Automated Composite Repair Patch Generation via 3D Scanning
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Solution Overview
Problem
Current composite repair techniques are time-consuming and operator-dependent, struggling to achieve precise and efficient repair patches for complex, irregularly shaped composite structures like aircraft components, due to the difficulty in defining individual repair ply shapes and consolidating them effectively.
Innovation Solution
A system and method that utilizes digital scanning to generate three-dimensional data of damaged areas, creating precise cutting files for a stack-up of repair plies, which can be cut remotely and shipped for application, incorporating a scanning module, repair patch model generator, and cutting tool to automate the repair patch creation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If paper patterns and manual tracing are used to define repair ply shapes, then the process is simple and accessible, but the manufacturing precision and time efficiency deteriorate due to operator dependence and iterative fitting
Solution Approach 1:
The patent uses digital scanning to create precise 3D copies of the damaged area and parent plies, replacing manual paper pattern tracing. The scanner generates accurate digital representations that are then used to define exact repair ply shapes, eliminating operator-dependent approximation while maintaining process accessibility through software-based workflows
Solution Approach 2:
The patent replaces the mechanical manual process of tracing and fitting paper patterns with an automated digital scanning and modeling system. The scanner and software automatically generate repair ply definitions from scanned data, substituting manual mechanical operations with automated digital processes that improve both precision and efficiency
2Device complexity
If manual tracing and mapping of scarfed parent plies are used, then the process requires minimal equipment, but the productivity deteriorates due to time-consuming iterative fitting and cutting
Solution Approach 1:
The digital scanning process creates accurate 3D copies of the damaged area and parent plies in minutes, replacing time-consuming manual tracing and mapping. These digital copies enable immediate generation of cutting files, eliminating the iterative fitting process and dramatically increasing productivity while keeping equipment requirements manageable
Solution Approach 2:
The scanner captures and processes the damaged area geometry in advance, creating ready-to-use digital models before the actual repair ply fabrication begins. This preliminary digital preparation eliminates on-site iterative fitting and allows repair plies to be cut to precise specifications before arrival at the repair location
3Loss of time
If paper patterns are used to approximate repair ply outlines, then the process is quick to set up, but the manufacturing precision deteriorates due to approximation errors in complex and contoured shapes
Solution Approach 1:
The digital scanner creates precise 3D copies of the complex damaged area geometry, capturing all contours and irregularities accurately. These digital copies serve as the basis for generating exact repair ply shapes, eliminating the approximation errors inherent in manual paper pattern methods while maintaining rapid setup through automated processing
Data Source
AI summary
A system for generating a repair patch for a damaged area of a composite structure may include a scanning module, a repair patch model generator and a cutting tool. The scanning module may be deployed at the location of the damaged composite structure. The scanning module may be configured to scan the damaged area to generate scanned data indicative of a shape, size and/or contours of the damaged area. The repair patch model generator may include processing circuitry configured to obtain the scanned data, obtain parent ply information of the damaged composite structure, and generating a patch model of a repair patch including size and shape definition for each of a plurality of plies based on the scanned data and the parent ply information. The cutting tool may be configured to receive cutting files based on the patch model to generate a plurality of cut plies that combine to form the repair patch.