Automated Ceramic Matrix Composite Ply Handling and Inspection
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Solution Overview
Problem
The hand-layup process for manufacturing ceramic matrix composite structures is plagued by variability in quality and consistency, requiring manual inspection and rework, and is time-intensive and labor costly.
Innovation Solution
A fully automated system and method for pick, peel, place, form, compact, and inspect ceramic matrix composite materials, utilizing a pick and place apparatus, peeling apparatus, and inspecting apparatus to ensure consistency and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a hand-layup process is used to manufacture ceramic matrix composite structures, then the process can be performed with simple equipment, but the quality consistency and repeatability deteriorate
Solution Approach 1:
The patent replaces manual mechanical operations (hand-layup, manual inspection, manual rework) with an automated system that uses robotic pick-and-place mechanisms, automated compaction rollers, and optical inspection systems. This substitution eliminates human variability while maintaining operational simplicity through integrated automation.
Solution Approach 2:
The system incorporates self-inspection and self-correction capabilities where the automated inspection apparatus detects defects and triggers automatic rework operations without human intervention. The system serves itself by automatically identifying and correcting quality issues, ensuring consistent manufacturing precision.
2Device complexity
If a hand-layup process is used to manufacture ceramic matrix composite structures, then the equipment required is simple, but the production time increases
Solution Approach 1:
The automated system performs pick, peel, place, form, compact, and inspect operations in continuous sequence without interruption. The robotic arm continuously picks plies, the peeling apparatus continuously removes backing layers, and the compaction roller continuously applies pressure, eliminating idle time between operations that occurs in manual processes.
Solution Approach 2:
The system performs preliminary actions such as pre-positioning plies on the forming surface, pre-removing backing layers before placement, and pre-applying compaction pressure immediately upon ply placement. These preliminary actions are integrated into the automated workflow to eliminate delays and reduce overall production time.
3Device complexity
If a hand-layup process is used to manufacture ceramic matrix composite structures, then the process setup is simple, but labor costs increase
Solution Approach 1:
The automated system performs multiple functions (picking, peeling, placing, forming, compacting, and inspecting) using a single integrated robotic platform. This multi-functional system replaces multiple specialized manual operations, reducing the need for skilled technicians while maintaining ease of manufacture through programmable automation.
Solution Approach 2:
The system substitutes human labor with automated mechanical and optical systems that perform all manufacturing operations. The robotic arm, peeling apparatus, compaction roller, and inspection system work together to eliminate the need for skilled technicians, thereby reducing labor costs while keeping the overall process setup relatively simple.
4Reliability
If manual inspection and rework are performed, then quality issues can be detected, but the cycle time increases
Solution Approach 1:
The optical inspection system performs quality detection immediately after each ply is placed and compacted, before moving to the next operation. This preliminary inspection catches defects early in the process, allowing for immediate automatic rework without delaying subsequent operations, thereby maintaining both quality detection and efficient cycle time.
Solution Approach 2:
The inspection and rework operations are integrated into the continuous automated workflow. The system continuously inspects each ply and automatically performs rework when defects are detected, without breaking the production flow. This continuous operation eliminates the time loss associated with manual inspection and rework cycles.
Data Source
AI summary
A method for manufacturing a ceramic matrix composite structure includes steps of: (1) picking up a ply of a ceramic matrix composite material at a staging location; (2) removing a bottom backing layer from the ply at a backing-removal location; (3) placing the ply on a forming surface at a forming location after removing the bottom backing layer; (4) compacting the ply on the forming surface; (5) removing a top backing layer from the ply after compacting the ply on the forming surface; and (6) inspecting the ply after compacting the ply on the forming surface.