Fiber Placement Head Indexing With Full-Resolution Surface Scanning

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Solution Overview

Problem

Current composite lamination processes face issues with laps, gaps, and inconsistencies due to variations in layer placement, which are compounded by the use of automated lamination equipment, necessitating a more accurate and efficient method for indexing the automated fiber placement head.

Innovation Solution

A system comprising first and second measurement systems with sensors to scan and locate the fiber placement head, generating a full resolution transformation for precise indexing and real-time monitoring, reducing the need for linear interpolation and probing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated lamination equipment is used, then productivity is improved, but manufacturing precision deteriorates due to laps, gaps, and inconsistencies in layer placement

Engineering Contradiction:

Improvelamination speedVSAvoidlayer placement accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary scanning of the mandrel surface and real-time tracking of the AFP head position before and during lamination. This advance measurement and indexing allows the system to pre-calculate transformation data and proactively compensate for deviations, preventing laps and gaps before they occur while maintaining high automated lamination speed

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors mandrel surface geometry and AFP head position during lamination, feeding this data back to the control system. Real-time feedback enables dynamic adjustment of layup parameters to maintain manufacturing precision of 0.010 inches or better while sustaining automated productivity

Inventive Principle:

Principle #23Feedback

2Device complexity

If traditional probing and linear interpolation are used for indexing, then device complexity is reduced, but measurement precision deteriorates due to insufficient data resolution

Engineering Contradiction:

Improveindexing system complexityVSAvoidmandrel surface measurement accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The system replaces traditional mechanical probing with optical scanning technology. The optical scanner captures high-resolution surface geometry data without physical contact, eliminating the need for complex mechanical probe systems while achieving superior measurement precision. This substitution maintains relative system simplicity while dramatically improving data resolution for accurate indexing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system transitions from point-by-point mechanical probing to comprehensive surface scanning that captures three-dimensional mandrel geometry. This dimensional approach provides full surface coverage and resolution, enabling precise transformation calculations without requiring complex mechanical indexing mechanisms

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12576630B2Composite lamination system and methods

Publication Date: 2026.03.17 THE BOEING CO

AI summary

A system and methods for indexing an automated fiber placement head to a surface of a substrate are provided. The system comprises a first measurement system comprising a first plurality of sensors configured to scan the surface of the substrate; a second measurement system comprising a second plurality of sensors configured to locate the automated fiber placement head; and a data management device configured to generate a full resolution transformation using measurements from the first measurement system and determine a position of the automated fiber placement head using data from the second measurement system.