Composite Ply Rollout Compaction Path Planning for Shear Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current compaction of ceramic matrix composite plies on layup tools is a manual operation, leading to variable quality, inconsistencies, and increased life cycle time due to the need for skilled technicians and time-intensive processes.
Innovation Solution
Development of path planning methods and environments for automated rollout compaction, using computing devices to generate path plans based on ply parametric data and tool design data, and implementing these plans with automated compaction rollers in a composite manufacturing layup cell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual compaction operations are used with skilled technicians, then compaction quality can be maintained through experience, but the process becomes time-intensive and increases life cycle time
Solution Approach 1:
The patent replaces manual mechanical compaction operations with an automated robotic system that uses computer-generated path plans to control compaction roller movements. This substitution eliminates the need for skilled technicians while maintaining consistent compaction quality through automated control, directly resolving the contradiction between maintaining manufacturing precision and reducing time loss.
Solution Approach 2:
The patent implements automated control of compaction parameters including roller speed, pressure, and path trajectory through computer-generated path plans. By precisely controlling these parameters automatically, the system achieves consistent compaction quality without the time-intensive manual operations, resolving the contradiction between manufacturing precision and life cycle time.
2Adaptability or versatility
If manual compaction operations are used, then flexibility in handling different ply configurations is maintained, but variable quality and inconsistencies occur
Solution Approach 1:
The patent implements a dynamic path planning system that automatically adapts to different ply configurations, tool geometries, and material characteristics. The computer-generated path plans are created specifically for each unique combination of parameters, enabling the automated system to handle various configurations with the same level of precision and consistency as manual operations, while eliminating variability through automation.
Solution Approach 2:
The system incorporates feedback mechanisms that allow the automated compaction process to adjust to different ply configurations and maintain consistent quality. The path planning software can be tailored to specific ceramic matrix composite plies, layup tools, and orientations, ensuring adaptability while maintaining manufacturing precision through controlled automated operations.
3Productivity
If automated compaction rollers are implemented, then productivity and consistency are improved, but device complexity increases
Solution Approach 1:
The patent develops a universal path planning software system that can generate compaction paths for various ceramic matrix composite plies, layup tools, and orientations using a single automated robotic platform. This multi-functionality approach consolidates what would otherwise require multiple specialized systems, improving productivity while managing device complexity through software-based versatility rather than hardware proliferation.
4Manufacturing precision
If path plans are tailored to specific plies and tools, then manufacturing precision is optimized, but the complexity of path plan development increases
Solution Approach 1:
The patent implements preliminary path plan generation through computer software that creates optimized compaction paths before actual manufacturing operations. By pre-calculating and storing path plans for different ply and tool combinations, the system achieves manufacturing precision optimization without increasing operational complexity during production, as the complex planning work is performed in advance through automated software.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method for developing a path plan for rollout compaction of a composite ply during composite manufacturing includes receiving ply parametric data based on characteristics of a ceramic matrix composite ply for placement on a layup tool and subsequent compaction using a compaction roller during the composite manufacturing and generating the path plan for automated manipulation of the compaction roller to compact the ceramic matrix composite ply on the layup tool based at least in part on the ply parametric data. The method further comprises identifying a maximum shear for the ceramic matrix composite ply based at least in part on the ply parametric data for the ceramic matrix composite play and the tool design data, comparing the maximum shear to a predetermined threshold, and based on the comparison generating a star-based path plan for the automated manipulation of the compaction roller by a robotic device.