CMC Component Weight Control via AFP Feedback
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Solution Overview
Problem
The variation in weight and bulk of prepreg material between different bobbins and the lack of compaction during automated fibre placement (AFP) processes lead to inconsistencies in the thickness of ceramic matrix composite (CMC) components before and after curing.
Innovation Solution
A method is developed to minimize bulk and weight variation by determining target weights for each manufacturing stage, calculating weight differences, and selectively disposing parts with minimal weight differences onto the CMC component, ensuring consistent weight and bulk before curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated fibre placement (AFP) process is used to layer prepreg plies, then manufacturing efficiency is improved, but weight and bulk variation between components increases
Solution Approach 1:
The patent implements a feedback mechanism where the actual weight of the preform is measured after each AFP cycle and compared against a target weight. The system automatically calculates the weight difference and uses this information to determine whether additional prepreg plies need to be added or removed, thereby maintaining consistent weight and bulk across multiple components while preserving the automated manufacturing process.
Solution Approach 2:
The patent changes the control parameter from purely process-based (AFP machine settings) to weight-based control. By measuring the actual weight of the preform and using this as the controlling parameter, the system can compensate for variations in prepreg material density and compaction, ensuring consistent final component weight and bulk despite variations in the automated laying process.
2Ease of manufacture
If prepreg material is layered without full compaction, then manufacturing simplicity is maintained, but bulk variation between preforms increases
Solution Approach 1:
The system measures the actual bulk or thickness of the preform after AFP and uses this information as feedback to determine whether additional compaction or material adjustment is needed. This allows the simple AFP process to achieve consistent bulk by automatically compensating for variations through weight-based control and subsequent adjustments.
Solution Approach 2:
The patent performs preliminary weighing of the preform after each AFP cycle before the curing process. This preliminary action allows the system to identify and correct bulk variations early in the manufacturing process, ensuring consistent final component properties without requiring complex compaction equipment or multi-stage manufacturing processes.
3Manufacturing precision
If target weight control is implemented at each manufacturing stage, then weight consistency is improved, but process complexity increases
Solution Approach 1:
The patent uses a feedback control system that automatically measures preform weight, compares it to the target weight, and determines the necessary adjustments. This automated feedback mechanism maintains weight consistency without requiring complex manual intervention or sophisticated equipment, as the system uses simple weighing and computational logic to control the manufacturing process.
Data Source
AI summary
A method of manufacturing a CMC component includes performing a plurality of manufacturing stages. Each manufacturing stage includes layering a ply on a mandrel if a current manufacturing stage is a first manufacturing stage; layering a ply on the CMC component formed in a preceding manufacturing stage if the current manufacturing stage is subsequent to the first manufacturing stage; determining an intermediate weight of the CMC component after layering the ply in the current manufacturing stage; determining a first weight difference between the intermediate weight of the CMC component and a target weight corresponding to the current manufacturing stage; determining a second weight difference between the first weight difference and the corresponding weight of remaining parts; selecting a part from the remaining parts for which the second weight difference is minimum; and disposing the selected part on the ply layered in the current manufacturing stage.