Composite Part Compensation System Using Laser Measurement
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Solution Overview
Problem
Existing composite manufacturing processes struggle to accurately measure and correct deviations in as-built parts to meet production specifications, leading to inefficiencies and material waste.
Innovation Solution
A laser radar measuring system captures the surface geometry of composite parts, compares it to design specifications, calculates and applies uniquely shaped compensation plies, and uses laser projection for precise placement to ensure dimensional compliance, minimizing waste through optimized nesting and re-curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional composite manufacturing processes are used, then production simplicity is maintained, but manufacturing precision deteriorates due to inability to accurately measure and correct deviations in as-built parts
Solution Approach 1:
The correction process is segmented into distinct phases: laser radar scanning to capture surface geometry, computational analysis to determine deviations, design of compensation plies, and laser-guided application. This segmentation allows each subsystem to be optimized independently while maintaining overall precision.
Solution Approach 2:
Traditional mechanical measurement and correction methods are replaced with laser radar scanning and laser projection systems. The optical-based measurement and positioning systems provide non-contact, high-precision data acquisition and guidance, eliminating the need for complex mechanical measurement apparatus.
2Manufacturing precision
If compensation plies are applied to correct deviations, then manufacturing precision is improved, but device complexity increases due to additional measurement and correction equipment
Solution Approach 1:
The laser-based system serves multiple functions: laser radar performs both scanning and measurement, the computational system handles both deviation analysis and compensation ply design, and the laser projection system provides both positioning guidance and verification. This multi-functionality reduces the need for separate specialized equipment.
Solution Approach 2:
The system uses the part's own surface geometry data to generate compensation plies that are specifically tailored to correct its deviations. The laser projection system projects patterns directly onto the part surface, using the part's own features as reference for alignment and positioning, eliminating the need for external fixtures or templates.
3Loss of substance
If conventional manufacturing methods are used, then process simplicity is maintained, but material waste increases due to inability to correct deviations
Solution Approach 1:
The system performs measurement and compensation ply design before the final curing process. By identifying deviations in the green state and preparing compensation plies in advance, the system prevents the need to scrap and remanufacture entire parts, significantly reducing material waste while maintaining efficient production flow.
Solution Approach 2:
Instead of discarding parts that fall outside tolerances, the system recovers them by applying compensation plies to correct the deviations. This approach transforms potential waste into recoverable material, extending the lifecycle of the base part and reducing overall material consumption.
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 method ensures that composite parts are brought within production tolerances, reducing material waste and improving manufacturing efficiency by enabling precise measurement and correction of deviations in real-time.
Implementation Method 1
A laser radar measuring system scans and captures the surface geometry of a first build of a composite part
Implementation Method 2
The plies are then located onto the as-built part guided by lasers for precise location
Data Source
AI summary
A method and system for assisting in the manufacture of composite parts such as those used for various high-strength assemblies such as aircraft wings, vertical stabilizers, racing car shells, boat hulls, and other parts which are required to have a very high strength to weight ratio. The system uses laser technology to measure the resultant surfaces of a first manufactured composite part. A computer system analyzes and compares the as-built dimensions with the required production specifications. Supplemental composite filler plies are designed including shape and dimensions. These plies are nested together into a single composite sheet and manufactured to minimize wasted material. The plies are then cut out and applied to the first part guided by a laser projection system for locating the plies on the part. The part is then re-cured. The final assembly is then re-measured for compliance with production dimensions.