Tape Course Generator for Composite Lamination
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Solution Overview
Problem
Existing composite part programming systems lack the capacity to efficiently define tape courses for complex surfaces, making it difficult to program high-rate composite material application machines with multiple heads to form a variety of composite parts without excessive manual programming.
Innovation Solution
A computer-implemented method and apparatus that approximates a contoured surface with a reference plane, maps ply and tape boundaries to the reference plane, and defines tape edges based on their intersection, enabling efficient generation of tape course definitions for complex surfaces in composite part programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing composite part programming systems are used to define tape courses for complex surfaces, then the machine can operate with standard programming capabilities, but the system lacks the capacity to efficiently define tape courses for complex surfaces requiring excessive manual programming
Solution Approach 1:
The patent creates a simplified reference plane that copies the essential geometric features of the complex contoured surface. By mapping the complex 3D surface onto a 2D reference plane, the system can generate tape courses on the simplified representation and then transfer them back to the original complex surface, avoiding the need for complex direct programming of the actual surface geometry
Solution Approach 2:
The reference plane acts as an intermediary between the complex contoured surface and the programming system. Instead of programming the complex surface directly, the system programs the intermediate reference plane which then serves as a bridge to generate the final tape courses on the complex surface, reducing programming complexity
2Manufacturing precision
If manual programming is used to define tape courses for complex surfaces, then precise control can be achieved, but excessive time and effort are required
Solution Approach 1:
The system performs preliminary mapping of the complex contoured surface onto a reference plane before actual tape course generation. This pre-processing step creates a simplified working model that maintains geometric accuracy while enabling automated course definition, reducing both programming time and manual intervention requirements
Solution Approach 2:
The patent transforms the problem from 3D complex surface coordinates to 2D reference plane coordinates, changing the parameter space in which tape courses are defined. This parameter transformation simplifies the mathematical operations required for tape course generation while maintaining precision through accurate mapping relationships
3Productivity
If a high-rate multihead composite material application machine is used to manufacture composite parts, then production efficiency is improved, but the capacity to efficiently define tape courses for complex surfaces with multiple heads is insufficient
Solution Approach 1:
The patent divides the complex surface into multiple regions that can be independently mapped to the reference plane. Each region can be processed by different machine heads simultaneously, allowing the multihead machine to efficiently cover complex surfaces by segmenting the work area and processing segments in parallel
Solution Approach 2:
The reference plane mapping system provides a universal approach that can handle various complex surface geometries (cylindrical, spherical, contoured) with a single methodology. This universal mapping framework enables the multihead machine to adapt to different complex surface types without requiring specialized programming for each geometry
Data Source
AI summary
A tape course generator produces tape course definitions for use in programming a CNC composite tape lamination machine. The tape course generator includes a reference surface parameterizer that maps a contoured surface onto a parametric reference surface, and a reference plane instantiator that maps the reference surface onto a reference plane. The tape course generator also includes a tape boundary plotter that plots a tape boundary, and a boundary mapper that maps the tape boundary and a ply boundary into the reference plane. In addition, the tape course generator includes an intersection locator that identifies intersections of the ply boundary and the tape boundary, and a tape course delimiter that defines tape cuts and determines which points in the reference plane are within a tape course. Moreover, the tape course generator includes a tape course transformer that maps the defined tape course back onto the contoured surface.