Composite Ply Laydown Path Correction for Surface Tolerance
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Solution Overview
Problem
In composite manufacturing, achieving precise surface quality and dimensional tolerances is challenging due to variations in raw materials and processing conditions, leading to inconsistencies and potential structural weaknesses from overlaps or gaps in composite structures.
Innovation Solution
A method and system that utilize measuring equipment to produce accurate surface measurements of intermediate surfaces, which are then used to modify tool paths for composite placement machines, ensuring that the laydown surface matches the measured surface, thereby reducing inconsistencies and improving surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional composite placement methods are used, then manufacturing process is simple, but surface quality and dimensional tolerances are poor due to material and processing variations
Solution Approach 1:
The patent measures the intermediate surface before completing the composite structure, allowing the tool path to be adjusted in advance based on actual surface conditions. This preliminary measurement and adjustment prevents surface quality issues from developing in the first place, rather than detecting and correcting them after the fact.
Solution Approach 2:
The system implements a closed-loop feedback mechanism where the measured intermediate surface data is fed back to modify the tool path for subsequent composite ply placement. This ensures that each layer is deposited with precise compensation for previously accumulated surface variations, maintaining tight dimensional tolerances throughout the structure.
2Reliability
If tight dimensional tolerances are required for mating surfaces, then joining quality is improved, but manufacturing complexity and time increase
Solution Approach 1:
The measurement and tool path adjustment is performed during the manufacturing process itself, before the composite structure is completed and before mating operations occur. This eliminates the need for post-manufacturing adjustments, shimming, or rework, thereby ensuring high joining quality without adding significant time to the overall manufacturing cycle.
Solution Approach 2:
The system uses the composite placement machine's own measurement and control capabilities to self-correct surface deviations. By integrating measurement and tool path modification within the same manufacturing system, the process becomes self-regulating and eliminates the need for separate inspection and adjustment operations, reducing overall manufacturing time.
3Manufacturing precision
If intermediate surfaces are measured and tool paths are modified, then inconsistencies and overlaps are reduced, but process complexity increases
Solution Approach 1:
The composite placement machine is equipped with both measurement capabilities and tool path modification capabilities, allowing a single device to perform multiple functions. This multi-functionality eliminates the need for separate measurement equipment and control systems, reducing overall device complexity while maintaining high dimensional consistency.
Solution Approach 2:
The patent combines the measurement system and tool path control system into an integrated workflow where both functions operate within the same manufacturing process. By merging these previously separate functions into a unified system, the patent reduces the number of discrete components and interfaces, thereby reducing overall system complexity while achieving consistent dimensional quality.
Data Source
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AI summary
An illustrative example of the present disclosure provides a method. A first set of composite plies (224) including a first outer ply (225) of a first composite structure (208) is laid up. A first intermediate surface (207) of the first outer ply (225) is measured to form a first set of measurements (206). A laydown surface (212) for a tool path (214) of a composite placement machine (203) is modified to form a modified tool path (216), wherein modifying the laydown surface (212) comprises modifying the laydown surface (212) such that a laydown surface (217) of the modified tool path (216) matches the first set of measurements (206). A composite ply (218) is laid down using the composite placement machine (203) and the modified tool path (216).