Lamination Tool Alignment Using Zone-Based Surface Compensation
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Solution Overview
Problem
Automated composite manufacturing requires high accuracy, but traditional methods for aligning lamination tools with numerically controlled composite placement machines are time-consuming and inefficient, especially when dealing with tools that exhibit local variations in position and shape.
Innovation Solution
A composite manufacturing system that includes a lamination tool with locating targets and a computer-aided measurement system to measure these targets and line profiles, generating master surface-data and target-data to establish a spatial relationship, allowing for efficient compensation of the NC machine and re-use of data for subsequent operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a scan of the entirety of the surface of the lamination tool is performed to establish rigid body transform alignment features, then alignment accuracy is improved, but the time and effort required increases significantly
Solution Approach 1:
The patent divides the lamination tool surface into multiple zones, each containing a subset of alignment features. Instead of scanning the entire surface, the system selectively scans only the zones that contain features relevant to the current manufacturing operation, thereby reducing scan time while maintaining alignment accuracy.
Solution Approach 2:
The patent implements local variation compensation by creating zone-specific transform alignments rather than a single global alignment. Each zone has its own rigid body transform parameters that account for local surface variations, allowing accurate alignment without requiring a complete surface scan.
2Device complexity
If traditional rigid body transform alignment is used for the entire lamination tool, then alignment is simplified, but local variations in tool position cannot be compensated
Solution Approach 1:
The patent segments the lamination tool into multiple zones, each with its own alignment features and transform parameters. This allows local variations in tool position to be compensated zone-by-zone while maintaining a manageable alignment process for each individual zone.
Solution Approach 2:
The patent applies partial action by performing alignment operations only on the specific zones that require compensation, rather than uniformly processing the entire tool surface. This selective approach enables local variation compensation without unnecessarily increasing overall process complexity.
Data Source
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.