Multihead Composite Programming via Path Assignment
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Solution Overview
Problem
Existing composite part programming systems lack the capacity to efficiently program multihead composite material application machines for producing a variety of composite parts, requiring excessive manual programming and limiting the production of large composite parts such as aircraft fuselage sections.
Innovation Solution
A computer-implemented method and apparatus that generates composite part programs for multihead composite material application machines, including a CAD interface, path generator, course head manager, and post-processor, to efficiently assign paths to multiple composite material application heads, reducing manual labor and overcoming limitations of existing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing composite part programming systems are used for multihead machines, then the system structure remains simple, but the productivity is low and excessive manual programming is required
Solution Approach 1:
The programming system is segmented into multiple functional modules: a part definition module that receives composite part definitions, a path generation module that creates paths for composite material segments, and a course head manager module that associates paths with tool carriage passes and assigns them to specific composite material application heads. This modular segmentation enables automated programming for multihead machines while maintaining manageable system complexity.
Solution Approach 2:
The course head manager acts as an intermediary component that bridges the path generation module and the multiple composite material application heads. It receives generated paths, associates them with tool carriage passes, and intelligently assigns specific paths to specific heads, thereby automating the complex coordination required in multihead machine programming without requiring excessive manual intervention.
2Loss of time
If manual programming is used for multihead machines, then the programming system remains simple, but the labor required is excessive and time-consuming
Solution Approach 1:
The system performs preliminary actions by automatically generating paths for composite material segments based on part definitions before the actual manufacturing process. The course head manager pre-associates these paths with tool carriage passes and pre-assigns them to specific composite material application heads, eliminating the need for time-consuming manual programming during production setup.
Solution Approach 2:
The programming system serves itself by automatically generating and assigning paths without requiring external manual intervention. The path generation module creates paths based on part definitions, and the course head manager automatically distributes these paths to appropriate heads, enabling the system to program itself for multihead operations.
3Productivity
If multiple composite material application heads are used, then the productivity increases, but the risk of collisions between heads increases
Solution Approach 1:
The course head manager implements a feedback mechanism that monitors the assignment of paths to multiple composite material application heads and tool carriage passes. By tracking which heads are assigned to which paths and coordinating their movements, the system can detect potential collision scenarios and adjust assignments to prevent collisions, thereby maintaining reliability while utilizing multiple heads for high productivity.
Data Source
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AI summary
A composite part program generator includes a computer-aided design (CAD) system interface, a path generator, a course head manager, a post-processor and a machine simulator. The composite part program generator produces composite part programs for use on a multihead composite material application machine, such as a composite tape lamination machine or an automated fiber placement (AFP) machine, to manufacture a complex composite parts, including relatively flat, contoured, or generally cylindrical composite parts. This programming method can reduce the labor and time required to produce a composite part program for a multihead composite material application machine by an order of magnitude with respect to manual or existing automated programming methods.