Composite Layup Cell Imaging for Targeted Ply Re-Compaction
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Solution Overview
Problem
Current methods for compaction of ceramic matrix composite plies on layup tools are manual, leading to variable quality, inconsistencies, and increased lifecycle time due to the need for skilled technicians and time-intensive processes.
Innovation Solution
The implementation of automated compaction techniques using path plans and surface imaging technology in a layup cell, which includes a robot control system, robotic arm, and end effector with a compaction roller and surface imaging device, to automate the compaction and rework of ceramic matrix composite plies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual compaction operations are performed using compaction roller hand tools, then the process can be executed with simple equipment, but the quality consistency and compaction uniformity deteriorate due to variable technician skill and time-intensive operations
Solution Approach 1:
The patent replaces manual mechanical compaction operations with an automated robotic system that uses imaging technology (optical/electromagnetic fields) to detect compaction quality and control the compaction process. The robot control system processes images to identify poorly compacted areas and automatically adjusts compaction operations, substituting human mechanical operations with automated sensor-based control to achieve consistent quality.
Solution Approach 2:
The system performs self-inspection and self-correction by using imaging technology to automatically detect poorly compacted areas and then automatically re-compacting those specific regions without human intervention. The robot control system enables the compaction process to monitor and correct its own deficiencies, creating a self-service quality assurance mechanism.
2Productivity
If automated compaction techniques are implemented using robot control systems and path plans, then productivity and quality consistency improve, but device complexity and initial manufacturing complexity increase
Solution Approach 1:
The system performs preliminary imaging and analysis of the composite ply before compaction operations begin. The robot control system captures images, identifies poorly compacted areas in advance, and generates optimized path plans that pre-determine the sequence and parameters of compaction operations. This preliminary action allows the system to execute high-speed automated compaction without real-time decision delays.
Solution Approach 2:
The patent introduces an intermediary robot control system that acts as a mediator between the imaging device and the compaction roller. This intermediary processes image data, generates path plans, and controls the robotic arm's movement, thereby managing the complexity of coordinating multiple automated components while enabling high productivity through centralized intelligent control.
3Manufacturing precision
If surface imaging technology is used to identify areas requiring re-compaction, then manufacturing precision improves through targeted rework, but measurement and detection complexity increases
Solution Approach 1:
The system creates a digital copy of the composite ply surface by capturing images with the imaging device. This image copy serves as a virtual representation that can be analyzed without physically touching or disturbing the actual composite. The robot control system processes this digital copy to identify poorly compacted areas, enabling precise measurement and detection while avoiding the complexity of direct physical measurement of the composite material itself.
Data Source
AI summary
A method for operation of a layup cell during composite manufacturing includes running a compaction application program at a robot control system of the layup cell using a path plan data file defining a path plan for automated manipulation of a compaction roller for compacting a ceramic matrix composite ply on a layup tool, capturing image data of the ceramic matrix composite ply after compaction on the layup tool using a surface imaging device, at least temporarily storing the image data for the ceramic matrix composite ply after compaction in a ply image data file and processing the ply image data file to identify one or more areas of the ceramic matrix composite ply that require re-compaction. The layup cell includes the layup tool, the ceramic matrix composite ply, the robot control system, a robotic arm and at least one end effector.