Automated Tape Laydown Machine Course Ordering Optimization
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Solution Overview
Problem
Conventional tape laydown machines face inefficiencies due to non-productive motion, which is not optimized, leading to reduced productivity in fabricating composite parts, especially with complex ply segments and varying machine dynamics.
Innovation Solution
An automated method that analyzes course structures, identifies and minimizes non-productive motion by optimizing the ordering and grouping of tape courses, generating machine-readable instructions to control the laydown machine based on machine characteristics and constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional tape laydown machines use manual or simple automated path generation, then the machine is easier to operate, but non-productive motion is not optimized leading to reduced productivity
Solution Approach 1:
The system performs preliminary analysis of the course structure and machine dynamics before generating the final path. By pre-calculating optimal course ordering, grouping, and partitioning based on machine-specific parameters (acceleration, velocities, head configurations), the system eliminates non-productive motion without requiring complex real-time adjustments during operation.
Solution Approach 2:
The path generation system adapts to different machine dynamics and configurations by incorporating machine-specific parameters into the optimization algorithm. The system dynamically adjusts course ordering and grouping strategies based on acceleration capabilities, axis velocities, and head turnaround characteristics of the particular machine being used.
2Loss of time
If the NC programmer manually optimizes machine paths based on experience and intuition, then some optimization is achieved, but the process is time-consuming and lacks systematic optimization
Solution Approach 1:
The system incorporates feedback loops that analyze the generated paths and iteratively improve them. The automated optimization process evaluates multiple course ordering scenarios, calculates non-productive motion for each, and selects the optimal sequence. This systematic feedback-driven approach replaces manual trial-and-error optimization with automated iterative improvement.
Solution Approach 2:
The path generation system performs self-optimization by automatically analyzing course structures, machine dynamics, and operational constraints to generate optimized paths without requiring manual intervention. The system serves itself by incorporating machine-specific parameters and automatically determining optimal course ordering, grouping, and partitioning strategies.
3Ease of operation
If courses are laid down in simple sequential order, then the programming is simpler, but non-productive motion between courses increases
Solution Approach 1:
The system segments the tape laying process into distinct courses that are analyzed individually for optimal ordering. By partitioning the work into discrete course segments and evaluating different ordering scenarios, the system identifies sequences that minimize non-productive motion between courses while maintaining operational simplicity through automated generation.
Solution Approach 2:
The optimization extends beyond simple sequential ordering by considering multi-dimensional factors including machine dynamics, head configurations, and spatial relationships between courses. The system evaluates paths in multiple dimensions (different ordering scenarios, grouping strategies, partitioning approaches) to find the optimal solution that balances simplicity with productivity.
Data Source
AI summary
The non-productive motion of an automatic composite tape laydown machine is optimized to increase the overall rate of the laydown. Ordering of tape courses is analyzed to determine the time required to move between courses using a time function that reflects operating characteristics and limitations of the tape laydown machine. The ordering is optimized by re-ordering, grouping and/or partitioning the tape courses so as to reduce the non-productive motion of the machine. The optimized ordering is used by a NC program that controls the operation of the machine.