Automated Fiber Placement Process Planning for Defect Minimization
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Solution Overview
Problem
Automated Fiber Placement (AFP) manufacturing in composite structures faces challenges with defects such as gaps, overlaps, angle deviation, and steering, which affect the quality and strength of the final laminate, especially on complex surfaces, due to interactions between tool surface geometry and fiber tows, and current process planning is manual, time-consuming, and prone to local optimums.
Innovation Solution
The development of Computer-Aided Process Planning (CAPP) software for AFP, which uses surrogate-based methods to optimize starting points, layup strategies, and tows per course, employing iterative optimization and defect scoring to minimize defect stacking through the thickness of the laminate, and incorporates surrogate modeling for rapid optimization of ply angles and layup strategies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual process planning is used for AFP manufacturing, then flexibility in handling complex surfaces is maintained, but time consumption and tendency to local optimums increase
Solution Approach 1:
The patent replaces manual mechanical process planning with an automated computer-based optimization system that uses algorithms to determine AFP parameters. The system automatically processes complex surface geometries and generates optimized layup strategies without manual intervention, resolving the contradiction between manual flexibility and time consumption.
Solution Approach 2:
The optimization system performs self-service by automatically evaluating multiple starting points and layup strategies, selecting the optimal configuration without requiring human expertise. The system serves itself by using built-in algorithms to navigate complex surfaces and generate defect-minimized paths autonomously.
2Manufacturing precision
If multiple starting points and layup strategies are evaluated to minimize defect stacking, then laminate quality improves, but computational complexity increases
Solution Approach 1:
The system performs preliminary evaluation of multiple starting points and layup strategies before final manufacturing. By pre-assessing defect potential across various configurations and selecting the optimal path in advance, the system ensures high laminate quality without requiring complex real-time computations during manufacturing.
Solution Approach 2:
The optimization process segments the evaluation into distinct stages: generating multiple candidate paths, evaluating each for defect potential, and selecting the optimal configuration. This segmentation manages computational complexity by breaking down the complex optimization problem into manageable sequential steps.
3Reliability
If optimization of starting points and layup strategies is performed, then defect occurrences are reduced, but processing time increases
Solution Approach 1:
The patent replaces time-consuming manual trial-and-error optimization with automated computational algorithms that rapidly evaluate multiple configurations. The computer-based system processes optimization calculations much faster than manual methods, achieving defect reduction without proportionally increasing processing time.
4Measurement precision
If comprehensive defect analysis is performed through laminate thickness, then defect stacking is identified, but measurement and evaluation complexity increases
Solution Approach 1:
The system extracts and evaluates each ply's defect characteristics separately, then combines these evaluations to assess cumulative defect stacking through the laminate thickness. By taking out and analyzing individual ply defects independently before aggregation, the system achieves comprehensive defect detection without overwhelming evaluation complexity.
Data Source
AI summary
Automated Fiber Placement (AFP) manufacturing with carbon fiber composites is increasingly used for complex and/or large structures. Computer-Aided Process Planning (CAPP) software supports process planning for AFP manufacturing to assist identifying optimal starting point location and layup strategy for each laminate ply. Ply optimization functions on measurement and scoring of geometry-based defects (gaps, overlaps, angle deviation, and steering). CAPP mitigates defect stacking through the laminate thickness by generating best ply scenarios and comparing ply defects to identify regions where defects are stacking up. Stacked defects frequency and severity are described using a disclosed scoring system, so process planners can craft fiber paths that mitigate the number and compounding effect of laminate geometry-based defects. Defects can be minimized in the process planning phase by optimizing the selection of input parameters such as starting points, layup strategies, and tows per course, using surrogate-based methods.