Adaptive Compaction Path Planning for Composite Ply Rollout
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Solution Overview
Problem
Current compaction of ceramic matrix composite plies on layup tools is a manual, time-intensive process that results in variable quality and inconsistencies due to the use of compaction roller hand tools, sweeps, hand pressure, and vacuum bags.
Innovation Solution
The development of adaptive path plans for automated compaction rollers, which involve selecting a working path plan data file, accessing compaction history data to identify inconsistencies, and generating path adaptations to form an adapted path plan for optimized compaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual compaction operations are performed using compaction roller hand tools, then the process can be executed with simple equipment, but the compaction quality becomes variable and inconsistent
Solution Approach 1:
The patent replaces manual mechanical compaction operations with an automated robotic system that uses imaging technology to detect inconsistencies and automatically adjusts compaction parameters. The robotic compaction head with force sensors and imaging devices substitutes human operators and hand tools, eliminating variability while maintaining manufacturing capability.
Solution Approach 2:
The system implements real-time feedback through imaging technology that captures images of the composite ply during compaction. The system analyzes these images to detect inconsistencies such as wrinkles, voids, or improper layup, and automatically adjusts compaction forces and roller paths based on this feedback to ensure consistent quality.
2Manufacturing precision
If manual compaction operations are performed by skilled technicians, then the process can achieve certain quality levels, but the operation becomes time intensive and requires rework
Solution Approach 1:
The automated system performs self-inspection through integrated imaging technology and self-correction by automatically adjusting compaction parameters based on detected inconsistencies. The robotic system monitors its own performance in real-time and makes corrections without human intervention, eliminating the need for separate inspection and rework operations that consume time in manual processes.
Solution Approach 2:
The robotic compaction system operates continuously without interruption for inspection or rework. The imaging and compaction occur simultaneously in an integrated process flow, eliminating the sequential steps of manual compaction followed by inspection and potential rework, thereby reducing total cycle time while maintaining quality.
3Manufacturing precision
If automated compaction rollers with path adaptation are implemented, then compaction consistency improves, but the device complexity increases
Solution Approach 1:
The robotic compaction head is designed as a multi-functional device that integrates imaging sensors, force sensors, compaction rollers, and control systems into a single unit. This universal device performs both inspection and compaction functions simultaneously, reducing the need for separate equipment and minimizing overall system complexity despite the advanced capabilities required for consistent compaction.
Data Source
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AI summary
Methods for developing a path plan for rollout compaction of a composite ply during composite manufacturing include: selecting a working path plan data file from a working path plan repository, running a path adaptation application program to access compaction history data files in a compaction history repository relating to the working path plan data file and to identify an inconsistency in the compaction history data files that is not resolved in the working path plan data file and generating a path adaptation for the working path plan data file based on the inconsistency that is not resolved to form an adapted path plan data file defining an adapted path plan that includes the path adaptation. Additional methods include using path plans for compaction on the layup tool, capturing image data and processing the image data to build and/or add to the compaction history data file.