Vision-Based Composite Ply Positioning for Tolerance Control

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Solution Overview

Problem

Current methods for manufacturing composite parts for aircraft are labor-intensive and prone to errors, leading to positioning issues that result in composite parts being out of tolerance.

Innovation Solution

A method that involves receiving an image of a composite ply, detecting natural features in the image, and using this feature data to position the composite ply during manufacturing, thereby improving accuracy and reducing errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated systems with end effectors are used to perform pick and place operations, then productivity is improved, but manufacturing precision deteriorates due to positioning errors

Engineering Contradiction:

Improveautomation of pick and place operationsVSAvoidpositioning accuracy of composite plies

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical positioning systems with a vision-based optical system. Cameras capture images of the composite ply and tool, and image processing algorithms automatically determine the precise position and orientation of the ply relative to the tool, eliminating reliance on mechanical end effector positioning accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates digital copies (images) of the physical objects (composite ply and tool). By processing these image copies to extract position and orientation data, the system determines placement accuracy without physical contact, and uses this information to correct positioning errors in real-time.

Inventive Principle:

Principle #26Copying

2Manufacturing precision

If human operators manually handle and transport plies, then manufacturing precision can be maintained through careful alignment, but productivity deteriorates due to labor-intensive processes

Engineering Contradiction:

Improvealignment accuracy of ply boundariesVSAvoidspeed of ply handling and processing

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system enables automated self-positioning of the composite ply. The vision system automatically detects the ply's position and orientation, calculates the required adjustments, and guides the placement device to achieve correct positioning without human intervention, combining the speed of automation with the precision previously requiring manual alignment.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements a feedback loop where the vision system continuously monitors the position of the composite ply and tool, compares the actual position with the desired position, and adjusts the placement operations accordingly. This closed-loop control maintains precision while enabling automated high-speed operations.

Inventive Principle:

Principle #23Feedback

3Ease of operation

If multiple human operators are used to transport large plies, then positioning can be achieved, but device complexity increases and the process becomes more tedious

Engineering Contradiction:

Improveability to handle large pliesVSAvoidnumber of operators and coordination required

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent extracts the positioning function from human operators and assigns it to an automated vision system. The system separately handles image capture, image processing, position calculation, and control signals, eliminating the need for multiple operators and their coordination while simplifying the overall process.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12327344B2Natural feature pick and place system for composite materials

Publication Date: 2025.06.10 THE BOEING CO

AI summary

A method, apparatus, system, and computer program product for processing a composite ply. An image of the composite ply is received. Natural features in the image of the composite ply are detected. Feature data for the natural features detected in association is saved with a ply identifier for the composite ply in a repository. The feature data is used to position the composite ply during manufacturing of a composite part using the composite ply.