Robotic Layup Cell Re-Compaction for Ceramic Matrix Composite Plies
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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
The implementation of automated compaction 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 skilled technicians can perform the compaction, but the quality is variable and inconsistencies occur
Solution Approach 1:
The patent replaces manual mechanical compaction operations with an automated robotic system that uses a compaction roller mounted on a robotic arm. The robotic arm executes pre-planned paths to apply consistent compaction force, eliminating the variability introduced by manual operations while maintaining the mechanical compaction function.
Solution Approach 2:
The system implements automated control of compaction parameters including force, speed, and path trajectory. By precisely controlling these parameters through the robotic system and using imaging technology to monitor surface characteristics, the patent achieves consistent compaction quality that cannot be reliably maintained through manual operations alone.
2Productivity
If manual compaction operations are performed, then compaction can be completed, but the life cycle time is increased due to inspection and rework requirements
Solution Approach 1:
The patent incorporates surface imaging technology that captures images of the composite ply during and after compaction. This imaging feedback allows the system to automatically detect areas with insufficient compaction and trigger re-compaction operations immediately, eliminating the need for separate inspection steps and reducing overall cycle time.
Solution Approach 2:
The system performs compaction along pre-planned paths that are designed to ensure complete coverage and proper compaction from the beginning. By planning the compaction paths in advance and executing them automatically, the system prevents defects before they occur, reducing the need for rework and time-consuming inspection cycles.
3Manufacturing precision
If automated compaction is implemented using path plans and surface imaging technology, then compaction consistency is improved, but device complexity increases
Solution Approach 1:
The robotic arm serves multiple functions: it positions the compaction roller, executes compaction paths, and can be reconfigured for different compaction operations. The surface imaging system also serves dual purposes by monitoring both compaction quality and providing feedback for automated re-compaction decisions, reducing the need for separate dedicated devices.
Solution Approach 2:
The patent introduces a control system that acts as an intermediary between the robotic arm and surface imaging device. This control system integrates the path planning, executes the compaction operations, processes imaging data, and coordinates re-compaction activities, thereby managing system complexity through centralized control rather than requiring complex direct integration between all components.
4Ease of operation
If manual compaction operations are used, then existing equipment can be utilized, but skilled labor is required and operational difficulty increases
Solution Approach 1:
The automated system performs compaction operations autonomously based on pre-programmed paths and real-time imaging feedback. The system self-regulates the compaction process, automatically detecting defects and triggering re-compaction without human intervention, thereby eliminating the need for skilled technicians while maintaining operational simplicity.
Data Source
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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. The method further comprises running a re-compaction path planning application program at the robot control system of the layup cell based on one or more areas of the ceramic matrix composite ply that require re-compaction, storing the re-compaction path plan in a re-compaction path plan data file; and running the compaction application program at the robot control system using the re-compaction path plan for automated maneuvering of the compaction roller and performing the re-compaction. A corresponding layup cell including a layup tool and a robot control system, a robotic arm and at least one end effector is also part of the invention.