Adaptive Roller Path Planning for Composite Ply Compaction
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Solution Overview
Problem
Current compaction of ceramic matrix composite plies on layup tools is a manual, time-intensive process that results in variable quality and inconsistencies due to the use of compaction roller hand tools, sweeps, hand pressure, and vacuum bags.
Innovation Solution
The development of adaptive path plans for automated compaction rollers, which involve selecting a working path plan data file, identifying inconsistencies in compaction history data, and generating path adaptations to form an adapted path plan for optimized compaction.
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 compaction quality becomes variable and inconsistent
Solution Approach 1:
The patent implements a feedback mechanism where compaction history data is captured and analyzed to identify inconsistencies, and path plans are adaptively adjusted based on this feedback to improve compaction consistency in subsequent operations
Solution Approach 2:
The system performs self-optimization by automatically analyzing its own compaction history data and generating adapted path plans without requiring external intervention, enabling continuous improvement of compaction quality
2Productivity
If manual compaction operations are performed by skilled technicians, then the process can be controlled with human judgment, but the operation time increases significantly
Solution Approach 1:
The patent replaces manual mechanical compaction operations with an automated robotic system that executes path plans, eliminating the time-consuming manual processes while maintaining or improving compaction quality through consistent automated execution
Solution Approach 2:
The system performs preliminary analysis of compaction history data to identify inconsistencies before executing compaction operations, and pre-generates adapted path plans to optimize the compaction process and reduce execution time
3Reliability
If manual compaction operations are performed, then the equipment cost is low, but inspection and rework are required leading to increased life cycle time
Solution Approach 1:
The patent implements continuous feedback through compaction history data capture and analysis, enabling real-time identification of quality issues and adaptive adjustment of path plans to prevent defects and eliminate the need for post-compaction inspection and rework
Solution Approach 2:
The system introduces an intermediary adaptive path planning layer between the compaction equipment and the workpiece, which processes compaction history data and generates optimized path plans to ensure quality outcomes without requiring subsequent inspection cycles
4Manufacturing precision
If automated compaction rollers are used with adaptive path plans, then compaction consistency improves, but the system complexity increases
Solution Approach 1:
The patent creates a universal adaptive path planning system that can handle multiple compaction scenarios and tool configurations through a single integrated platform, reducing the apparent complexity by providing a multi-functional solution that adapts to different requirements
Data Source
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AI summary
Methods for developing a path plan for rollout compaction of a composite ply during composite manufacturing include: selecting a working path plan data file from a working path plan repository, running a path adaptation application program to access compaction history data files in a compaction history repository relating to the working path plan data file and to identify an inconsistency in the compaction history data files that is not resolved in the working path plan data file and generating a path adaptation for the working path plan data file based on the inconsistency that is not resolved to form an adapted path plan data file defining an adapted path plan that includes the path adaptation. Additional methods include using path plans for compaction on the layup tool, capturing image data and processing the image data to build and/or add to the compaction history data file.