Composite structure warpage control system

Abstract

A method, apparatus, and system for managing a composite part (104). An acceptable level (114) of bending (116) is identified for the composite part (104). The bending (116) for the composite part (104) is a change in the composite part (104) as it is manufactured deviating from the design specifications (119) for the composite part (104). A direction (118) is selected in a lamination sequence (120) for the plies (122) of the composite part (104) to form a selected direction (126) so as to result in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124). The composite part (104) is manufactured using the selected direction (126).

Description

Technology Field

[0001] The present invention generally relates to manufacturing, in particular to the manufacturing of composite parts. In particular, the present invention relates to a method, apparatus, and system for controlling bending in the manufacturing of composite parts. Background Technology

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

[0003] Due to warping, composite parts may not fit together as intended when assembling aircraft components. Consequently, gaps may exist when the parts are placed together for assembly.

[0004] Shims can be used in these situations. A shim is a structure used to align parts. A shim can be, for example, a washer, a wedge, a strip of material, or some other structure that fills a gap between two parts caused by the bending of one or more parts.

[0005] However, the use of shims is time-consuming and can increase manufacturing costs. For example, it is necessary to identify and measure gaps between parts. In some cases, warping can result in sufficiently small gaps that close when parts are connected. In these situations, shims are unnecessary.

[0006] When the gap is too large, a shim is manufactured to fit the gap. In some cases, the gap may have a complex shape that requires more time and effort to create a shim to fit the gap. Then, a human operator installs the shim in the gap.

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

[0008] Therefore, it would be desirable to have a method and apparatus that considers not only at least some of the problems discussed above but also other possible problems. For example, it would be desirable to have a method and apparatus that overcomes technical problems associated with manufacturing a composite part having dimensions that deviate from the specifications for the composite part. means of solving the problem

[0009] Embodiments of the present invention provide a method for managing a composite part. An acceptable level of warping is identified for the composite part. Warping for the composite part is a variation of the composite part resulting from manufacturing the composite part outside of its design specifications. A direction is selected to form a selected direction in the lamination sequence for the plies of the composite part, and manufacturing the composite part using the selected direction results in a composite part having an acceptable level of warping and a desired strength.

[0010] Another embodiment of the present invention 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 warping for the composite part. Warping is a change in the composite part resulting from manufacturing the composite part deviating from the design specifications for the composite part. The composite part designer selects a direction in a lamination sequence for the plies of the composite part to form a direction selected in the lamination sequence, and manufacturing the composite part using the direction selected in the lamination sequence results in a composite part having an acceptable level of warping and a desired strength.

[0011] Another embodiment of the present invention provides a product management system configured to include a manufacturing machine and a controller that communicates with the manufacturing machine. The controller is configured to control the manufacturing machine to manufacture a composite part using a part design having a direction selected in the stacking sequence for the plies of the composite part to form a direction selected in the stacking sequence. Manufacturing the composite part using the direction selected in the stacking sequence results in a composite part having an acceptable level of warping and a desired strength, and warping is a change in the composite part when manufactured deviating from the design specifications for the composite part.

[0012] Features and functions may be achieved independently in various embodiments of the present invention, or may be combined in another embodiment for which further details can be known by referring to the following description and drawings. Brief explanation of the drawing

[0013] Novel features considered to be characteristic of exemplary embodiments are described in the appended claims. However, not only exemplary embodiments but also preferred modes of use, additional purposes and features thereof will be best understood by referring to the following detailed description of exemplary embodiments of the invention when read together with the accompanying drawings. FIG. 1 is an example of a composite material component environment according to an exemplary embodiment; FIG. 2 is an example of a block diagram of a user interface system for designing a composite part according to an exemplary embodiment; FIG. 3 is an example of a result displayed in a graphical user interface according to an exemplary embodiment; FIG. 4 is an example of a result displayed in a graphical user interface according to an exemplary embodiment; FIG. 5 is an example of a result displayed in a graphical user interface according to an exemplary embodiment; FIG. 6 is an example of a result displayed in a graphical user interface according to an exemplary embodiment; FIG. 7 is an example of a flowchart of a process for managing composite parts according to an exemplary embodiment; FIG. 8 is an example of a flowchart of a process for selecting orientations for plies in a composite part according to an exemplary embodiment; FIG. 9 is an example of a flowchart of a process for selecting the orientation of a ply in a composite part according to an exemplary embodiment; FIG. 10 is an example of a flowchart of a process for displaying results from analyzing the orientation of a fly according to an exemplary embodiment; FIG. 11 is an example of a flowchart of a process for manufacturing a composite part according to an exemplary embodiment; FIG. 12 is an example of a block diagram of a data processing system according to an exemplary embodiment; FIG. 13 is an example of an aircraft manufacturing and servicing method according to an exemplary embodiment; FIG. 14 is an example of a block diagram of an aircraft in which an exemplary embodiment can be implemented; FIG. 15 is an example of a block diagram of a product management system illustrated according to an exemplary embodiment; Specific details for implementing the invention

[0014] The exemplary embodiment recognizes and takes into account one or more considerations. For example, the exemplary embodiment recognizes and takes into account that the bending of a panel having a balanced and symmetric layup is considered to be the inherent behavior of the composite and is not related to laminate in-plane properties. The exemplary embodiment recognizes and takes into account that the bending is not considered to be a foreseeable defect.

[0015] The exemplary embodiment recognizes and considers that the current design process does not use the level of warpage as a variable. The exemplary embodiment recognizes and considers that it is desirable for the current design process to focus on providing the desired performance of the composite structure, such as the lower wing panel, regardless of any warpage that may occur. For example, the exemplary embodiment recognizes and considers that the desired performance may be the absence of splitting in the composite part, such as the skin panel on the underside of the aircraft wing.

[0016] Accordingly, the exemplary example provides a method, apparatus, and system for designing and manufacturing a composite part that achieves a desired level of warping and maintains the desired performance of the composite part. For example, the exemplary example manages a composite part. An acceptable level of warping is identified for the composite part. Warping of the composite part is a variation of the composite part resulting from manufacturing that deviates from the design specifications for the composite part. Manufacturing the composite part using a selected direction in a stacking sequence for the plies of the composite part, such that the direction is selected to form a selected direction, results in a composite part having an acceptable level of warping and desired strength.

[0017] Referring to the drawings, particularly FIG. 1, an example of a composite part environment is illustrated according to an exemplary embodiment. The composite part environment (100) is an environment in which a composite part (102) is designed to be used in a product (104), such as an aircraft (106). The composite part (102) takes on a number of different forms. For example, the composite part (102) may be a skin panel, a fairing, an engine housing, a stringer, a door, a wing, a panel, and one of several other suitable forms of parts that can be used in the product (104), particularly the aircraft (106).

[0018] In this exemplary example, the design (108) for the composite part (102) is generated by the composite part designer (110) of the part manager (111) of the computer system (112). As illustrated, the composite part designer (110) may be implemented as software, hardware, firmware, or a combination thereof. When software is used, the operation performed by the composite part designer (110) may be implemented as program code configured to be executed on hardware, such as a processor unit. When firmware is used, the operation performed by the composite part designer (110) may be implemented as program code and data to be executed on a processor unit and stored in permanent memory. When hardware is adopted, the hardware may include a circuit that operates to perform the operation in the composite part designer (110).

[0019] In exemplary examples, the hardware may take the form selected from at least one of a circuit system, an integrated circuit, an application-specific integrated circuit (ASIC), a programmable logic device, or some other suitable form of hardware configured to perform a number of operations. According to a programmable logic device, the device may be configured to perform a number of operations. The device may be reconfigured later or permanently configured to perform a number of operations. Programmable logic devices include, for example, programmable logic arrays, programmable array logic, field programmable logic arrays, field programmable gate arrays, and other suitable hardware devices. Additionally, the process may be implemented with organic components integrated with inorganic components, or may be composed entirely of organic components excluding humans. For example, the process may be implemented as a circuit of organic semiconductors.

[0020] The computer system (112) is a physical hardware system and includes one or more data processing systems. When one or more data processing systems exist in the 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 several other suitable data processing systems.

[0021] As used herein, when used with a list of items, the phrase "one or more of" means that multiple combinations of one or more of the enumerated items may be used, and that only one of each item in the list may be required. That is, "at least one of" means a specific combination of items, and while multiple items may be used from the list, not all items in the list are required. An item may be a specific entity, thing, or category.

[0022] For example, “at least one of item A, item B, or item C” may include item A, item A and item B, or item B. The present example may also include item A, item B, and item C, or item B and item C. Of course, certain combinations of these items may exist. In some exemplary examples, “at least one of” may be, for example, without limitation, two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations.

[0023] As described, the composite part designer (110) operates to manage the composite part (102). Management of the composite part (102) by the composite part designer (110) includes identifying an acceptable level (114) of bending (116) for the composite part (102). Bending (116) for the composite part (102) is a change in the composite part (102) resulting from manufacturing outside of the design specifications (119) for the composite part (102). In an exemplary example, the design specifications (119) specify parameters for the composite part (102) including at least one of dimensions, strength, tolerances, or other parameters for the composite part (102).

[0024] In this exemplary example, the composite part designer (110) selects a direction (118) in the stacking sequence (120) for the plies (122) of the composite part (102) to form a direction (126) selected in the stacking sequence (120). Manufacturing the composite part (102) using the direction (126) selected in the stacking sequence (120) results in a composite part (102) having an acceptable level (114) of bending (116) and a desired strength (124) to form the selected direction (126).

[0025] Bending (116) is treated as a variable by the composite part designer (110) in selecting the direction (118). The selection of the direction (118) is made so that the composite part (102) has both an allowable level (114) of bending (116) and a desired strength (124). In this exemplary example, the desired strength (124) may be based on design specifications (119). The specifications may specify a desirable margin of safety for the composite part (102).

[0026] In an exemplary example, the composite part designer (110) can select an orientation (118) for a ply (122) in the composite part (102) to form a plurality of selected orientations (126), resulting in a composite part (102) having an acceptable level (114) of bending (116) and a desired strength (124). For example, the composite part designer (110) can select candidate orientations (128) in a stacking sequence (120) for the ply (122). The composite part designer (110) can perform a stress analysis (130) on the composite part (102) using the candidate orientations (128) in the stacking sequence (120) for the ply (122). As illustrated, the stress analysis (130) includes a simulation of one or more forms of forces that can be applied to the composite part (102). For example, the simulation may be a series of loads applied to the composite part (102). Other forces may include frictional force, tension force, or other suitable forms of force.

[0027] In an exemplary example, stress analysis (130) may take the form of laminate analysis (131). Laminate analysis (131) may be implemented using currently available analysis algorithms that can be used to analyze a composite part (102). These algorithms may implement Classic Laminate Plate Theory. In this theory, the engineering and physical properties of the ply are developed based on the fiber angle with respect to the main load direction. The properties can be summed in a specific direction with respect to the ply thickness and divided by the total thickness. Laminate analysis (131) may be performed on the composite part design (150) to determine parameters such as strength, damage resistance, or other parameters for the composite part (102) manufactured using the composite part design (150). Laminate analysis (131) can be used to calculate the characteristics of a laminate, such as a composite part (102) having a ply (122) having a direction (118) in a lamination sequence (120).

[0028] In this exemplary example, one of the characteristics of the composite part (102) is the amount or level of bending (116). The amount of bending (116) can be determined by a laminate analysis (131) using a lamination sequence (120) which includes the orientation (118) of the ply (122) in addition to other information, such as dimensions, the shape of the material, or other information required to analyze the design (108). In this exemplary example, the laminate analysis (131) is α as illustrated in FIG. 4 and as described in FIG. 4 below. Y and α X Warpage data such as and normalized warpage (α Y / α X Calculate )

[0029] When the result from the stress analysis (130) indicates that the composite part (102) has an acceptable level (114) of bending (116) and a desired strength (124) for the composite part (102), the composite part designer (110) uses a candidate direction (128) in the stacking sequence (120) as the selected direction (126).

[0030] When a stress analysis (130) performed on a composite part (102) having a candidate direction (128) indicates that the composite part (102) does not have the desired strength (124), the composite part designer (110) may select a new direction (132) in the stacking sequence (120). By changing the direction in the stacking sequence (120), the position of the ply (122) may be changed to a different position in the stacking sequence (120).

[0031] The composite part designer (110) performs a stress analysis (130) on the composite part (102) using a new direction (132) in the stacking sequence (120) for the plies (122) as a candidate direction (128). The composite part designer (110) selects a new direction (132) as a candidate direction (128) and repeats the stress analysis (130) on the composite part (102) using the candidate direction (128) in the stacking sequence (120) for the plies (122) until a desired strength (124) exists in the composite part (102).

[0032] The selected direction (126) may consist of at least one of a 90-degree fly, a +45-degree fly, a -45-degree fly, or a 0-degree fly. For example, the selected direction (126) may consist of a 90-degree fly, a +45-degree fly, a -45-degree fly, and a 0-degree fly. In another exemplary example, the selected direction (126) may consist of at least 10% of the flies having a 90-degree direction. In another exemplary example, the selected direction (126) may consist of at least 12.5% ​​to 20% of the flies having a 90-degree direction. In yet another exemplary example, the selected direction (126) may consist of 40% to 50% of the flies having a 45-degree direction. In this example, the 45-degree direction may be a +45-degree direction, a -45-degree direction, or some combination thereof.

[0033] In an exemplary example, the angles for various directions may be based on a reference axis. For instance, these angles may be relative to the part axis for the composite part (102). In another example, the angle of the ply (122) may be relative to the tool head of a machine, such as an automatic tape laying machine or other automated tool.

[0034] Examples of multiple plies for these directions are provided merely as exemplary examples and do not limit the way multiple plies can be selected in multiple directions. These and other directions may be used for the selected direction (126) such that an acceptable level (114) for bending (116) exists and a desired strength (124) exists for the composite part (102). Furthermore, the positions of the multiple directions forming the stacking sequence (120) may be a third variable in addition to the acceptable level (114) for bending (116) and the desired strength (124).

[0035] In an exemplary example, at least one of the candidate direction (128) or the new direction (132) may be selected by the composite part designer (110) in a number of different ways. The selection may be made using an input (134) received from at least one of a human operator (136) or an artificial intelligence system (138).

[0036] In the illustrated example, the human operator (136) is a person who designs composite parts (102) for use in an aircraft (106). The artificial intelligence system (138) is a system capable of having intelligent behavior and being based on the functions of a human brain.

[0037] As described, the artificial intelligence system (138) comprises at least one of an artificial neural network, a cognitive system, a Bayesian network, fuzzy logic, an expert system, a natural language system, or some other suitable system. Machine learning is used to train the artificial intelligence system. Machine learning includes inputting data into a process and enabling the process to adjust and enhance the functions of the artificial intelligence system.

[0038] A cognitive system is a computing system that mimics the functions of the human brain. A cognitive system could be, for example, IBM Watson, available from International Business Machines Corporation.

[0039] In this exemplary example, the part manager (111) may also include a controller (140) in a computer system (112). As illustrated, the controller (140) is configured to control the manufacturing of a composite part (102) in a product management system (142) using a selected direction (126). That is, the composite part (102) can be manufactured in the product management system (142) using a selected direction (126).

[0040] Depending on the direction (126) selected in the stacking sequence (120), the composite part designer (110) can 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) so that the composite part (102) has an acceptable level (114) of bending (116) and a desired strength (124). The design may be, for example, a CAD (computer-aided design) model, a CAM (computer-aided manufacturing) model, a CNC (computer numerical control) program, or other forms of models.

[0041] In an exemplary example, the composite part design (150) is in contrast to the design (108). The design (108) includes design specifications (119). The design specifications (119) may include a layup of plies (122) having an initial lamination sequence having an orientation for the plies (122) in the initial lamination sequence. These orientations may be varied to form a selected orientation (126) in the lamination sequence (120), resulting in an acceptable level (114) of bending (116) and a desired strength (124) for the composite part (102) manufactured using the selected orientation (126) in the lamination sequence (120).

[0042] For example, a controller (140) may use a composite part design (150) that includes a direction (126) selected in a stacking sequence (120) for a ply (122) of a composite part (102) to manufacture a composite part (102). The controller (140) may control the operation of a ply layup system (144) to lay up a ply (122) for a composite part (102) using the direction (126) selected in the composite part design (150) to form a composite layup (146). In this exemplary example, the ply layup system (144) may be, for example, an automated fiber placement machine, a tape-laying machine, or at least one of other suitable hardware equipment capable of operating to lay up a ply (122) in the selected direction (126) to form a composite layup (146).

[0043] In an exemplary example, the control of one or more machines of the fly 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 numeric control (CNC) automated fiber placement machine. The CNC program may be generated from the design of a part, such as a computer-aided design (CAD) drawing. This program may be executed by a controller (140) to control the operation of the automated fiber placement machine. In some exemplary examples, the controller (140) may be part of the automated fiber placement machine.

[0044] Additionally, the controller (140) may control the curing system (148) to cure the composite layup (146) to form the composite part (102). As illustrated, the curing system (148) may 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).

[0045] In this exemplary example, the part manager (111) is part of the composite part system (115). At least one of the fly layup system (144) or the curing system (148) may also be part of the composite part system (115).

[0046] Next, referring to FIG. 2, an example of a block diagram of a user interface system for designing composite parts is illustrated according to an exemplary embodiment. In the exemplary example, the same reference numeral may be used in one or more drawings. Such reuse of reference numerals in multiple drawings indicates the same element in multiple drawings.

[0047] In this exemplary example, the user interface system (200) provides an interface for a human operator (136) to interact with at least one of a composite material component designer (110) or a controller (140) in the computer system (112) of FIG. 1.

[0048] As described, the user interface system (200) comprises a display system (202) and an input system (204). These components may be connected to or considered as part of a computer system (112).

[0049] In the present exemplary example, the display system (202) is a physical hardware system and includes one or more display devices on which a graphical user interface (206) can be displayed. The display device 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 head-up display (HUD), or some other suitable device capable of outputting information for a visual representation of information.

[0050] As described, the display system (202) is configured to display a graphical user interface (206). A human operator (136) is a person capable of interacting with the graphical user interface (206) through user input (208) generated by an input system (204) for the computer system (112). The input system (204) is a physical hardware system and may be selected from at least one of a mouse, keyboard, trackball, touch screen, stylus, motion-sensing input device, cyber glove, or some other suitable form of input device.

[0051] For example, a human operator (136) can select or create a composite part design (150) for a composite part (102) using a graphical user interface (206). In this exemplary example, the human operator (136) can generate user input (208) to select an acceptable level (114) of bending (116) and a desired strength (124) for the composite part (102), as shown in the block form in FIG. 1.

[0052] User input (208) may be generated to identify a selected direction (126) in a stacking sequence (120) for plies (122) to form a composite part design (150). The composite part design (150) is a design used by the controller (140) to manufacture the composite part (102).

[0053] As illustrated, the composite part design (150) includes a lamination sequence (120) for plies (122) forming the composite part (102). In this exemplary example, the lamination sequence (120) can be obtained from the design (108) of FIG. 1 for the composite part (102).

[0054] In this exemplary example, the human operator (136) can select a candidate direction (128). As illustrated, the user input (208) can also select which plies in the stacking sequence (120) have a specific direction. That is, the human operator (136) can maintain the same percentage of candidate directions (128), but can change which layers in the stacking sequence (120) have a specific direction.

[0055] As described, a set of candidate directions (128) may be displayed on a graphical user interface (206) as ply percentage envelopes (220). The set of candidate directions (128) is a ply percentage in this exemplary example. For example, the set of candidate directions may be 35 / 50 / 15, where 35 is a percentage of plies (122) having a 0-degree direction; 50 is a percentage of plies (122) having a + / -45-degree direction; and 15 is a percentage of plies (122) having a 90-degree direction in the stacking sequence (120).

[0056] These fly percentage envelopes may be percentages for flies in various directions. These percentages may be specific values ​​or ranges of flies, such as 0-degree flies, + / -45-degree flies, and 90-degree flies. In this exemplary example, the + / -45-degree flies are the same percentages as the +45-degree flies and the -45-degree flies. For example, selecting 30% for the + / -45-degree flies means that 15% of the flies are +45 degrees and 15% of the flies are -45 degrees.

[0057] The selection of one ply percentage envelope in the ply percentage envelope (220) results in a set of candidate directions (128) for a stacking sequence (120) sent from user input (208) to the composite part designer (110).

[0058] A composite part designer (110) may perform stress analysis (130) using a set of candidate directions (128) for a stacking sequence (120) to produce a result (210). The result (210) may include data or information regarding at least one of strength, safety limit, bending, lamination efficiency, or other information regarding a composite part (102) having candidate directions (128) in a stacking sequence (120) for a composite part (102).

[0059] The stress analysis (130) is in the form of a laminate analysis (131) in this exemplary example. The laminate analysis (131) can receive structural loads (222; structural loads) to perform an analysis on a set of candidate directions (128) selected by user input (208).

[0060] In this exemplary example, the result (210) may be displayed in a graphical user interface (206) for viewing by a human operator (136). The result (210) may be displayed in a number of different ways. For example, the result (210) may be displayed using a line graph, a bar graph, text, raw simulation data, or other suitable form of display.

[0061] Furthermore, the composite part designer (110) may also display a stacking sequence (120) and other appropriate information in relation to the design (108) of the composite part (102). For example, a visualization of the composite part (102) having a bend (116) may be displayed, and a visualization of the composite part (102) without a bend (116) following the design (108) may be displayed.

[0062] Based on the result (210) displayed in the graphical user interface (206), the human operator (136) may select a new direction (132) to be used as a candidate direction (128) by selecting the ply percentage envelope (220) displayed in the graphical user interface (206). A laminate analysis (131) may be performed on the updated candidate direction. This process may be performed repeatedly until the candidate direction (128) provides the desired result for an acceptable level (114) of bending (116) and the desired strength (124).

[0063] In some exemplary examples, a set of multiple candidate directions (128) may provide an acceptable level (114) of bending (116) and a desired strength (124). In this situation, the set of candidate directions (128) may be selected based on several factors. These factors may include at least one of cost, manufacturing difficulty, maximum strength, minimum bending amount, or other suitable factors.

[0064] For example, a set of several candidate directions (128) can provide both an acceptable level (114) of bending (116) and a desired strength (124). However, some of the set of candidate directions (128) can provide a lower level of bending (116) even if all bending (116) is within the acceptable level (114). That is, the acceptable level (114) of bending (116) may be a threshold for the maximum level of acceptable bending (116).

[0065] As another example, even if all sets of candidate directions (128) provide the desired strength (124), some of the sets of candidate directions (128) may provide a higher level of strength. That is, the desired strength (124) may be a minimum or threshold level of strength for the composite part (102).

[0066] Furthermore, the results (210) displayed on the graphical user interface (206) may include suggestions for ply percentage envelopes (220) that correspond to an acceptable level (114) of bending (116) and a desired strength (124). These suggestions and results (210) may be generated by at least one of a laminate analysis (131) or an artificial intelligence system (138). A human operator (136) may generate a user input (208) to select one of the suggested ply percentage envelopes (220). The selection results in the selected ply percentage envelope being used in the composite part design (150).

[0067] An example of a fly percentage envelope (220) in a graphical user interface (206) is provided as one way for a human operator (136) to select a candidate direction (128) from the analysis. This example is not intended to limit the way in which a candidate direction (128) can be selected. In another exemplary example, instead of selecting one fly percentage envelope from the fly percentage envelope (220), the human operator (136) may input a candidate direction (128) for a stacking sequence (120) in the graphical user interface (206). In another exemplary example, an artificial intelligence system (138) may select a candidate direction (128) without the necessary user input (208) generated by the human operator (136).

[0068] In one exemplary example, there exists one or more technical solutions for overcoming the technical problems associated with manufacturing composite parts having dimensions that deviate from the specifications for the composite parts. In particular, there exists one or more technical solutions for reducing the number of shims installed in objects such as aircraft. Consequently, in the exemplary example, one or more technical solutions may provide a technical effect of reducing the gap between assembled composite parts. In the exemplary example, the number of shims manufactured and installed may be reduced depending on the composite parts having smaller gaps that require shims.

[0069] The computer system (112) may be configured to perform at least one of the steps, actions, or operations described in other exemplary examples using software, hardware, firmware, or a combination thereof. Consequently, the computer system (112) operates as a special-purpose computer system in which the composite part designer (110) of the computer system (112) handles bending (116) as a variable and generates a composite part design that can be used to manufacture a composite part having an acceptable level (114) of bending (116) and a desired strength (124). In particular, the composite part designer (110) converts the computer system (112) into a special-purpose computer system compared to a currently available general computer system that does not have the composite part designer (110).

[0070] In an exemplary example, the use of a composite part designer (110) in a computer system (112) integrates a process into an actual application for managing composite parts, which increases the performance of the computer system (112) in controlling the manufacturing of composite parts in a product management system. That is, the composite part design (150) in the computer system (112) relates to the actual application of the process integrated into the composite part design (150) in the computer system (112) for selecting a direction (118) in a stacking sequence (120) for a ply (122). In this exemplary example, the direction (118) may be selected to form a selected direction (126) in the stacking sequence (120). A stacking sequence (120) having a selected direction (126) can perform composite part design (150), which can be used to manufacture a composite part (102). Manufacturing a composite part (102) using a composite part design (150) can result in a composite part (102) having desired characteristics such as an acceptable level of bending (116) (114) and desired strength (124).

[0071] The example of the composite component environment (100) of FIG. 1 is not intended to imply any physical or structural limitations on the manner in which the exemplary embodiment may be implemented. Other components that are added to or substitute for those exemplified may be used. Some components may be unnecessary. Additionally, blocks are provided to describe some functional components. One or more of these blocks may be combined, divided, or combined and divided into multiple blocks when implemented in the exemplary embodiment.

[0072] Although exemplary examples are described in relation to aircraft (106), other exemplary examples may be applied to other types of platforms. The platform may be, for example, a mobile platform, a stationary platform, a land-based structure, an underwater-based structure, and a space-based structure. In particular, the platform may be a surface vessel, a tank, a troop transport vehicle, a train, a spacecraft, a space station, a satellite, a submarine, a car, a power plant, a bridge, a dam, a house, a manufacturing facility, a building, and other suitable platforms utilizing composite parts.

[0073] FIGS. 3 through 6 are examples of one implementation of a graphical user interface (206) displayed on a display system (202) for a human operator (136). The human operator (136) may interact with the graphical user interface (206) to select a candidate direction (128) and generate user input (208) using an input system (204). Furthermore, these drawings also illustrate various forms in which the result (210) of FIG. 2 may be taken when displayed to the human operator (136). The display of the graphical user interface (206) may be performed by a composite part designer (110).

[0074] First, referring to FIG. 3, an example of a result displayed in a graphical user interface is illustrated according to an exemplary embodiment. In this figure, the graphical user interface (300) is an example of one implementation of a graphical user interface (206) for displaying the result (210) of FIG. 2.

[0075] In this example, the table (302) illustrates parameters for various ply percentage envelopes. As illustrated, the column (304) illustrates various forms of ply percentage envelopes.

[0076] In this exemplary example, the laminae of row (304) are composite parts having layers of plies all having the same orientation, such as 0 degrees. In other rows, the ply percentage envelopes represent the percentage of plies oriented in the order of 0 degrees, + / -45 degrees, and 90 degrees. In this exemplary example, "+ / -" degrees means that the percentage of 45-degree plies is evenly distributed between -45 degrees and +45 degrees.

[0077] As illustrated, column (306) contains values ​​for the elastic modulus in the x direction, and column (308) contains values ​​for the elastic modulus in the y direction. Column (310) is V xy It includes a value for Poisson's ratio, which represents the straining of a laminate having planar XY in the y direction caused by loading in the X direction. As shown in column (312), V yx is the Poisson ratio of deformation in the X direction caused by a load in the Y direction on the XY plane.

[0078] In the table (302), column (314) contains values ​​for the Poisson ratio divided by the elastic modulus in the x-direction. The values ​​in this column are derived from the generalized Hooke's law, which is the governing law for orthotropic materials, including composite materials, in relation to the application of Betti's law. This information is used to determine the elastic properties, shear modulus, G xy Regardless of, it means controlling the strength contribution of the given lamina in a given direction within the context of the laminate.

[0079] Column (316) contains values ​​for layup efficiency. As can be seen, the laminae of row (305) have the best efficiency. Efficiency takes into account factors such as bending, ply direction, ply percentage, and other factors.

[0080] In this exemplary example, a graphical indicator (318) identifies recommended percentage ply envelopes. In this example, the recommended ply percentage envelopes are indicated by a graphical indicator (318) having 37 / 45 / 18; 40 / 40 / 20; and 40 / 45 / 15.

[0081] The bar graph (320) indicates the laminate effectiveness for composite parts having various ply percentage envelopes compared to laminae. The bar graph (320) graphically displays the values ​​of column (316) in the graphical user interface (300).

[0082] Referring to FIG. 4, an example of a result displayed in a graphical user interface is illustrated according to an exemplary embodiment. In this figure, the graphical user interface (400) is an example of one implementation of a graphical user interface (206) for displaying the result (210) of FIG. 2.

[0083] In this example, the line graph (402) illustrates a comparison of the effect of ply percentage on warpage for a composite part such as a panel. As illustrated, the x-axis (403) represents the ply percentage envelope, and the y-axis (401) represents normalized warpage. Normalized warpage is warpage normalized with respect to one of the ply percentage envelopes so that the ply percentage envelopes can be compared with one another. In this exemplary example, ply percentage envelope 37 / 45 / 18 is selected because it is the layup for the composite part with the lowest warpage of the ply percentage envelope.

[0084] In this exemplary example, line (404) is normalized bending. Line (406) is the ratio of 0-degree plies and 90-degree plies, and line (408) represents the percentage of + / -45 degree plies in various ply percentage envelopes. Line (406) illustrates the effect of + / -45 plies on the bending of a composite part.

[0085] A graphic indicator (410) identifies an effective layup range. This range covers the following fly percentage envelopes: 35 / 50 / 15; 37 / 45 / 18; and 40 / 40 / 20. Depending on these fly percentage envelopes, the percentages are in the following order: 0-degree fly; + / -45-degree fly; 90-degree fly.

[0086] As described, the graphic indicator (410) displayed on the graphic user interface (400) indicates a suitable or recommended fly percentage envelope.

[0087] In FIG. 5, an example of a result displayed in a graphical user interface is illustrated according to an exemplary embodiment. In this figure, the graphical user interface (500) is an example of one implementation of a graphical user interface (206) for displaying the result (210) of FIG. 2.

[0088] As illustrated, the line graph (502) represents the lamination efficiency versus Poisson's mismatch ratios. In this example, the x-axis (501) represents the ply percentage envelope, and the y-axis (503) represents the lamination efficiency relative to the Poisson's mismatch ratio.

[0089] In this exemplary example, line (504) of line graph (502) illustrates the lamination efficiency for a composite part using various ply percentage envelopes. Lamination efficiency represents the efficiency of a composite part manufactured using a specific ply percentage envelope. In this exemplary example, the maximum efficiency is considered to be a ply with a 0-degree orientation. This form of the composite part has a management efficiency of 1.0.

[0090] Line (506) of line graph (502) illustrates the Poisson ratio mismatch for various ply percentage envelopes. As can be seen from line graph (502), there is a direct correlation between lamination efficiency and Poisson ratio mismatch. A lower Poisson ratio mismatch results in higher lamination efficiency. For example, it is desirable to have a Poisson ratio of 0.34 for individual plies. This value is chosen to ensure that the plies do not overextend in order to reduce the possibility of premature delamination or despond. A Poisson ratio of less than 0.34 can reduce or eliminate problems such as delamination or disbonding. As the Poisson ratio decreases, the mechanical residual stresses of the composite part decrease.

[0091] In this exemplary example, the graphic indicator (508) identifies recommended percentage envelopes for use in composite parts. In this exemplary example, the graphic indicator (508) recommends the following ply percentage envelopes: 35 / 50 / 15; 37 / 45 / 18; and 40 / 40 / 20. According to these ply percentage envelopes, the percentages are in the following order: 0 degree ply; + / -45 degree ply; 90 degree ply.

[0092] Now, referring to FIG. 6, an example of a result displayed in a graphical user interface is illustrated according to an exemplary embodiment. In this drawing, the graphical user interface (600) is an example of one implementation of a graphical user interface (206) for displaying the result (210) of FIG. 2.

[0093] As illustrated, the line graph (602) represents laminate strength versus warpage. In this example, the x-axis (601) represents the ply percentage envelope, and the y-axis (603) represents the ratio of warpage to laminate efficiency.

[0094] In the line graph (602), the line (604) represents normalized bending. The bending can be normalized using a ply percentage envelope having the smallest amount of bending.

[0095] Line (606) indicates the lamination efficiency. In this example, a composite part with a ply having a 0-degree orientation has a deficiency of 1.0 because the load is distributed along the ply. Other plies, such as + / -45 degrees and 90 degrees, have a lower level of efficiency compared to the 0-degree ply.

[0096] As illustrated, the graphic indicator (608) identifies the recommended ply percentage envelope for use. In this exemplary example, the graphic indicator (608) identifies the following ply percentage envelopes: 35 / 50 / 15; 37 / 45 / 18; and 40 / 40 / 20. According to these ply percentage envelopes, the percentages are in the following order: 0 degree ply; + / -45 degree ply; 90 degree ply.

[0097] Examples of graphic user interfaces in FIGS. 3 through 6 are provided for the purpose of illustrative examples of how the graphic user interface (206) illustrated in block form in FIG. 2 can be implemented. For example, other forms of graphic displays may use other forms of charts. For example, a scatter chart, a waterfall chart, an area chart, or other forms of graphs or charts may be used in addition to or instead of those illustrated in these figures. As another example, a graphic indicator may include at least one of an animation, text, an icon, an image, or other suitable form of graphic indicator that can draw the attention of a human operator to a specific fly percentage or other information displayed in the graphic user interface.

[0098] Furthermore, other percentages of plies may be used in addition to or instead of those depicted. Furthermore, although directions are depicted as 0 degrees, +45 degrees, -45 degrees, and 90 degrees, other directions may be used in addition to or instead of those depicted, such as 30 degrees, 60 degrees, or some other suitable directions. Some plies percentage envelopes may include only two directions rather than three sections, as shown in the exemplary example.

[0099] Next, referring to FIG. 7, an example of a flowchart for a process for managing composite parts is illustrated according to an exemplary 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 on one or more hardware devices in one or more computer systems. For example, the process may be implemented in a part manager (111) of the computer system (112) of FIG. 1. The management of composite parts includes the design of composite parts, the manufacture of composite parts, or at least one of the design and manufacture of composite parts.

[0100] The process begins by identifying an acceptable level of warping for the composite part (Operation 700). Warping of the composite part is a variation of the composite part resulting from manufacturing outside of the composite part's design specifications. In this example, warping is a variable that can be selected to determine the direction of the plies.

[0101] The process selects a direction in the stacking sequence for plies of composite parts that results in a composite part having an acceptable level of bending and desired strength to form the selected direction (Operation 702). Then the process is terminated. The composite part can be manufactured using the selected direction.

[0102] Next, referring to FIG. 8, a flowchart of a process for selecting the orientation of a ply in a composite part is illustrated according to an exemplary embodiment. The process of FIG. 8 is an example of one way in which the operation (702) in FIG. 7 can be implemented.

[0103] The process begins by selecting a candidate orientation in the stacking sequence for the plies (Operation 800). The process performs a stress analysis on the composite part using the candidate orientation in the stacking sequence for the plies (Operation 802). When the stress analysis indicates that the composite part has a strength corresponding to the desired strength for the composite part, the process uses the candidate orientation in the stacking sequence as the selected orientation (Operation 804). The process then terminates.

[0104] Next, referring to FIG. 9, a flowchart of a process for selecting the orientation of a ply in a composite part is illustrated according to an exemplary embodiment. The process of FIG. 9 is an example of one way in which the operation (702) in FIG. 7 can be implemented.

[0105] The process is initiated by selecting a candidate direction in a stacking sequence for the plies (action 900). Action (900) can be performed by receiving user input selecting a candidate direction. For example, user input made to a graphical user interface may be received selecting a set of candidate directions displayed on a graphical user interface. The set of candidate directions may be plies percentage envelopes. Each plies percentage envelope is a set of candidate directions.

[0106] The process performs a stress analysis on a composite part using candidate orientations in the stacking sequence for the plies (operation 902). The process determines whether the composite part with the candidate orientations has a strength that meets the desired strength for the composite part from the results of the stress analysis (operation 904).

[0107] If stress analysis indicates that a composite part with a candidate orientation has strength corresponding to the desired strength for the composite part, the process uses the candidate orientation in the stacking sequence as the selected orientation (step 906). Then the process is terminated.

[0108] Referring back to operation (904), if the stress analysis indicates that the composite part with the candidate direction has a strength that does not meet the desired strength for the composite part, the process then selects a new direction for the candidate direction in the stacking sequence (operation 908). The process returns to operation (902) to perform a stress analysis for the composite part using the candidate direction in the stacking sequence for the plies.

[0109] Referring to FIG. 10, an example of a flowchart of a process for displaying results from analyzing the direction of a fly is illustrated according to an exemplary 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 on one or more hardware devices in one or more computer systems.

[0110] For example, the process can be implemented in a component manager (111) of the computer system (112) of FIG. 1. In particular, the process can be implemented in a composite component designer (110) to display the result (210) on a graphical user interface (206) on the display system (202) of FIG. 2.

[0111] The process begins by identifying a composite part design that includes candidate orientations in the stacking sequence for the plies used to form the composite part (Operation 1000). The process performs a stress analysis using the composite part design (Operation 1002).

[0112] The process receives results from the stress analysis (operation 1004). In this exemplary example, the results may include information selected from at least one of a graphic indicator identifying a level of bending, strength, ratio of directions, percentage of directions, set of candidate directions, or an optimal set of candidate directions or a range of sets of candidate directions.

[0113] The process displays the result in the graphical user interface of the display system (Operation 1006). The process also displays candidate directions in the stacking sequence (Operation 1008).

[0114] A decision is made as to whether user input allowing candidate directions is received (Operation 1010). If user input is received to allow candidate directions, the candidate directions are used as the selected directions in the stacking sequence of the composite part design (Operation 1012). Then the process is terminated.

[0115] Referring back to operation (1010), if no user input is received to allow candidate directions, the process receives user input selecting a new direction as a candidate direction (operation 1014). Then, the process returns to operation (1002).

[0116] Referring to FIG. 11, an example of a flowchart of a process for manufacturing a composite part is illustrated according to an exemplary 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 on one or more hardware devices in one or more computer systems. For example, the process may be implemented in a part manager (111) of the computer system (112) of FIG. 1. Management of the composite part includes at least one of designing the composite part, manufacturing the composite part, or designing and manufacturing the composite part.

[0117] The process begins by identifying a composite part for manufacturing (Operation 1100). The process identifies a composite part design for a composite part that includes a selected orientation for a ply in the stacking sequence of the composite part (Operation 1102). In this exemplary example, the selected orientation is chosen so that the manufactured composite part has an acceptable level of bending and a desired strength.

[0118] The process controls the operation of the ply layup system to lay up the plies using a stacking sequence having a selected orientation to form a composite layup (Operation 1104). This composite layup is the uncured form of the composite part. The process controls the curing system to cure the composite layup to form the composite part (Operation 1106). Then the process is terminated.

[0119] In several illustrated embodiments, flowcharts and block diagrams illustrate the structure, function, and operation of some possible implementations of the device and method in exemplary embodiments. In this regard, each block of the flowchart or block diagram may represent at least one of a module, segment, function, or part of an operation or step. For example, one or more of the blocks may be implemented as program code, hardware, or a combination of program code and hardware. When implemented as hardware, the hardware may take the form of an integrated circuit manufactured or configured to perform one or more operations in the flowchart or block diagram, for example. When implemented as a combination of program code and hardware, the implementation may take the form of firmware. Each block of the flowchart or block diagram may be implemented using a special-purpose hardware system that performs several operations or combinations of special-purpose hardware and program code executed by special-purpose hardware.

[0120] In some alternative implementations of the exemplary embodiments, functions or functions known in the blocks may occur out of the order known in the drawings. For example, in some cases, two blocks drawn in succession may be performed substantially simultaneously, or, depending on the functions included, blocks may be performed in reverse from time to time. Additionally, other blocks may be added in addition to the blocks illustrated in the flowchart or block diagram.

[0121] Referring again to 12, an example of a block diagram of a data processing system is illustrated according to an exemplary embodiment. The data processing system (1200) may be used to implement one or more data processing systems in the computer system (112) of FIG. 1. In this exemplary example, the data processing system (1200) includes a processor unit (1204), a memory (1206), a permanent storage (1208), a communication unit (1210), an input / output (I / O) unit (1212), and a communication framework (1202) that provides communication between a display (1214). In this example, the communication framework (1202) takes the form of a bus system.

[0122] The processor unit (1204) functions to execute instructions for software that can be loaded into memory (1206). The processor unit (1204) includes one or more processors. For example, the processor unit (1204) may be selected from at least one of a multicore processor, a central processing unit (CPU), a graphics processing unit (GPU), a physics processing unit (PPU), a digital signal processor (DSP), a network processor, or some other suitable type of processor.

[0123] Memory (1206) and permanent storage (1208) are examples of storage devices (1216). A storage device is a predetermined number of hardware capable of storing information, such as, for example, without limitation, data, program code in a functional form, or at least one of other suitable information on a temporary base, a permanent base, or both a temporary base and a permanent base. The storage device (1216) may also be referred to as a computer-readable storage device in these exemplary examples. In these examples, the memory (1206) may be, for example, random access memory or a predetermined other suitable volatile or non-volatile storage device. Permanent storage (1208) may take various forms depending on the specific implementation.

[0124] For example, the permanent storage (1208) may include one or more components or devices. For example, the permanent storage (1208) may be a hard drive, a solid-state drive (SSD), flash memory, a rewritable optical disc, a rewritable magnetic tape, or some combination thereof. The medium used by the permanent storage (1208) may also be removable. For example, a removable hard drive may be used for the permanent storage (1208).

[0125] In these exemplary examples, the communication unit (1210) provides communication with another data processing system or device. In these exemplary examples, the communication unit (1210) is a network interface card.

[0126] The input / output unit (1212) allows for the input and output of data with other devices that can be connected to the data processing system (1200). For example, the input / output unit (1212) may provide a connection for user input through at least one of a keyboard, a mouse, or several other suitable input devices. Furthermore, the input / output unit (1212) may send output to a printer. The display (1214) provides a mechanism for displaying information to the user.

[0127] Instructions for at least one of an operating system, application, or program may be located in a storage device (1216) that communicates with a processor unit (1204) through a communication framework (1202). Processes of various embodiments may be performed by the processor unit (1204) using computer-implemented instructions that may be located in memory, such as memory (1206).

[0128] These instructions are referred to as program code, computer-available program code, or computer-readable program code that can be read and executed by a processor in a processor unit (1204). In several embodiments, the program code may be implemented on various physical or computer-readable storage media, such as memory (1206) or permanent storage (1208).

[0129] The program code (1218) is positioned in a functional form on a computer-readable medium (1220) which is optionally removable and can be loaded or transmitted onto a data processing system (1200) for execution by a processor unit (1204). The program code (1218) and the computer-readable medium (1220) form a computer program product (1222) in these exemplary examples. In the exemplary examples, the computer-readable medium (1220) is a computer-readable storage medium (1224).

[0130] In these exemplary examples, the computer-readable storage medium (1224) is a physical or tangible storage device used to store the program code (1218) rather than a medium for propagating or transmitting the program code (1218).

[0131] Alternatively, the program code (1218) may be transmitted to a data processing system (1200) using a computer-readable signal medium. The computer-readable signal medium may be, for example, a propagated data signal containing the program code (1218). For example, the computer-readable signal medium may be at least one of an electromagnetic signal, an optical signal, or some other suitable form of signal. These signals may be transmitted via a connection such as a wireless connection, a fiber optic cable, a coaxial cable, a wire, or some other suitable form of connection.

[0132] The various components illustrated for the data processing system (1200) are not intended to provide structural limitations on how various embodiments may be implemented. In some exemplary examples, one or more of the components may be integrated into other components or form part of other components. For example, memory (1206), or part thereof, may be integrated into the processor unit (1204) in some exemplary examples. Various exemplary embodiments may be implemented in a data processing system that includes components that are added to or substitute for those illustrated for the data processing system (1200). Other components illustrated in FIG. 12 may be changed from the illustrated exemplary examples. Various embodiments may be implemented using a certain hardware device or system capable of executing program code (1218).

[0133] An exemplary embodiment of the present invention may be described in the context of the aircraft manufacturing and service method (1300) illustrated in FIG. 13 and the aircraft (1400) illustrated in FIG. 14. Referring first to FIG. 13, an example of the aircraft manufacturing and service method is illustrated according to an exemplary embodiment. During pre-production, the aircraft manufacturing and service method (1300) may include the specifications and design (1302) and material procurement (1304) of the aircraft (1400) of FIG. 14. During production, the manufacturing of components and subassemblies (1306) and system integration (1308) of the aircraft (1400) of FIG. 14 occur. Subsequently, the aircraft (1400) of FIG. 14 may undergo certification and delivery (1310) to be deployed in service (1312). While the aircraft (1400) of FIG. 14 is in service (1312) by a customer, regular maintenance and inspection (1314) is scheduled, which may include modification, reconfiguration, repair, and other maintenance or inspection.

[0134] Each process of the aircraft manufacturing and service method (1300) may be performed or carried out by a system integrator, a third party, an operator, or a combination thereof. In these examples, the operator may be a customer. For the purposes of this description, the system integrator may include, without limitation, a certain number of aircraft manufacturers and major system subcontractors; the third party may include, without limitation, a certain number of sales companies, subcontractors, and suppliers; and the operator may be an airline, a leasing company, a military organization, a service organization, etc.

[0135] Now, referring to FIG. 14, an example of an aircraft in which an exemplary embodiment may be implemented is illustrated. In this example, the aircraft (1400) may comprise a body (1402; airframe) having a plurality of systems (1404) and an interior (1406; interior) produced by the aircraft manufacturing and service method (1300) of FIG. 13. Examples of systems (1404) include one or more of a propulsion system (1408), an electrical system (1410), a hydraulic system (1412), and an environmental system (1414). A predetermined number of other systems may be included. Although an aerospace example is illustrated, various exemplary embodiments may be applied to other industries, such as the automotive industry.

[0136] The device and method implemented herein may be adopted during at least one of the steps of the aircraft manufacturing and service method (1300) of FIG. 13.

[0137] In one exemplary example, the component or subassembly produced in the component and subassembly manufacturing (1306) of FIG. 13 may be manufactured or produced in a manner similar to the component or subassembly produced while the aircraft (1400) is in service (1312) of FIG. 13. As another example, one or more device embodiments, method embodiments, or combinations thereof may be used during production stages such as the component and subassembly manufacturing (1306) and system integration (1308) of FIG. 13. One or more device embodiments, method embodiments, or combinations thereof may be used while the aircraft (1400) is in service (1312), during maintenance and inspection (1314) of FIG. 13, or both. The use of a number of exemplary embodiments can substantially facilitate the assembly of the aircraft (1400), reduce the cost of the aircraft (1400), or facilitate the assembly of the aircraft (1400) and reduce the cost of the aircraft (1400).

[0138] For example, the use of composite parts manufactured according to exemplary examples can reduce the number of shims required to assemble the aircraft (1400). Consequently, because the need to manufacture and install shims as part of the assembly components to form the aircraft (1400) is reduced, the time and cost required for manufacturing at least one component and subassembly (1306) or system integration (1308) can be reduced.

[0139] A similar reduction in time costs may be caused during maintenance and inspection (1314) by reducing the number of deliberations for which replacement parts need to be fabricated and installed to add parts during at least one of regular maintenance, refurbishment, reconfiguration, modification, or other maintenance.

[0140] Now, referring to FIG. 15, an example of a block diagram of a product management system is illustrated according to an exemplary embodiment. The product management system (1500) is a physical hardware system. In this exemplary example, the product management system (1500) includes at least one of a manufacturing system (1502) or a maintenance system (1504).

[0141] The manufacturing system (1502) is configured to manufacture a product such as the aircraft (1400) of FIG. 14. As illustrated, the manufacturing system (1502) includes manufacturing equipment (1506). The manufacturing equipment (1506) includes at least one of manufacturing equipment (1508) or assembly equipment (1510).

[0142] The manufacturing equipment (1508) is equipment used to manufacture components for parts used to form the aircraft (1400) in FIG. 14. For example, the manufacturing equipment (1508) may include machines and tools. These machines and tools may be at least one of a drill, a hydraulic press, a furnace, a mold, a composite tape laying machine, a vacuum system, a lathe, or other suitable forms of equipment. The manufacturing equipment (1508) may be used to manufacture at least one of metal parts, composite parts, semiconductors, circuits, fasteners, ribs, skin panels, spars, antennas, or other suitable forms of parts.

[0143] Assembly equipment (1510) is equipment used to assemble parts to form the aircraft (1400) in FIG. 14. In particular, assembly equipment (1510) is used to assemble components and parts to form the aircraft (1400) in FIG. 14. Assembly equipment (1510) may also include machines and tools. These machines and tools may be at least one of a robotic arm, a crawler, a faster installation system, a rail-based drilling system, or a robot. Assembly equipment (1510) may be used to assemble parts such as a seat, a horizontal stabilizer, a wing, an engine, an engine housing, a landing gear system, and other parts for the aircraft (1400) in FIG. 14.

[0144] In this exemplary example, the maintenance system (1504; maintenance system) includes maintenance equipment (1512). The maintenance equipment (1512) may include certain equipment necessary to perform maintenance on the aircraft (1400) of FIG. 14. The maintenance equipment (1512) may include tools for performing various operations on parts on the aircraft (1400) of FIG. 14. These operations may include disassembling parts, refurbishing parts, inspecting parts, reworking parts, manufacturing replacement parts, or at least one of other operations for performing maintenance on the aircraft (1400) of FIG. 14. These operations may be for regular maintenance, inspection, upgrade, refurbishing, or other forms of maintenance operations.

[0145] In exemplary examples, the maintenance equipment (1512) may include an ultrasonic inspection device, an X-ray imaging system, vision systems, a drill, a crawler, and other suitable devices. In some cases, the maintenance equipment (1512) may include manufacturing equipment (1508), assembly equipment (1510), or manufacturing equipment (1508) for producing and assembling parts required for maintenance.

[0146] The product management system (1500) also includes a control system (1514). The control system (1514) is a hardware system and may include software or other forms of components. The control system (1514) is configured to control the operation of at least one of the manufacturing system (1502) or the maintenance system (1504). In particular, the control system (1514) may control the operation of at least one of the manufacturing equipment (1508), the assembly equipment (1510), or the maintenance equipment (1512).

[0147] In this exemplary example, the control system (1514) may include the controller (140) of FIG. 1. In this exemplary example, the controller (140) may receive a composite part design (150) from a composite part designer (110) to manufacture a composite part (102) and control the operation of the manufacturing equipment (1508). In this exemplary example, the manufacturing equipment (1508) may include a fly layup system (144) and a curing system (148).

[0148] The hardware of the control system (1514) may be implemented using hardware that may include computers, circuits, networks, and other forms of equipment. The control may take the form of direct control of the manufacturing equipment (1506). For example, robots, computer-controlled machines, and other equipment may be controlled by the control system (1514). In other exemplary examples, the control system (1514) may manage actions performed by a human operator (1516) in manufacturing or maintaining the aircraft (1400). For example, the control system (1514) may perform tasks, provide commands, display models, or perform other actions to manage actions performed by the human operator (1516). As illustrated in these exemplary examples, the controller (140) of FIG. 1 may be implemented in the control system (1514) to manage at least one of the manufacturing or maintenance of the aircraft (1400) of FIG. 14.

[0149] In several exemplary examples, a human operator (1516) may operate or interact with at least one of manufacturing equipment (1506), maintenance equipment (1512), or control system (1514). This interaction may be caused to manufacture an aircraft (1400) in FIG. 14.

[0150] Of course, the product management system (1500) may be configured to manage products other than the aircraft (1400) in FIG. 14. Although the product management system (1500) has been described in relation to manufacturing in the aerospace industry, the product management system (1500) may be configured to manage products for other industries. For example, the product management system (1500) may be configured to manufacture products for the automotive industry and other suitable industries.

[0151] Accordingly, exemplary embodiments provide a method, apparatus, and system for managing a composite part. An acceptable level of warping is identified for the composite part. Warping for the composite part is a variation of the composite part resulting from manufacturing the composite part outside of the design specifications for the composite part. In a lamination sequence for the plies of the composite part, an orientation is selected to form a selected orientation in the lamination sequence, and manufacturing the composite part using the selected orientation in the lamination sequence results in a composite part having an acceptable level of warping and a desired strength.

[0152] In an exemplary example, there exists one or more technical solutions for overcoming the technical problems associated with manufacturing composite parts having dimensions that deviate from the specifications for the composite parts. In particular, in an exemplary example, there exists one or more technical solutions for reducing the number of shims installed in objects such as aircraft. Consequently, in an exemplary example, one or more technical solutions may provide a technical effect of reducing the gap between the assembled composite parts. In an exemplary example, the number of shims manufactured and installed may be reduced depending on the composite parts having smaller gaps that require shims.

[0153] The description of various exemplary embodiments is provided for illustrative and illustrative purposes only and is not intended to encompass or limit the embodiments in the disclosed form. Various exemplary embodiments describe components that perform an action or operation. In exemplary embodiments, the components may be configured to perform the described action or operation. For example, the components may have a configuration or design for a structure that provides a component capable of performing the action or operation described in the exemplary embodiments as performed by the components.

[0154] Furthermore, the present invention comprises an embodiment according to the following provisions:

[0155] Clause 1. A method for manufacturing a composite part (104), wherein the method is:

[0156] A step of identifying an acceptable level (114) of bending (116) of a composite part (104), wherein the bending (116) of the composite part (104) is a change in the composite part (104) resulting from manufacturing the composite part (104) as deviating from the design specifications (119) for the composite part (104); and

[0157] A method for manufacturing a composite part, characterized by including the step of selecting a direction (118) in a lamination sequence (120) for a ply (122) of a composite part (104) to form a direction (126) selected in a lamination sequence (120) such that manufacturing the composite part (104) using a direction (126) selected in a lamination sequence (120) results in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124).

[0158] Clause 2. A step of selecting a direction (118) in the lamination sequence (120) for a ply (122) of a composite part (104) to form a direction (126) selected in the lamination sequence (120) such that manufacturing a composite part (104) using a direction (126) selected in the lamination sequence (120) results in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124):

[0159] A step of selecting a candidate direction (128) in a stacking sequence (120) for a fly (122);

[0160] A step of performing a stress analysis (130) on a composite part (104) using a candidate direction (128) in a stacking sequence (120) for a ply (122); and

[0161] The method is characterized by including the step of using a candidate direction (128) in a stacking sequence (120) as a selected direction (126) when a stress analysis (130) indicates that the composite part (104) has a desired strength (124) for the composite part (104).

[0162] Clause 3. A step of selecting a direction (118) in the lamination sequence (120) for a ply (122) of a composite part (104) to form a direction (126) selected in the lamination sequence (120) so that manufacturing a composite part (104) using a direction (126) selected in the lamination sequence (120) results in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124):

[0163] A step of selecting a new direction (132) for the candidate direction (128) in the stacking sequence (120) when the stress analysis (130) for the composite part (104) according to the candidate direction (128) indicates that the composite part (104) does not have the desired strength (124);

[0164] A step of performing a stress analysis (130) on a composite part (104) using a candidate direction (128) in a stacking sequence (120) for a ply (122); and

[0165] The method further comprises the step of repeating the step of selecting a new direction (132) for the composite part (104) using a candidate direction (128) in the stacking sequence (120) for the plies (122) and the step of performing stress analysis (130) until the desired strength (124) is provided to the composite part (104).

[0166] Clause 4. The method of Clause 2 is characterized by including a simulation of one set of structural loads (222) applied to a composite part (104) in the stress analysis (130).

[0167] Clause 5. A step of selecting a candidate direction (128) in a stacking sequence (120) for a fly (122) in the method of Clause 2:

[0168] The method includes the step of receiving a user input (208) consisting of a graphic user interface (206) in a display system (202), and is characterized by the user input (208) selecting a set of candidate directions (128) displayed on the graphic user interface (206).

[0169] Clause 6. The method of any one of the above clauses further includes the step of manufacturing a composite part (104) in a product management system using a selected direction (126).

[0170] Clause 7. A step of controlling a ply layup system (144) to lay up a ply (122) for a composite part (104) using a selected direction (126) to form a composite layup (146) in the method of any one of the above clauses; and

[0171] It is characterized by further including the step of curing the composite layup (146) to form the composite part (104).

[0172] Clause 8. By the method of any one of the above clauses, the selected direction (126) is characterized by including a 90-degree fly (122), a +45-degree fly (122), a -45-degree fly (122), and a 0-degree fly (122).

[0173] Clause 9. By the method of any one of the above clauses, the selected direction (126) is characterized by comprising at least 10% of the plies (122) having a 90-degree direction.

[0174] Clause 10. By the method of any one of the above clauses, the selected direction (126) is characterized by comprising at least 12.5% ​​to 20% of the plies (122) having a 90-degree direction.

[0175] Clause 11. By the method of any one of the above clauses, the selected direction (126) is characterized by comprising 40% to 50% of the ply (122) having a 45-degree direction.

[0176] Clause 12. By the method of any one of the above clauses, the composite part (104) is characterized as being a skin panel, fairing, engine housing, stringer, door, wing, and panel.

[0177] Clause 13. Computer system (112); and

[0178] The computer system (112) is configured to have a composite part design machine (110); and the composite part design machine (110) is:

[0179] Identify an allowable level (114) of bending (116) for a composite part (104), wherein the bending (116) for the composite part (104) is a change in the composite part (104) resulting from manufacturing outside the design specifications (119) for the composite part (104); and

[0180] A composite part system (115) characterized by being configured to select a direction (118) in the lamination sequence (120) for a ply (122) of a composite part (104) to form a direction (126) selected in the lamination sequence (120) so that manufacturing a composite part (104) using a direction (126) selected in the lamination sequence (120) results in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124).

[0181] Clause 14. In selecting a direction (118) in a lamination sequence (120) for a ply (122) of a composite part (104) to form a direction (126) selected in a lamination sequence (120) such that manufacturing a composite part (104) using a direction (126) selected in a lamination sequence (120) results in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124), the composite part designer (110):

[0182] Select a candidate direction (128) from the stacking sequence (120) for the fly (122);

[0183] A stress analysis (130) for a composite part (104) is performed using a candidate direction (128) in a stacking sequence (120) for a ply (122);

[0184] It is characterized by being configured to use a candidate direction (128) in the stacking sequence (120) as a selected direction (126) when the stress analysis (130) indicates that the composite part (104) has a desired strength (124) for the composite part (104).

[0185] Clause 15. In selecting a direction (118) in a lamination sequence (120) for a ply (122) of a composite part (104) to form a direction (126) selected in a lamination sequence (120) such that manufacturing a composite part (104) using a direction (126) selected in a lamination sequence (120) results in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124), the composite part designer (110):

[0186] When a stress analysis (130) of a composite part (104) according to a candidate direction (128) indicates that the composite part (104) does not have the desired strength (124), a new direction (132) for the candidate direction (128) is selected in the stacking sequence (120);

[0187] A stress analysis (130) for a composite part (104) is performed using a candidate direction (128) in a stacking sequence (120) for a ply (122);

[0188] The method is further configured to repeat the steps of selecting a new direction (132) for the composite part (104) using a candidate direction (128) in the stacking sequence (120) for the plies (122) and performing a stress analysis (130) until the desired strength (124) is provided to the composite part (104).

[0189] Clause 16. The composite part system (115) of Clause 14 is characterized by including a stress analysis (130) that includes a simulation of one set of structural loads (222) applied to the composite part (104).

[0190] Clause 17. In selecting a candidate direction (128) in a stacking sequence (120) for a ply (122) in the composite part system (115) of Clause 14, the composite part designer (110) is characterized by receiving a user input (208) consisting of a graphic user interface (206) in a display system (202), and selecting a set of candidate directions (128) displayed on the graphic user interface (206) for the user input (208).

[0191] Clause 18. A composite component system (115) of any one of Clauses 13 to 17,

[0192] The computer system (112) is further configured to include a controller (140), and the controller (140) is configured to control the manufacturing of a composite part (104) in a product management system using a selected direction (126).

[0193] Clause 19. A composite material component system (115) of any one of Clauses 13 to 18,

[0194] The computer system (112) is further configured to include a controller (140), wherein the controller (140) controls a ply layup system (144) to lay up a ply (122) for a composite part (104) using a selected direction (126) to form a composite layup (146), and controls a curing system (148) to cure the composite layup (146) to form a composite part (104).

[0195] Clause 20. A composite material component system (115) of any one of Clauses 13 to 19, characterized in that the selected direction (126) includes a 90-degree ply (122), a +45-degree ply (122), a -45-degree ply (122), and a 0-degree ply (122).

[0196] Clause 21. A composite material component system (115) of any one of Clauses 13 to 20, characterized in that the selected direction (126) comprises at least 10% of a ply (122) having a 90-degree direction.

[0197] Clause 22. A composite component system (115) of any one of Clauses 13 to 21, characterized in that the selected direction (126) comprises at least 12.5% ​​to 20% of a ply (122) having a 90-degree direction.

[0198] Clause 23. A composite component system (115) of any one of Clauses 13 to 22, characterized in that the selected direction (126) comprises 40% to 50% of a ply (122) having a 45-degree direction.

[0199] Clause 24. A composite part system (115) of any one of Clauses 13 to 23, characterized in that the composite part (104) is a skin panel, fairing, engine housing, stringer, door, wing, and panel.

[0200] Clause 25. Manufacturing equipment (1508); and

[0201] A product management system (1500) characterized by comprising: a controller (140) communicating with manufacturing equipment (1508), wherein the controller (140) is configured to control the manufacturing equipment (1508) to manufacture a composite part (104) using a part design having a direction (126) selected in a stacking sequence (120) for a ply (122) of a composite part (104), thereby resulting in a composite part (104) having a bend (116) having an allowable level (114) of bend (116) and a desired strength (124), and a change in the composite part (104) when the bend (116) deviates from the design specifications (119) for the composite part (104).

[0202] Clause 26. The product management system (1500) of Clause 25 is further configured to include a composite part designer (110), wherein the composite part designer (110) identifies an acceptable level (114) of bending (116) for a composite part (104); and wherein the composite part (104) is manufactured using a selected direction (126) in a lamination sequence (120) to form a selected direction (126) for a ply (122) of a composite part (104) such that manufacturing the composite part (104) using the selected direction (126) results in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124).

[0203] Clause 27. A product management system of any one of Clauses 25 to 26, wherein the manufacturing equipment (1508) is:

[0204] A fly layup system (144) for laying up a fly (122) for a composite part (104) using a selected direction (126) to form a composite layup (146) under the control of a controller (140); and

[0205] It is characterized by being configured with a curing system (148) that cures a composite layup (146) to form a composite part (104) under the control of a controller (140).

[0206] Many changes and variations will be apparent to those skilled in the art. Furthermore, various exemplary embodiments may provide various features compared with other preferred embodiments. Selected embodiments or embodiments are chosen and described to best illustrate the principles and practical applications of the embodiments and to enable those skilled in the art to understand the disclosure of various embodiments having various modifications suitable for the specific use considered.

Claims

Claim 1 A method for managing a composite part (104), wherein the method comprises: a step of identifying an acceptable level (114) of bending (116) for the composite part (104), wherein the bending (116) for the composite part (104) is a change in the composite part (104) resulting from manufacturing deviating from the design specifications (119) for the composite part (104); a step of selecting a candidate direction (128) in a stacking sequence (120) for a ply (122) of the composite part (104) to form a direction (126) selected in the stacking sequence (120) such that manufacturing the composite part (104) using a direction (126) selected in the stacking sequence (120) results in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124); and a candidate in the stacking sequence (120) for the ply (122) A step of performing a stress analysis (130) on a composite part (104) using a direction (128); a step of using a candidate direction (128) as a selected direction (126) in a stacking sequence (120) when the stress analysis (130) indicates that the composite part (104) has a desired strength (124) for the composite part (104); a step of selecting a new direction (132) for the candidate direction (128) in a stacking sequence (120) when the stress analysis (130) on the composite part (104) according to the candidate direction (128) indicates that the composite part (104) does not have a desired strength (124); a step of performing a stress analysis (130) on a composite part (104) using a new direction (132) for the candidate direction (128) in a stacking sequence (120) for the plies (122). A method for managing a composite part, characterized by including the step of selecting a new direction (132) until a desired strength (124) exists in the composite part (104), and the step of performing a stress analysis (130) on the composite part (104) using the new direction (132) for the candidate direction (128) in the stacking sequence (120) for the plies (122). Claim 2 delete Claim 3 delete Claim 4 A method for managing a composite part according to claim 1, characterized in that the stress analysis (130) includes the simulation of a set of structural loads (222) applied to the composite part (104). Claim 5 A method for managing a composite part according to claim 1, wherein the step of selecting a candidate direction (128) in a stacking sequence (120) for a ply (122) comprises: receiving a user input (208) consisting of a graphical user interface (206) in a display system (202), and wherein the user input (208) selects a set of candidate directions (128) displayed on the graphical user interface (206). Claim 6 A method for managing a composite part, characterized in that, in claim 1, it further includes the step of manufacturing a composite part (104) in a product management system using a selected direction (126). Claim 7 A method for managing a composite part, further comprising: a step of controlling a ply layup system (144) to lay up a ply (122) for a composite part (104) using a selected direction (126) to form a composite layup (146); and a step of curing the composite layup (146) to form a composite part (104). Claim 8 A method for managing a composite part according to claim 1, characterized in that the selected direction (126) includes a 90-degree ply (122), a +45-degree ply (122), a -45-degree ply (122), and a 0-degree ply (122). Claim 9 A method for managing a composite part according to claim 1, characterized in that the selected direction (126) comprises at least 10% of a ply (122) having a 90-degree direction. Claim 10 A method for managing a composite part according to claim 1, characterized in that the selected direction (126) comprises at least 12.5% ​​to 20% of a ply (122) having a 90-degree direction. Claim 11 A method for managing a composite part according to claim 1, characterized in that the selected direction (126) comprises 40% to 50% of a ply (122) having a 45-degree direction. Claim 12 A method for managing a composite part according to claim 1, characterized in that the composite part (104) is a skin panel, fairing, engine housing, stringer, door, wing, and panel. Claim 13 A system (115) for managing composite parts, comprising: a computer system (112), wherein the computer system (112) comprises a composite part design device (110) configured to perform the method of any one of claims 1 and 4 to 12. Claim 14 As a product management system (1500): manufacturing equipment (1508); as a controller (140) communicating with the manufacturing equipment (1508), the controller (140) is configured to control the manufacturing equipment (1508) to manufacture a composite part (104) using a part design having a direction (126) selected in a stacking sequence (120) for a ply (122) of a composite part (104), thereby resulting in a composite part (104) having a bend (116) having an acceptable level (114) of bend (116) and a desired strength (124), wherein the bend (116) is a change in the composite part (104) when manufactured deviating from the design specifications (119) for the composite part (104); and composite part design device (110); wherein the composite part design device (110) identifies an acceptable level (114) of bending (116) for a composite part (104); selects a candidate direction (128) in a stacking sequence (120) to form a selected direction (126) for a ply (122) of a composite part (104) such that manufacturing the composite part (104) using a selected direction (126) in a stacking sequence (120) results in a composite part (104) having an acceptable level (114) of bending (116) and a desired strength (124); and performs a stress analysis (130) for the composite part (104) using the candidate direction (128) in the stacking sequence (120) for the ply (122); When the stress analysis (130) indicates that the composite part (104) has the desired strength (124) for the composite part (104), the candidate direction (128) in the stacking sequence (120) is used as the selected direction (126); when the stress analysis (130) for the composite part (104) according to the candidate direction (128) indicates that the composite part (104) does not have the desired strength (124), a new direction (132) for the candidate direction (128) in the stacking sequence (120) is selected;A product management system (1500) characterized by being configured to perform a stress analysis (130) on a composite part (104) using a new direction (132) for a candidate direction (128) in a stacking sequence (120) for a ply (122); and to repeat selecting a new direction (132) for the composite part (104) and performing a stress analysis (130) using a new direction (132) for a candidate direction (128) in a stacking sequence (120) for a ply (122) until a desired strength (124) exists in the composite part (104). Claim 15 delete

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