Fiber Placement Head Indexing for Precise Composite Lamination

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Solution Overview

Problem

Current composite lamination processes face challenges such as laps, gaps, and inconsistencies due to variations in layer orientations and thicknesses, which can lead to defects in composite parts.

Innovation Solution

A system comprising a first measurement system with sensors like LIDAR or high-resolution cameras for scanning the substrate surface, and a second measurement system for locating and tracking the automated fiber placement head, along with a data management device to generate full resolution transformations and determine the head's position accurately.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated fiber placement is used for composite lamination, then productivity is improved, but manufacturing precision deteriorates due to laps, gaps, and inconsistencies in layers

Engineering Contradiction:

Improveautomation of fiber placementVSAvoidlayer consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary scanning of the mandrel surface and existing composite layers before fiber placement begins. This advance measurement allows the system to pre-calculate compensation values for surface irregularities and thickness variations, ensuring precise fiber placement from the start without manual intervention during the automated process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors the actual fiber placement process by scanning deposited layers and comparing them against the target geometry. Real-time feedback enables dynamic adjustment of placement parameters to compensate for deviations, maintaining manufacturing precision throughout the automated lamination process

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If multiple layers of prepreg are laid up in different orientations, then the composite structure meets design requirements, but manufacturing precision deteriorates due to compounding variations and inconsistencies

Engineering Contradiction:

Improvelayer orientation flexibilityVSAvoidlayer thickness consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Before each layer is deposited, the system scans the current surface topology and pre-calculates the optimal placement path that compensates for accumulated variations from previous layers. This preliminary adjustment ensures that each new layer conforms to the target geometry regardless of orientation or underlying irregularities

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system applies location-specific compensation values to different regions of the composite structure based on locally measured thickness variations and surface irregularities. Each area receives customized adjustment parameters tailored to its specific geometric requirements and accumulated error profile

Inventive Principle:

Principle #3Local quality

3Device complexity

If linear interpolation is used for mandrel scanning, then device complexity is reduced, but measurement precision deteriorates due to insufficient resolution

Engineering Contradiction:

Improvescanning system simplicityVSAvoidsurface geometry accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The mandrel surface is divided into multiple discrete measurement points arranged in a grid pattern, with each point scanned independently by the sensor system. This segmentation allows high-resolution data collection across the entire surface without requiring complex continuous scanning mechanisms, achieving high measurement precision through simple point-by-point sampling

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This system enhances the accuracy of composite layup by reducing or eliminating linear interpolation, achieving precision within 127 µm (0.005 inches), and minimizing gaps and laps in composite material, thereby improving the quality and consistency of composite parts.

Implementation Method 1

The first plurality of sensors may comprise one or more of an array of light detection and ranging (LIDAR) devices

Methodology Applied

Scientific EffectLIDAR: LIDAR

Implementation Method 2

an array of time-of-flight sensors

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Implementation Method 3

The second plurality of sensors may comprise one or more of an array of light detection and ranging (LIDAR) devices

Methodology Applied

Scientific EffectLIDAR: LIDAR

Data Source

PatentEP4494855A1Composite lamination system and methods

Publication Date: 2025.01.22 THE BOEING CO

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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.