Composite Part Imprinted Features for Robotic Drilling Precision

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Solution Overview

Problem

Existing technologies face challenges in precisely performing multiple operations on composite parts, particularly in accurately positioning fastener holes, using conventional robotic systems that rely on global coordinate systems.

Innovation Solution

The use of layup mandrels with embedded textured pins, where the mandrel body defines a layup surface with a specific finish roughness, and includes regions of isotropic surface finish with greater roughness, corresponding to desired fastener hole locations. This allows for precise imprinting of these features onto the composite material during the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If conventional robotic systems with global coordinate systems are used, then automation is achieved, but positioning precision for fastener holes deteriorates

Engineering Contradiction:

ImproveautomationVSAvoidpositioning precision

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The patent creates physical imprints of the mandrel surface features directly onto the composite part surface. These imprints serve as precise physical copies or templates of the desired fastener hole locations, allowing the robotic system to locate features by detecting these imprinted markers rather than relying solely on global coordinate calculations, thereby improving positioning precision while maintaining automation

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent utilizes surface finish roughness changes as visual markers. The imprinted regions have different surface roughness characteristics (isotropic surface finish with greater roughness) compared to the surrounding smooth mandrel contact areas. This surface finish variation creates detectable visual or tactile markers that the robotic vision or sensing system can identify to precisely locate fastener holes, effectively using surface property changes as positioning aids

Inventive Principle:

Principle #32Color changes

2Manufacturing precision

If smooth mandrel surfaces are used, then composite part surface quality improves, but feature detection by robotic systems deteriorates

Engineering Contradiction:

Improvesurface qualityVSAvoidfeature detection

Core Design Contradiction:

Manufacturing precisionVSDifficulty of detecting and measuring

Solution Approach 1:

The patent applies different surface qualities to different regions of the mandrel. The majority of the mandrel surface maintains a smooth finish for overall part quality, while specific localized regions have isotropic surface finish with greater roughness. These localized rough regions correspond to desired fastener hole locations and create detectable imprints on the composite part, enabling feature detection without compromising overall surface quality

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates asymmetric surface properties on the mandrel by introducing localized rough regions amidst smooth areas. The imprinted features on the composite part exhibit asymmetric surface finish characteristics - smooth regions from mandrel contact and rougher isotropic regions from textured pin contact. This asymmetry in surface properties provides distinctive detectable markers for robotic systems to identify fastener hole locations

Inventive Principle:

Principle #4Asymmetry

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables the precise and accurate formation of composite parts with imprinted features that can be reliably detected by robotic systems, facilitating precise operation such as drilling fastener holes, thereby improving the overall precision and efficiency of composite part manufacturing.

Implementation Method 1

The conforming includes imprinting, within at least a mandrel-contacting ply of the plurality of plies of composite material, the layup surface finish roughness within regions of the mandrel-contacting ply that contact the layup surface and the isotropic surface finish roughness within regions of the mandrel-contacting ply that contact the plurality of regions of isotropic surface finish

Methodology Applied

Scientific EffectSurface finish imprinting:

Data Source

PatentUS12269224B2Systems for forming composite parts, methods of forming composite parts, and methods of precisely performing a plurality of operations on a composite part

Publication Date: 2025.04.08 THE BOEING CO

AI summary

Systems for forming composite parts, methods of forming composite parts, and methods of precisely performing a plurality of operations on a composite part. The systems include a layup mandrel that includes a mandrel body and a plurality of regions of isotropic surface finish. The methods of forming the composite part include positioning a plurality of plies of composite material on a layup mandrel, conforming the plurality of plies of composite material to a layup surface shape of the layup mandrel, and curing the plurality of plies of composite material. The methods of precisely performing the plurality of operations on a composite part include detecting a corresponding imprinted feature of a plurality of imprinted features, aligning an operating assembly of an end effector relative to the corresponding imprinted feature, and performing a corresponding operation of the plurality of operations on the composite part.