Composite Ply Placement with Measured Surface Tool Path Correction
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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 tool dimensions, leading to inconsistencies and structural weaknesses in composite structures, particularly in thick parts where tolerances and variances accumulate, resulting in undesirable overlaps and gaps.
Innovation Solution
A method involving measuring intermediate surfaces using high-accuracy equipment, such as laser trackers, to generate modified tool paths for composite placement machines, ensuring that the laydown surface matches the measured surface profiles, thereby ensuring accurate and consistent composite ply placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional composite manufacturing methods are used without surface measurements, then the manufacturing process is simpler and faster, but the surface quality and dimensional tolerances deteriorate with variances exceeding 0.010"
Solution Approach 1:
The patent applies preliminary action by measuring the intermediate surface before completing the composite structure manufacturing. The measured surface data is used to modify the tool path in advance for subsequent plies, preventing tolerance accumulation before it becomes a problem rather than correcting it after the fact.
Solution Approach 2:
The patent implements feedback by using measuring equipment to capture actual intermediate surface geometry and feeding this information back to modify the tool path for subsequent composite ply placement. This closed-loop approach ensures that variations in raw materials and tool dimensions are compensated for in real-time.
2Productivity
If no intermediate surface measurements are taken, then the manufacturing process is faster and less complex, but tolerance accumulation in thick parts causes overlaps and gaps
Solution Approach 1:
The patent takes preliminary action by measuring intermediate surfaces during the manufacturing process and modifying tool paths before subsequent plies are applied. This prevents tolerance accumulation in thick parts by addressing deviations early, maintaining precision without requiring complete re-manufacturing.
Solution Approach 2:
The patent applies segmentation by dividing the composite structure manufacturing into discrete stages with intermediate measurements. Each measurement stage provides data for modifying the next tool path segment, allowing precision control in thick parts through multiple smaller corrections rather than one large correction at the end.
3Manufacturing precision
If high-accuracy measuring equipment and tool path modification are implemented, then surface quality improves to within 0.010" tolerances, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent performs measurements and tool path modifications as preliminary actions during the manufacturing process rather than as post-processing steps. This integrates the time-consuming activities into the natural flow of manufacturing, reducing overall cycle time by preventing rework and ensuring precision is built-in from the start.
Solution Approach 2:
The patent maintains continuity of useful action by seamlessly integrating measurement and tool path modification into the continuous composite manufacturing process. The system continuously measures intermediate surfaces and continuously updates tool paths, eliminating idle time and keeping the manufacturing process flowing without interruption.
Data Source
AI summary
An illustrative example of the present disclosure provides a machine configured to form a composite structure. The machine includes a composite placement machine, measuring equipment, a tool path generator, and compaction equipment. The composite placement machine lays up composite plies. The measuring equipment measures surfaces of the composite plies to form measurements during layup of the composite plies. A computer includes a model of the composite plies for a structure. The tool path generator forms a modified tool path based upon a difference between the measurements and expected measurements for the composite plies in the model.