AR Ply Placement Guidance for Composite Assembly Precision
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Solution Overview
Problem
Conventional methods for assembling composite structures, such as composite laminates, face challenges with complex geometries, precision in ply placement, and the need for expensive laser projection systems, as well as cumbersome prototype fixtures for bonded assemblies, which are time-consuming and prone to design changes and wear.
Innovation Solution
The implementation of an augmented reality (AR) assisted manufacturing method using AR viewing devices to guide operators through precise placement and orientation of layers, plies, and fasteners, eliminating the need for expensive laser systems and prototype fixtures by providing holographic overlays and interactive menus for assembly sequences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser projection systems are used for ply placement guidance, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses augmented reality headsets to create a virtual copy of the final composite structure overlayed onto the physical mold. This virtual model provides ply placement guidance, splice locations, and assembly instructions without requiring physical laser projection equipment. The AR interface copies the essential guidance information into a wearable display format that operators can view hands-free during assembly.
Solution Approach 2:
The patent replaces the mechanical laser projection system with an electronic augmented reality display system. Instead of using external laser projectors to display guidance information on the mold surface, the system uses AR headsets with electronic displays that overlay virtual information directly into the operator's field of view, eliminating the need for complex optical projection equipment.
2Device complexity
If manual measurement and templates are used for ply placement, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The AR system creates a virtual copy of the precise ply placement pattern directly in the operator's field of view. Instead of using physical templates that require manual alignment and interpretation, the virtual overlay precisely marks ply edges, splice locations, and orientation guides, providing high precision through digital rather than physical reference copies.
3Manufacturing precision
If prototype fixtures are used for bonded assemblies, then manufacturing precision is improved, but loss of time and storage space increase
Solution Approach 1:
The patent creates a virtual copy of the fixture guidance system through AR displays. Instead of manufacturing physical prototype fixtures that take weeks to design and build, the system projects virtual alignment guides, fastener locations, and assembly sequences into the operator's field of view. This virtual fixture provides the same precision benefits without the time-consuming physical fabrication process.
Solution Approach 2:
The patent replaces physical prototype fixtures with an augmented reality guidance system. The AR headset displays virtual references for fastener locations, bonding surfaces, and assembly sequences, eliminating the need for physical fixtures while maintaining assembly precision. This substitution removes the time required for fixture design, manufacturing, and storage.
4Productivity
If multiple operators use laser projection systems, then productivity is improved through parallel assembly, but the overall pace is limited by the slowest operator
Solution Approach 1:
The AR system creates identical virtual guidance copies for multiple operators simultaneously. Each operator receives the same high-quality visual instructions for ply placement, splice locations, and assembly sequences, ensuring consistent performance across all operators regardless of experience level. This eliminates the skill dependency that limits parallel assembly productivity.
Data Source
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AI summary
A method for augmented reality (AR) assisted ply placement for assembly and manufacture of composite structures is disclosed. In embodiments, the method includes providing AR viewing devices (402) to individuals directly involved in the assembly of the composite structure and loading an assembly sequence for the particular composite structure. For each step of the assembly structure, the AR viewing devices display virtual representations of each ply or layer in the order of assembly, indicating the proper positioning and orientation of each ply over adjacent previously installed layers or plies. The AR viewing devices display any operator alerts associated with assembly steps and accept control input from the operators indicating completion of an assembly step. The AR devices capture or record the completion of each step and generate a record of the full assembly sequence based on each completed step for quality assurance.