Coordinated Fiber Placement for Composite Structures
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Solution Overview
Problem
Current manufacturing systems for composite structures, particularly in aircraft production, face challenges in efficiently placing composite materials along long lengths and complex shapes, leading to increased complexity and time due to limitations in device coordination and access to all surfaces of the tool.
Innovation Solution
A system comprising fiber placement devices, an overhead track system with a linear track running co-axial to the tool, and a scheduling controller that coordinates the operation of fiber placement devices to work simultaneously and independently, allowing for continuous fiber placement along the tool's length and access to all surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single fiber placement device is used to place composite material along the entire length of a tool, then the device must traverse the full length of the tool, but this increases the time required to complete the manufacturing process and reduces productivity
Solution Approach 1:
The patent divides the fiber placement task into multiple segments by using multiple fiber placement devices (e.g., devices 108a, 108b, 108c) that work simultaneously on different sections of the tool. Each device handles a portion of the total length, allowing parallel execution of fiber placement operations and significantly reducing overall manufacturing time.
2Productivity
If multiple fiber placement devices are used to work simultaneously on different sections of the tool, then productivity increases, but coordination complexity and device synchronization requirements increase
Solution Approach 1:
The system employs a controller (112) that receives real-time feedback from multiple fiber placement devices about their positions, operational status, and completion status. This feedback mechanism enables the controller to dynamically coordinate device movements, manage task assignments, and ensure synchronized operation, thereby handling the complexity of multiple devices through intelligent control rather than mechanical synchronization.
3Adaptability or versatility
If the tool is rotated to allow fiber placement devices access to all surfaces, then complete coverage is achieved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
Instead of rotating the tool to access different surfaces, the patent positions fiber placement devices in three-dimensional space around and above the tool. Devices can move vertically and laterally to access top, bottom, and side surfaces without requiring tool rotation, thereby achieving complete surface coverage while maintaining a simpler, non-rotating tool configuration.
4Length of moving object
If structural members are manufactured in sections and joined together to achieve required lengths, then the manufacturing process can handle long structures, but additional joining steps and process complexity are introduced
Solution Approach 1:
The patent applies segmentation to the manufacturing process by using multiple fiber placement devices that can simultaneously fabricate different sections of a long structural member in parallel. This allows the entire length to be manufactured as a continuous piece without requiring post-manufacturing joining operations, thereby simplifying the overall process while achieving required lengths.
Data Source
AI summary
A system for manufacturing a composite part. The system comprises fiber placement devices, an overhead track system, and a scheduling controller. The fiber placement devices are configured to operate in a coordinated manner to place fibers at locations on a tool used for manufacturing the composite part. The overhead track system comprises a linear track running co-axial to the tool. The overhead track system is associated with the fiber placement devices and configured to move the fiber placement devices to the locations along a length of the tool. The scheduling controller is configured to coordinate operation of the fiber placement devices such that the fiber placement devices perform tasks simultaneously to place the fibers in a desired configuration on the tool.