performing a stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking order (120) of the plies (122) until the composite part (104) has a desired strength (124). 3. The method of claim 2, further comprising:

[0160] Clause 4. The method of clause 2, wherein the stress analysis (130) includes simulating a set of structural loads (222) applied to the composite component (104).

[0161] Clause 5. Selecting a candidate orientation (128) for a stacking order (120) of plies (122), receiving a user input (208) made to a graphical user interface (206) of the display system (202), the user input (208) selecting a set of candidate orientations (128) displayed on the graphical user interface (206); 3. The method according to claim 2, comprising:

[0162] Clause 6. Manufacturing the composite part (104) using the selected orientation (126) in a product management system. 6. The method of any one of clauses 1 to 5, further comprising:

[0163] Clause 7. Controlling a ply layup system (144) to lay up plies (122) of a composite part (104) using a selected orientation (126) to form a composite layup (146); curing the composite layup (146) to form a composite part (104); 7. The method of any one of clauses 1 to 6, further comprising:

[0164] Clause 8. The method of any one of clauses 1 to 7, wherein the selected orientations (126) include a 90 degree ply (122), a +45 degree ply (122), a -45 degree ply (122), and a 0 degree ply (122).

[0165] Clause 9. The method of any one of clauses 1 to 8, wherein the selected orientation (126) includes at least 10 percent of the plies (122) having a 90 degree orientation.

[0166] Clause 10. The method of any one of clauses 1 to 9, wherein the selected orientation (126) comprises at least 12.5 percent to 20 percent of the plies (122) having a 90 degree orientation.

[0167] Clause 11. The method of any one of clauses 1 to 10, wherein the selected orientation (126) comprises 40 percent to 50 percent of the plies (122) having a 45 degree orientation.

[0168] Clause 12. The method of any one of clauses 1 to 11, wherein the composite part (104) is a skin panel, a fairing, an engine housing, a stringer, a door, a wing, and a panel.

[0169] Article 13. A computer system (112); A composite part designer (110) of a computer system (112) and A composite part designer (110) identifying an acceptable level (114) of warpage (116) of the composite part (104), which is a variation of the composite part (104) during manufacture that deviates from a design specification (119) of the composite part (104); A composite part system (115) configured to select an orientation (118) for a stacking sequence (120) of plies (122) of a composite part (104) to form the selected orientation (126) for the stacking sequence (120), such that manufacturing the composite part (104) using the selected orientation (126) for the stacking sequence (120) results in a composite part (104) having an acceptable level (114) of warpage (116) and a desired strength (124).

[0170] Clause 14. A composite part designer (110) selects an orientation (118) for a stacking sequence (120) of plies (122) of a composite part (104) to form the selected orientation (126) for the stacking sequence (120) such that manufacturing the composite part (104) using the selected orientation (126) for the stacking sequence (120) will result in a composite part (104) having an acceptable level (114) of warpage (116) and a desired strength (124), Selecting a candidate orientation (128) for the stacking order (120) of the ply (122); performing a stress analysis (130) of the composite part (104) using the candidate orientation (128) for the stacking order (120) of the plies (122); 14. The composite part system (115) of claim 13, configured to use the candidate orientation (128) for the stack sequence (120) as the selected orientation (126) when the stress analysis (130) indicates that the composite part (104) has a desired strength (124) of the composite part (104).

[0171] Clause 15. By manufacturing a composite part (104) using a selected orientation (126) for a stacking sequence (120), an orientation (118) for a stacking sequence (120) of plies (122) of the composite part (104) is selected to form the selected orientation (126) for the stacking sequence (120) so that a composite part (104) having an acceptable level (114) of warpage (116) and a desired strength (124) is obtained, the composite part (104) is selecting a new orientation (132) for the stacking sequence (120) when a stress analysis (130) of the composite part (104) having a candidate orientation (128) indicates that the composite part (104) does not have the desired strength (124); performing a stress analysis (130) of the composite part (104) using the new orientation (132) of the stacking sequence (120) of the plies (122); 15. The composite part system (115) of claim 14, further configured to iteratively select new orientations (132) for the candidate orientations (128) and perform a stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking order (120) of the plies (122) until the composite part (104) has a desired strength (124).

[0172] Clause 16. The composite component system (115) of clause 14, wherein the stress analysis (130) includes simulating a set of structural loads (222) applied to the composite component (104).

[0173] Clause 17. A composite part system (115) as described in clause 14, wherein when selecting candidate orientations (128) for the stacking order (120) of the plies (122), a composite part (104) designer receives user input (208) made to a graphical user interface (206) of a display system (202), the user input (208) selecting a plurality of sets of candidate orientations (128) displayed on the graphical user interface (206).

[0174] Clause 18. A controller (140) within the computer system (112) and configured to control manufacturing of the composite part (104) in a product management system using the selected orientation (126). 18. The composite component system (115) of any one of clauses 13 to 17, further comprising:

[0175] Clause 19. A controller (140) within the computer system (112) configured to control a ply layup system (144) to lay up plies (122) of a composite part (104) using a selected orientation (126) to form a composite layup (146), and to control a curing system (148) to cure the composite layup (146) to form the composite part (104). 19. The composite component system (115) of any one of clauses 13 to 18, further comprising:

[0176] Clause 20. The composite component system (115) of any one of clauses 13 to 19, wherein the selected orientations (126) include a 90 degree ply (122), a +45 degree ply (122), a -45 degree ply (122), and a 0 degree ply (122).

[0177] Clause 21. The composite component system (115) of any one of clauses 13 to 20, wherein the selected orientation (126) includes at least 10 percent of the plies (122) having a 90 degree orientation.

[0178] Clause 22. The composite component system (115) of any one of clauses 13 to 21, wherein the selected orientation (126) includes at least 12.5 percent to 20 percent of the plies (122) having a 90 degree orientation.

[0179] Clause 23. The composite component system (115) of any one of clauses 13 to 22, wherein the selected orientation (126) includes between 40 percent and 50 percent of the plies (122) having a 45 degree orientation.

[0180] Clause 24. The composite component system (115) of any one of clauses 13 to 23, wherein the composite component (104) is a skin panel, a fairing, an engine housing, a stringer, a door, a wing, and a panel.

[0181] Article 25. Manufacturing equipment (1508) and a controller (140) in communication with the production equipment (1508); and wherein the controller (140) is configured to control the fabrication equipment (1508) to manufacture the composite part (104) using a part design having a selected orientation (126) for the stacking sequence (120) of the plies (122) of the composite part (104) that results in the composite part (104) having a warp (116) within an acceptable level (114) and a desired strength (124), wherein the warp (116) is a change in the composite part (104) as manufactured that deviates from a design specification (119) for the composite part (104).

[0182] Article 26. Composite Part Designer (110) 26. The product management system of claim 25, further comprising: the composite part designer (110) configured to identify an acceptable level (114) of warpage (116) of the composite part (104) and to select an orientation (118) for the stack sequence (120) to form the selected orientation (126) for the plies (122) of the composite part (104) such that manufacturing the composite part (104) using the selected orientation (126) for the stack sequence (120) results in a composite part (104) having the acceptable level (114) of warpage (116) and a desired strength (124).

[0183] Article 27. Manufacturing equipment (1508) a ply layup system (144) for laying up plies (122) of the composite part (104) using the selected orientations (126) to form a composite layup (146) under the control of a controller (140); a curing system (148) for curing the composite layup (146) to form the composite part (104) under the control of the controller (140); 27. A product management system according to clause 25 or 26, comprising:

[0184] Numerous modifications and variations will be apparent to those skilled in the art. Furthermore, different exemplary embodiments may provide different features as compared to other preferred embodiments. The selected embodiment or embodiments have been chosen and described in order to best explain the principles and practical applications of the embodiments and to facilitate understanding by others skilled in the art of the disclosure of the various embodiments and various modifications suitable for the particular application contemplated.

Claims

1. A method for managing a composite part (104), comprising: identifying an acceptable level (114) of warpage (116) of the composite part (104), which is a variation of the composite part (104) during manufacture that deviates from a design specification (119) of the composite part (104); selecting an orientation (118) for the stacking sequence (120) of the plies (122) of the composite part (104) to form the selected orientation (126) for the stacking sequence (120) of the plies (122) such that manufacturing the composite part (104) using the selected orientation (126) for the stacking sequence (120) of the plies (122) results in the composite part (104) having the acceptable level (114) of warpage (116) and a desired strength (124); A method comprising: selecting an orientation (118) for the stacking sequence (120) of the plies (122) of the composite part (104) to form a selected orientation (126) for the stacking sequence (120); selecting a candidate orientation (128) for the stacking sequence (120) of the ply (122); performing a stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking sequence (120) of the plies (122); using the candidate orientation (128) for the stack sequence (120) as the selected orientation (126) when the stress analysis (130) indicates that the composite part (104) has the desired strength (124) of the composite part (104); selecting a new orientation (132) for the candidate orientation (128) in the stack sequence (120) when the stress analysis (130) of the composite part (104) having the candidate orientation (128) indicates that the composite part (104) does not have the desired strength (124); performing the stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking sequence (120) of the plies (122); iteratively selecting the new orientation (132) and performing the stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking order (120) of the plies (122) until the composite part (104) has the desired strength (124). A method comprising:

2. The method of claim 1 , wherein the stress analysis (130) comprises a simulation of a set of structural loads (222) applied to the composite component (104).

3. selecting the candidate orientation (128) for the stacking order (120) of the ply (122); receiving a user input (208) made to a graphical user interface (206) of a display system (202), the user input (208) selecting one of a plurality of sets of candidate orientations (128) displayed on the graphical user interface (206); The method of claim 1 , comprising:

4. manufacturing said composite part (104) in a product management system using said selected orientation (126). The method of claim 1 , further comprising:

5. controlling a ply layup system (144) to lay up the plies (122) of the composite part (104) using the selected orientation (126) to form a composite layup (146); curing the composite layup (146) to form the composite part (104); The method of claim 1 , further comprising:

6. 6. The method of any one of claims 1 to 5, wherein the selected orientations (126) include a 90 degree ply (122), a +45 degree ply (122), a -45 degree ply (122), and a 0 degree ply (122).

7. The method of any one of claims 1 to 6, wherein the selected orientation (126) comprises at least 10 percent of the plies (122) having a 90 degree orientation.

8. The method of any one of claims 1 to 7, wherein the selected orientation (126) comprises at least 12.5 percent to 20 percent of the plies (122) having a 90 degree orientation.

9. The method of any one of claims 1 to 8, wherein the selected orientation (126) comprises between 40 percent and 50 percent of the plies (122) having a 45 degree orientation.

10. The method of any one of claims 1 to 9, wherein the composite part (104) is a skin panel, a fairing, an engine housing, a stringer, a door, a wing, and a panel.

11. A computer system (112); a composite part designer (110) of the computer system (112); 11. A composite part system (115) comprising: a composite part designer (110) configured to perform the method of any one of claims 1 to 10.

12. A production device (1508); a controller (140) in communication with the fabrication equipment (1508); Composite part designer (110) the controller (140) is configured to control the fabrication equipment (1508) to manufacture a composite part (104) using a part design having a selected orientation (126) for a stacking sequence (120) of plies (122) of the composite part (104) that results in a composite part (104) having a warp (116) within an acceptable level (114) and the warp (116) having a desired strength (124), wherein the warp (116) is a change in the composite part (104) during fabrication that deviates from a design specification (119) of the composite part (104); the composite part designer (110) is configured to identify the acceptable level (114) of the warp (116) of the composite part (104) and to select an orientation (118) for the stack sequence (120) to form the selected orientation (126) in the plies (122) of the composite part (104) such that manufacturing the composite part (104) using the selected orientation (126) for the stack sequence (120) results in the composite part (104) having the acceptable level (114) of the warp (116) and the desired strength (124); The composite part designer (110): selecting a candidate orientation (128) for the stacking sequence (120) of the ply (122); performing a stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking sequence (120) of the plies (122); using the candidate orientation (128) for the stack sequence (120) as the selected orientation (126) when the stress analysis (130) indicates that the composite part (104) has the desired strength (124) of the composite part (104); selecting a new orientation (132) for the candidate orientation (128) in the stacking sequence (120) when the stress analysis (130) of the composite part (104) having the candidate orientation (128) indicates that the composite part (104) does not have the desired strength (124); performing the stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking sequence (120) of the plies (122); and a product management system (1500) configured to iteratively select the new orientation (132) and perform the stress analysis (130) of the composite part (104) using the candidate orientations (128) for the stacking order (120) of the plies (122) until the desired strength (124) is present in the composite part (104).

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