Automated Patch Fabrication for Composite Rework
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Solution Overview
Problem
The existing method for fabricating patches in composite structures is prone to copying and cutting errors, leading to inefficiencies and increased costs due to human intervention in tracing and cutting processes, resulting in patches that may not fit properly, which can lead to repeated rework cycles and potential discarding of composite structures.
Innovation Solution
A method and apparatus that utilize image processing to identify boundary geometries and orientations of exposed layers in a rework area, generating a description for a patch, and controlling a ply cutting system to fabricate the patch accurately, reducing human error and improving fitment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If human operators manually trace and cut plies to fabricate patches, then flexibility and adaptability are maintained, but copying and cutting errors occur leading to reduced manufacturing precision
Solution Approach 1:
The patent replaces manual mechanical tracing and cutting operations with an automated system that uses imaging technology to capture layer boundaries and a controlled cutting system to fabricate plies. The imaging system captures images of the rework area, identifies layer boundaries automatically, and the cutting system executes precise cuts based on digital instructions, eliminating human error in manual tracing and cutting while maintaining operational flexibility through programmable control.
2Manufacturing precision
If automated imaging and cutting systems are used to fabricate patches, then manufacturing precision and fitment accuracy are improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a unified automated patch fabrication system. The same imaging system that captures layer boundaries is used to generate cutting instructions, and the controlled cutting system can fabricate multiple plies with different orientations and geometries from a single digital model. This multi-functional integration reduces the need for separate manual operations and equipment, managing system complexity while achieving high manufacturing precision.
Solution Approach 2:
The system creates a digital copy of the layer boundaries through imaging, then uses this digital representation to generate precise cutting instructions. This digital copying process eliminates the need for manual tracing and allows for accurate reproduction of complex geometries. The digital model can be stored and reused for fabricating multiple plies and patches, reducing overall system complexity through information reuse.
3Device complexity
If manual tracing and copying of layer boundaries is performed, then equipment cost is reduced, but time consumption and rework cycles increase
Solution Approach 1:
The automated system enables continuous operation by eliminating the stop-start nature of manual tracing and cutting. The imaging system captures all layer boundaries in a single or minimal number of images, the processing system generates all cutting instructions digitally, and the controlled cutting system executes cuts continuously without manual intervention between plies. This continuous automated process significantly reduces fabrication time compared to manual methods, increasing productivity despite higher equipment investment.
4Reliability
If multiple copies of patches are fabricated for testing, then reliability is improved, but material waste and production time increase due to manual copying errors
Solution Approach 1:
The system uses digital copying of the layer boundary images to generate identical copies of patch patterns for multiple plies and test specimens. The digital model ensures that all copies are exact reproductions without the cumulative errors that occur in manual tracing. This allows rapid fabrication of multiple test patches from the same digital instructions, improving reliability through consistent testing while reducing time loss by eliminating manual recopying of each test specimen.
Data Source
AI summary
A method and apparatus for managing a rework of a composite structure. Boundary geometries are identified for the layer boundaries in an image of a rework area. The image includes layer boundaries for exposed layers in the rework area. Layer orientations are identified for the exposed layers. A description of a patch for installation in the rework area is generated using the boundary geometries and layer orientations. The patch has plies having ply boundaries with the boundary geometries corresponding to the layer boundaries and ply orientations corresponding to the layer orientations. An operation of a ply cutting system is controlled using the group of files describing the patch, enabling fabricating the patch for the rework area using the group of files describing the patch.