Composite Manufacturing Feedback Analytics for Yield Consistency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional composite manufacturing processes are prone to errors and inconsistencies, leading to reduced yield, increased scrap, and performance/weight penalties due to structural knockdowns, especially when dealing with large composite components.
Innovation Solution
Implementing data analytics to monitor and analyze manufacturing processes, including machine tool operations and composite structure properties, to produce feedback data that identifies outliers, trends, and patterns, allowing for adjustments to improve process consistency and tool performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional composite manufacturing processes are used, then manufacturing simplicity is maintained, but manufacturing precision deteriorates due to errors and inconsistencies
Solution Approach 1:
The patent implements a feedback mechanism where data from sensors monitoring the manufacturing process (temperature, pressure, humidity, machine tool operations) is collected, analyzed, and used to generate feedback reports that identify outliers, trends, and patterns. This feedback loop enables continuous improvement of manufacturing precision by detecting and correcting deviations from optimal process parameters.
Solution Approach 2:
The patent replaces conventional mechanical monitoring and quality control methods with data analytics and automated analysis systems. Sensors and computing devices substitute for manual inspection and mechanical measurement tools, enabling more precise and consistent quality control through digital data processing and pattern recognition.
2Manufacturing precision
If data analytics and monitoring systems are implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The manufacturing system performs self-diagnosis and self-optimization through automated data analysis. The system monitors its own process parameters, identifies deviations and patterns, and generates feedback for process adjustment without requiring external intervention. This self-service capability reduces the need for complex external monitoring systems while improving precision.
Solution Approach 2:
The data analytics platform serves multiple functions: it monitors process parameters, detects outliers, identifies trends, generates feedback reports, and supports decision-making for process optimization. This multi-functional system consolidates what would otherwise require multiple separate devices into a single integrated platform, managing complexity while enhancing precision.
3Productivity
If conventional manufacturing processes are used, then process simplicity is maintained, but productivity deteriorates due to reduced yield and increased scrap
Solution Approach 1:
The system performs preliminary analysis of process data to identify potential quality issues before they result in defective composite structures. By detecting outliers and trends early in the manufacturing process, the system enables preventive adjustments that avoid scrap and rework, thereby improving productivity without requiring complex post-manufacturing inspection systems.
Data Source
AI summary
A method is provided that includes monitoring a process of manufacturing a composite structure that includes introducing a matrix material to a reinforcement material, applying the reinforcement material into a mold cavity or onto a mold surface with a first machine tool, subjecting the matrix material to a melding event with a second machine tool, and inspecting the composite structure. Data including at least one of first measurement data, error data or second measurement data is determined, and an analysis of the data is performed to summarize the data and thereby produce feedback data including a summary of the data. At least one of the process, the first machine tool or the second machine tool is adjusted based on feedback including the summary, and for manufacture of a next composite structure.