Composite Lamination Tool Alignment Using Targeted Surface Profiles
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Solution Overview
Problem
Traditional methods for aligning a numerically controlled composite placement machine with a lamination tool require a full surface scan, which is time-consuming and inefficient for compensating local variations, hindering accurate composite manufacturing.
Innovation Solution
A composite manufacturing system that uses first and second locating targets and line profiles to generate master surface-data and target-data, establishing a spatial relationship through a master file, allowing for efficient data collection and automated compensation of the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a full surface scan is performed to establish rigid body transform alignment features, then manufacturing precision is improved, but productivity deteriorates due to significant time consumption
Solution Approach 1:
The patent divides the lamination tool surface into multiple zones, each with its own locating targets. Instead of scanning the entire surface, the system selectively scans only the zones containing locating targets, significantly reducing data collection time while maintaining alignment precision through distributed target measurement
Solution Approach 2:
The patent pre-establishes the spatial relationships and rigid body transforms between locating targets and lamination surface features during tool setup. This preliminary characterization allows subsequent manufacturing operations to use pre-computed transformation matrices, eliminating the need for repeated full-surface scanning and enabling rapid repositioning and realignment
2Manufacturing precision
If a full surface scan is performed to establish rigid body transform alignment features, then manufacturing precision is improved, but device complexity worsens due to extensive data processing requirements
Solution Approach 1:
The patent extracts only the essential alignment information from the locating targets (their positions and spatial relationships) rather than processing complete surface geometry data. By focusing measurement and computation solely on the locating targets and pre-establishing their transforms to the lamination surface, the system dramatically reduces data processing complexity while preserving alignment precision
3Manufacturing precision
If traditional alignment methods are used, then manufacturing precision is maintained through rigid body transform, but adaptability deteriorates for local variation compensation
Solution Approach 1:
The patent implements local quality by associating different rigid body transforms with different zones of the lamination tool, each zone having its own locating targets and transformation characteristics. This allows the system to adapt to local variations in tool geometry and positioning across different regions, rather than applying a single global transform, thereby maintaining precision while improving adaptability to local conditions
Data Source
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AI summary
A composite manufacturing system includes a lamination tool, including a lamination surface, first locating targets extending the lamination surface, and second locating targets extending the lamination surface. The system includes a computer-aided measurement system to measure the first locating targets, the second locating targets, and line profiles of the lamination surface and to generate master surface-data and master target-data. The master target-data represents target positions of the first locating targets and the second locating targets. The master surface-data represents profile positions of the line profiles. The line profiles are associated with target pairs. Each one of the target pairs includes one of the first locating targets and an opposing one of the second locating targets. The system includes a computing device to generate a master file that establishes a spatial relationship between the master target-data and the master surface-data and to associate the master file with the lamination tool.