CN117261284A

CN117261284A - Composite manufacturing system and method

Info

Publication number: CN117261284A
Application number: CN202310666762.4A
Authority: CN
Inventors: M·A·拉比加; M·K·路易; E·G·谢拉德; T·拉德伯格; R·E·伍德; L·A·珀拉; B·坡
Original assignee: Boeing Co
Current assignee: Boeing Co
Priority date: 2022-06-22
Filing date: 2023-06-06
Publication date: 2023-12-22

Abstract

Composite manufacturing systems and methods. A composite manufacturing system includes a lamination tool including a lamination surface, a first alignment target extending the lamination surface, and a second alignment target extending the lamination surface. The system includes a computer-aided measurement system to measure line profiles of the first positioning target, the second positioning target, and the laminate surface and to generate primary surface data and primary target data. The main target data represents target positions of the first positioning target and the second positioning target. The main surface data indicates the contour position of the line contour. The line profile is associated with the target pair. Each target pair includes a first positioning target and an opposing second positioning target. The system includes a computing device to generate a master file establishing a spatial relationship between the master target data and the primary surface data and associate the master file with the lamination tool.

Description

Composite manufacturing system and method

Technical Field

The present disclosure relates generally to composite manufacturing, and more particularly, to a composite manufacturing system and method that compensates a digitally controlled composite layup machine for positional variation of a lamination tool.

Background

The percentage of composite materials in the design and manufacture of platforms such as aircraft and automobiles is increasing. For example, composite materials are used in aircraft to reduce the weight of the aircraft. This weight reduction improves performance characteristics such as payload capacity and fuel efficiency. In addition, the composite material provides a longer service life for various components in the aircraft.

Automated composite manufacturing requires high precision. For example, automated composite manufacturing typically requires scanning a lamination tool, determining the position of the lamination tool, and aligning a numerical control composite layup machine with the position of the tool. Conventional solutions require scanning the entire surface of the lamination tool to establish rigid body transformation alignment features that require reuse. This process requires a lot of time and effort and does not allow for efficient local variation compensation. Accordingly, those skilled in the art continue to develop in the field of automated composite manufacturing.

Disclosure of Invention

Examples of a composite manufacturing system, a composite manufacturing method, and a computer system for a composite manufacturing system are disclosed. The following is a non-exhaustive list of examples that may or may not be claimed in accordance with the presently disclosed subject matter.

In an example, the disclosed composite manufacturing system includes a lamination tool. The lamination tool includes a lamination surface, a plurality of first positioning targets extending the lamination surface along a first side of the lamination tool, and a plurality of second positioning targets extending the lamination surface along a second side of the lamination tool opposite the first side. The system also includes a computer-aided measurement system. The computer-aided measurement system measures a series of line contours of the first positioning target, the second positioning target, and the laminate surface, and generates primary surface data and primary target data. The primary target data represents target positions of the first positioning target and the second positioning target. The main surface data represents the contour position of the line contour of the lamination surface. Each line profile is associated with and extends between one of a plurality of target pairs. Each target pair includes a first positioning target and an opposing second positioning target. The system further includes a computing device adapted to generate a master file establishing a spatial relationship between the master target data and the master surface data and associating the master file with the lamination tool.

In an example, a composite manufacturing method includes the steps of: (1) Measuring a series of line contours of the laminating surface of the laminating tool, the first positioning target and the second positioning target; (2) generating primary surface data and primary target data; (3) Generating a master file establishing a spatial relationship between master target data and master surface data; and (4) associating the master file with the lamination tool. The primary target data represents target positions of the first positioning target and the second positioning target. The main surface data represents the contour position of the line contour of the lamination surface. Each line profile is associated with and extends between one of a plurality of target pairs. Each target pair includes a first positioning target and an opposing second positioning target.

In an example, the disclosed computer system includes a processor unit coupled to a storage device that includes program code executable by the processor unit to: (1) Instructing the computer-aided measurement system to measure a series of line contours of the laminating surfaces of the plurality of first positioning targets, the plurality of second positioning targets, and the laminating tool and generate primary surface data and primary target data; (2) Generating a master file establishing a spatial relationship between master target data and master surface data; and (3) associating the master document with the lamination tool. The primary target data represents target positions of the first positioning target and the second positioning target. The main surface data represents the contour position of the line contour of the lamination surface. Each line profile is associated with and extends between one of a plurality of target pairs. Each target pair includes a first positioning target and an opposing second positioning target.

According to one aspect of the present disclosure, a composite manufacturing system includes:

lamination tool comprising

Laminating the surfaces;

a plurality of first positioning targets extending the laminating surface along a first side of the laminating tool; and

a plurality of second positioning targets extending the lamination surface along a second side of the lamination tool opposite the first side;

a computer-aided measurement system adapted to measure a series of line contours of the first positioning object, the second positioning object and the laminating surface and to generate primary surface data and primary object data, wherein:

the main target data represents target positions of the first positioning target and the second positioning target;

the main surface data represents the contour position of the line contour of the laminated surface;

each line profile is associated with and extends between one of a plurality of target pairs; and is also provided with

Each target pair includes a first positioning target and an opposing second positioning target; and

a computing device adapted to:

generating a master file establishing a spatial relationship between master target data and master surface data; and is also provided with

The master file is associated with a lamination tool.

Advantageously, the composite manufacturing system is such that:

The computing device is adapted to:

dividing a main file into a plurality of partitions; and is also provided with

The zones are associated with corresponding portions of the laminating surface,

each partition includes a portion of the main surface data representing three line profiles and a portion of the main target data representing three target pairs associated with the three line profiles; and is also provided with

Each of the partitions overlaps with a directly adjacent one of the partitions such that a portion of the main surface data representing one line profile and a portion of the main target data representing one target pair associated with the one line profile are shared by the directly adjacent pair of partitions.

Preferably, the composite manufacturing system is such that:

the computer-aided measurement system is adapted to re-measure the first and second positioning targets and to generate measured target data;

the measured target data represents target positions of the first positioning target and the second positioning target; and is also provided with

The computing means is adapted to determine the contour position of the line contour of the lamination surface from the measured target data based on the spatial relationship between the main target data and the main surface data established by the main file.

Preferably, the composite manufacturing system further comprises a numerically controlled composite lay-up machine configured to perform the composite lay-up operation based on the nominal position of the lamination surface,

Wherein:

the computing device is adapted to:

comparing the contour position of the line contour of the laminated surface represented by the partitioned main surface data with the nominal position of the corresponding portion of the laminated surface;

determining a plurality of local deviations between the contour position and the nominal position;

determining a total deviation from the local deviation; and is also provided with

Transmitting the total deviation to a numerical control composite material laying machine; and is also provided with

The numerical control composite lay-up machine compensates the numerical control program path based on the total deviation.

Preferably, the composite manufacturing system is such that:

the computer-aided measurement system is adapted to re-measure the selected first and second positioning targets corresponding to a partition and to generate measured target data; and is also provided with

The computing device is adapted to:

determining, from the measured target data, a contour position of a line contour of the laminated surface represented by the main surface data and associated with the selected first positioning target and the second positioning target corresponding to the one partition based on a spatial relationship between the main target data and the main surface data established by the main file;

comparing the contour position of the line contour represented by the one partitioned main surface data with the nominal position of the corresponding portion of the lamination surface;

Determining a local deviation between the contour position and the nominal position;

correcting the total deviation by using the local deviation; and is also provided with

The numerical control composite lay-up machine compensates the numerical control program path based on the total deviation corrected by the local deviation.

Preferably, the composite manufacturing system further comprises a vision system configured to visually inspect the composite laminate formed on the lamination surface of the lamination tool during a composite lay-up operation performed by the digitally controlled composite lay-up machine,

wherein:

the computing device is adapted to:

detecting anomalies in the composite laminate; and is also provided with

Determining a partition corresponding to a portion of the lamination surface associated with the abnormal position; and is also provided with

The selected first and second positioning targets re-measured by the computer-aided measuring system correspond to the one partition.

Preferably, the composite manufacturing system further comprises a plurality of lamination tools, each lamination tool further comprising an identifier,

wherein:

the computer-aided measurement system is adapted to measure a series of line contours of the first positioning object, the second positioning object and the laminating surface and generate primary surface data and primary object data for each lamination tool; and is also provided with

The computing device is adapted to:

generating, for each lamination tool, a master document establishing a spatial relationship between master target data and master surface data; and is also provided with

The master file is associated with an identifier corresponding to one of the lamination tools.

According to another aspect of the present disclosure, a composite manufacturing method includes the steps of:

measuring a series of line profiles of the laminating surfaces of the first positioning object, the second positioning object and the laminating tool;

generating primary surface data and primary target data, wherein:

Each target pair includes a first positioning target and a second positioning target;

generating a master file establishing a spatial relationship between master target data and master surface data; and

the master file is associated with a lamination tool.

Advantageously, the composite manufacturing further comprises the steps of:

dividing a main file into a plurality of partitions; and

the zones are associated with corresponding portions of the laminating surface,

Wherein:

Preferably, the composite manufacturing method further comprises the steps of:

re-measuring the first positioning target and the second positioning target;

generating measured target data, wherein the measured target data represents target positions of the first positioning target and the second positioning target; and

a contour position of a line contour of the lamination surface is determined from the measured target data based on a spatial relationship between the main target data and the main surface data established by the main file.

Preferably, the composite manufacturing method further comprises the steps of:

comparing the contour position of the line contour represented by the partitioned main surface data with the nominal position of the corresponding portion of the lamination surface;

Determining a total deviation from the local deviation;

transmitting the total deviation to a numerical control composite material laying machine;

compensating a numerical control program path of the numerical control composite material laying machine based on the total deviation; and

and performing a composite material laying operation by using a numerical control composite material laying machine according to the numerical control program path based on total deviation compensation.

Preferably, the composite manufacturing method further comprises the steps of:

re-measuring the selected first positioning object and second positioning object corresponding to one partition;

generating measured target data;

determining a contour position of a line contour of the laminated surface associated with the selected first positioning target and the second positioning target corresponding to the one partition from the measured target data based on a spatial relationship between the main target data and the main surface data established by the main file;

correcting the total deviation by using the local deviation;

compensating a numerical control program path based on the total deviation; and

Preferably, the composite manufacturing method further comprises the steps of:

inspecting the composite laminate formed on the lamination surface of the lamination tool during a composite lay-up operation performed by the digitally controlled composite lay-up machine;

detecting anomalies in the composite laminate; and

determining a zone corresponding to a portion of the lamination surface associated with the anomaly location,

wherein the re-measured selected first and second positioning targets correspond to the one partition.

Preferably, the composite manufacturing method further comprises the steps of:

measuring a series of line contours of the laminating surface of each of the first positioning target, the second positioning target, and the plurality of laminating tools;

generating primary surface data and primary target data for each lamination tool;

generating, for each lamination tool, a master document establishing a spatial relationship between master target data and master surface data; and

According to another aspect of the present disclosure, a computer system for a composite manufacturing system includes a processor unit coupled to a storage device including program code executable by the processor unit to:

Instructing the computer-aided measurement system to measure a series of line contours of the laminating surfaces of the plurality of first positioning targets, the plurality of second positioning targets, and the laminating tool and generate primary surface data and primary target data, wherein:

Each target pair includes a first positioning target and an opposing second positioning target;

The master file is associated with a lamination tool.

Advantageously, the computer system is such that the program code is executable by the processor unit to:

dividing a main file into a plurality of partitions; and is also provided with

The zones are associated with corresponding portions of the laminating surface,

wherein:

Preferably, the computer system is such that the program code is executable by the processor unit to:

instructing a computer-aided measurement system to re-measure the first positioning target and the second positioning target and to generate measured target data, wherein the measured target data represents target positions of the first positioning target and the second positioning target; and is also provided with

Preferably, the computer system is such that:

the program code is executable by the processor unit to:

comparing the profile position represented by the partitioned main surface data with a nominal position of a corresponding portion of the laminating surface;

Transmitting the total deviation to a numerical control composite lay-up machine configured to perform a composite lay-up operation based on the nominal position; and is also provided with

Preferably, the computer system is such that:

the program code is executable by the processor unit to:

instructing the computer-aided measurement system to re-measure the selected first and second positioning targets corresponding to one partition and to generate measured target data;

comparing the profile position represented by the one partitioned main surface data with a nominal position of a corresponding portion of the lamination surface;

The total deviation is transmitted to a numerical control composite material laying machine,

instructing the computer-aided measurement system to measure a series of line contours of the first positioning target, the second positioning target, and the laminating surface and generating primary surface data and primary target data for each of the plurality of laminating tools;

Other examples of the disclosed composite manufacturing system, method, and computer system will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

Drawings

FIG. 1 is a schematic block diagram of an example of a composite manufacturing system;

FIG. 2 is a schematic perspective view of an example of a lamination tool of a composite manufacturing system;

FIG. 3 is a schematic perspective view of an example of a lamination tool with a partial change in shape;

FIG. 4 is a schematic plan view of an example of the laminating tool shown in FIG. 2;

FIG. 5 is a schematic plan view of an example of the laminating tool shown in FIG. 4, depicting a plurality of line contours of the laminating surface;

FIG. 6 is a schematic diagram of an example of the laminating tool shown in FIG. 2 represented by collected measurement data;

FIG. 7 is a schematic diagram of an example of the lamination tool shown in FIG. 3 represented by collected measurement data;

FIG. 8 is a schematic diagram of an example of a lamination tool represented by collected measurement data after a series of partial rigid body transformations;

FIG. 9 is a flow chart of an example of a composite manufacturing method;

FIG. 10 is a schematic block diagram of a computing device of the composite manufacturing system;

FIG. 11 is a schematic diagram of an example of a composite manufacturing system;

FIG. 12 is a flow chart of an example of an aircraft manufacturing and service method;

fig. 13 is a schematic illustration of an example of an aircraft.

Detailed Description

Referring generally to fig. 1-8 and 11, as an example, the present disclosure relates to a composite manufacturing system 100, which may also be referred to generally herein as system 100. The system 100 enables efficient collection of data representative of the laminating tool 108. The system 100 also enables automatic compensation of a Numerical Control (NC) composite material placement machine 102 based on the actual position (e.g., position, orientation, and shape) of the lamination tool 108 represented by the collected data. The system 100 also enables reuse of previously collected data during subsequent machine compensation operations.

Referring now to fig. 1, in one or more examples, the system 100 includes a lamination tool 108. The lamination tool 108 includes a lamination surface 110 that supports the formation of the composite laminate 240. The system 100 includes an NC composite material placement machine 102, such as a tape laminator or a fiber placement machine. NC composite layup machine 102 lays up the composite layers on lamination tool 108 to form composite laminate 240. The system 100 includes a computer-aided measurement system (CAMS) 126. The computer-aided measuring system 126 measures the laminating tool 108 and provides data representing the tool position (e.g., relative to a tool coordinate system) of the laminating tool 108 in the tool space. The system 100 includes a computing device 134. The computing device 134 determines a difference between the tool position of the lamination tool 108 in the tool space and a nominal position of the lamination tool 108 in the machine space (e.g., relative to a machine coordinate system). The NC composite layup machine 102 is compensated for based on this difference before performing the composite layup operation.

Typically, in manufacturing the composite laminate 240, the NC composite layup machine 102 is used to automatically lay up (e.g., lay up or laminate in a layer-by-layer manner) the composite layup 208 (e.g., composite layer) on the lamination tool 108. The composite layup 208 may take the form of a fabric, strip, drop, or other suitable form. In some cases, the resin may be infused or pre-impregnated into the layer. The composite layup 208 may be laid in different orientations and different numbers of layers may be used depending on the thickness of the composite laminate 240 being manufactured. The composite layup 208 may be compacted or otherwise consolidated or compacted (e.g., by a compaction apparatus). After disposing the composite layup 208, the composite laminate 240 is cured (e.g., via application of heat and/or pressure) to form a composite structure. The composite laminate 240 may be cured on the lamination tool 108 or may be transferred from the lamination tool 108 to a curing tool (not shown) to perform the curing operation.

The NC composite material placement machine 102 is computer numerically controlled and is operable by following coded program instructions (e.g., G-codes) to meet process specifications without requiring a manual operator to directly control the process operations. As an example, the NC composite material placement machine 102 includes a platform 212 (e.g., as shown in fig. 11) having a plurality of degrees of freedom (e.g., a robotic arm) and a control unit 210 (e.g., shown in fig. 1) that operates the platform 212 according to a Numerical Control (NC) program 220. The NC composite layup machine 102 includes a layup head 206 (e.g., a tool head) coupled to a platform 212. As an example, the placement head 206 forms an end effector of the NC composite placement machine 102 and is configured to deposit individual composite layups 208 on the laminate surface 110 or previously deposited composite layups 208.

In general, the placement head 206 defines a machine point of the NC composite material placement machine 102. During a composite lay-up (e.g., lamination or lay-up) operation, the lay-up head 206 (e.g., machine point) is positioned and moved relative to the lamination tool 108 (e.g., lamination surface 110) along a Numerical Control (NC) program path 222 (e.g., tool path) according to NC program 220. In one or more examples, the NC composite placement machine 102, such as the control unit 210 or NC program 220, includes a tool path generator that generates an NC program path 222 based on a nominal position of the laminating tool 108.

Generally, the NC program 220 (more specifically, the NC program path 222 of the NC composite material placement machine 102) is generated based on the nominal position of the lamination tool 108 (more specifically, the nominal position of the lamination surface 110). The nominal position of the lamination tool 108 (e.g., lamination surface 110) refers to or represents the known theoretical position, orientation, and shape of the lamination tool 108 (e.g., lamination surface 110) in machine space. However, when laying down the laminating tool 108 in the work cell 104 of the manufacturing environment 200 (e.g., as shown in fig. 11), the tool position of the laminating tool 108 (more specifically, the surface position of the laminating surface 110) may not match the nominal position used to create the NC program 220. The tool position of the laminating tool 108 (more specifically, the surface position of the laminating surface 110) refers to or represents the known actual position, orientation, and shape of the laminating tool 108 (e.g., the laminating surface 110) in the tool space.

Thus, a transformation is typically used to transform the tool position to a nominal position and to determine the difference between the tool position and the nominal position. The NC composite material placement machine 102 is compensated for the differences determined from the transformation. As an example, a global rigid body transformation is calculated by determining the difference in position of features on the lamination tool 108 in the tool space and in the machine space. The location of features is known in tool space (e.g., based on measurements of lamination tool 108) and in machine space (e.g., based on design specifications). The accuracy of the transformation is iteratively tested by manipulating the six independent variables of the transformation (e.g., X, Y, Z, rX, rY, rZ) until the transformation error is minimized. NC program 220 is compensated based on the calculated global transformation.

Lamination tools having high aspect ratios (e.g., lamination tool 108 shown in fig. 2 and 3) may not appear to be rigid. As an example (shown in fig. 3), one or more portions of the lamination tool 108 may bend about an axis perpendicular to the longitudinal axis A1 of the lamination tool 108 (e.g., about the Y-axis and/or the Z-axis), or may twist about an axis parallel to the longitudinal axis A1 (e.g., about the X-axis), which results in a localized change in tool position. Due to these local variations in tool position of the lamination tool 108, the above-described rigid body transformation operations may not provide sufficient machine compensation accuracy to enable the NC composite layup machine 102 to manufacture the composite laminate 240 to the required tolerances. Thus, a series of local rigid body transformations are computed for the corresponding sections of the lamination tool 108 (e.g., by techniques similar to the global transformations described above). NC program 220 is compensated based on the calculated series of local transformations.

In general, the lamination surface 110 of the lamination tool 108 is used as a feature for computing the global transformation and/or a series of local transformations described above. However, these methods typically require full surface measurements (e.g., measuring all or a majority of the lamination surface 110) each time the lamination tool 108 is loaded in the work unit 104 in order to provide sufficient accuracy. Thus, the process for measuring the laminating surface 110, calculating the transformation, and compensating the NC program 220 for the difference between the tool position and the nominal position is time consuming and requires a lot of processing resources.

Accordingly, the system 100 disclosed herein provides improvements relating to the type of data collected and used for machine compensation and the manner in which such data is collected. As an example, the system 100 facilitates reducing an amount of data representing the lamination tool 108 and used for machine compensation. As another example, the system 100 facilitates efficient and at least partially automated collection of data. As another example, the system 100 facilitates reuse of collected data despite local variations in tool position of the laminating tool 108 that may occur each time the laminating tool 108 is loaded in a work cell.

Referring now to fig. 2 and 3, examples of lamination tools 108 that the system 100 includes or is otherwise used are shown. The lamination tool 108 may also be referred to as a laying tool or a laying mandrel. In one or more examples, the lamination tool 108 is elongated along the longitudinal axis A1, or has a high aspect ratio (e.g., a length dimension along the longitudinal axis A1 is on the order of magnitude greater than a width dimension transverse to the longitudinal axis A1). As shown in fig. 4, the lamination tool 108 may bend, twist, sag, or otherwise include localized variations in position, orientation, and/or shape when loaded in the work unit 104 to facilitate manufacturing of the composite laminate 240

Referring now to fig. 4, in one or more examples, the lamination tool 108 further includes a plurality of first positioning targets 112 and a plurality of second positioning targets 152. In one or more examples, the first positioning target 112 is positioned (e.g., at or near) and extends proximate to the lamination surface 110 along the longitudinal axis A1 of the lamination tool 108. For example, the first positioning target 112 is disposed on a first side 172 of the laminating tool 108. The second positioning target 152 is positioned and extends along the longitudinal axis A1 of the laminating tool 108 proximate the laminating surface 110. For example, the second positioning target 152 is disposed on a second side 174 of the lamination tool 108 opposite the first side 172. As described in greater detail herein below, the first positioning target 112 and the second positioning target 152 are used to reproducibly determine the actual tool position of the laminating tool 108, and thus the actual surface position of the laminating surface 110, without requiring subsequent measurements of the laminating surface 110.

In one or more examples, each first positioning target 112 corresponds to or is associated with one second positioning target 152. As an example, the first positioning target 112A may correspond to or otherwise be associated with the second positioning target 152A, the first positioning target 112B may correspond to or otherwise be associated with the second positioning target 152B, the first positioning target 112C may correspond to or otherwise be associated with the second positioning target 152C, and so on.

In one or more examples, the first positioning target 112 and the second positioning target 152 may be identified as a plurality of target pairs 156. Each target pair 156 includes a first positioning target 112 and a corresponding second positioning target 152. As an example, target pair 156A includes first positioning target 112A and second positioning target 152A, target pair 156B includes first positioning target 112B and second positioning target 152B, target pair 156C includes first positioning target 112C and second positioning target 152C, and so on.

In one or more examples, each first positioning target 112 is directly opposite, or at least approximately aligned, with a corresponding one of the second positioning targets 152. In other examples, one or more first positioning targets 112 may be offset or misaligned from corresponding second positioning targets 152.

In various examples, the lamination tool 108 may include any suitable number of first and second positioning targets 112, 152. The number of first positioning targets 112 and second positioning targets 152 may depend on various factors such as, but not limited to, the number and type of tool holders (e.g., tool holders 218 shown in fig. 11) used to support the laminating tool 108 in the work cell 104, the size and/or shape of the laminating tool 108, the material composition of the laminating tool 108, and the like.

In one or more examples, the number of target pairs 156 (e.g., first positioning target 112 and corresponding second positioning target 152) and the linear distance or spacing (e.g., along longitudinal axis A1) between any one target pair 156 and an immediately adjacent one of target pairs 156 are determined and selected to minimize errors in local rigid body transformation operations for machine compensation, to minimize the number of target pairs 156 required for accurate local rigid body transformation operations, and/or to maximize the linear distance between adjacent target pairs 156 suitable for accurate local rigid body transformation operations. In one or more examples, the number of target pairs 156 and the linear distance (e.g., pitch) between immediately adjacent target pairs 156 may be calculated by any suitable analysis technique (e.g., by finite element analysis).

In one or more examples, the linear distance between one target pair 156 and an immediately adjacent one target pair 156 is different from the linear distance between another target pair 156 and an immediately adjacent one target pair 156. As an example, the linear distance between the target pair 156A and the immediately adjacent target pair 156B (e.g., located at a wider or stiffer portion of the lamination tool 108) may be different (e.g., greater) than the linear distance between the target pair 156D and the immediately adjacent target pair 156E (e.g., located at a thinner or less stiff portion of the lamination tool 108).

Referring to fig. 1 and 5, in one or more examples, the computer-aided measurement system 126 is configured to measure the lamination tool 108. As an example, the computer-aided measurement system 126 measures a series of line profiles 154 of the first positioning target 112, the second positioning target 152, and the laminating surface 110. In one or more examples, the line profile 154 is used as a feature of known (e.g., measured or otherwise determined) position in the tool space and the machine space in order to perform a transformation for compensating the NC composite material placement machine 102. In one or more examples, the first positioning target 112, the second positioning target 152, and the line profile 154 are used as features of known locations in the tool space and in the machine space in order to perform transformations for compensating the NC composite material placement machine 102.

The computer-aided measurement system 126 is configured to generate data representative of the lamination tool 108. In one or more examples, the computer-aided measurement system 126 generates primary surface data 116 and primary target data 118. The primary target data 118 represents target locations (e.g., positions and orientations) of the first positioning target 112 and the second positioning target 152. The major surface data 116 represents the contour location (e.g., position, orientation, and shape) of the line contour 154 of the laminating surface 110.

In one or more examples, the primary target data 118 includes measurement data (e.g., X, Y, Z coordinates) representing target locations corresponding to the first positioning target 112 and the second positioning target 152. In one or more examples, the major surface data 116 includes measurement data (e.g., X, Y, Z coordinates) representative of the contour location and, therefore, the shape of each line contour 154. Thus, in combination, the contour position of the line contour 154 represents the surface position (e.g., position, orientation, and shape) of the laminating surface 110.

Referring now to FIG. 5, in one or more examples, each line profile 154 is associated with and extends between a target pair 156. Each target pair 156 includes a first positioning target 112 and a corresponding (e.g., opposite) second positioning target 152. As an example, the line profile 154A extends across the laminating surface 110 between the first positioning target 112A and the second positioning target 152A, the line profile 154B extends across the laminating surface 110 between the first positioning target 112B and the second positioning target 152B, the line profile 154C extends across the laminating surface 110 between the first positioning target 112C and the second positioning target 152C, and so on.

Each line profile 154 includes or is formed by a relatively small portion of the laminating surface 110. Each line profile 154 measured by the computer-aided measurement system 126 represents the position (location, orientation, and shape) of the surface profile of a portion of the laminating surface 110. Thus, the primary surface data 116 includes a series of data point sets (e.g., data point set 170 shown in fig. 1). Each set of data points 170 includes data (e.g., X, Y, Z coordinates) representing a contour position for a corresponding one of the line contours 154.

In one or more examples, the one or more line profiles 154 (e.g., line profile 154A) are linear (e.g., straight). In one or more examples, one or more line profiles 154 (e.g., line profile 154B) are non-linear (e.g., curved). In one or more examples, the one or more line profiles 154 include linear and nonlinear portions.

In one or more examples, one or more line profiles 154 (e.g., line profile 154A and line profile 154B) are continuous. As an example, the line profile 154A extends continuously between the first positioning target 112A and the second positioning target 152A. In one or more examples, one or more line profiles 154 (e.g., line profile 154C) are discontinuous. By way of example, the line profile 154C includes a profile first portion 192 and a profile second portion 194. The contoured first portion 192 extends from the first locating target 112C and across a portion of the laminating surface 110 toward the second locating target 152C. The contoured second portion 194 extends from the second locating target 152C and across a portion of the laminating surface 110 toward the first locating target 112C.

Referring again to fig. 1, in one or more examples, computing device 134 is configured to generate master file 114. The computing device 134 is also configured to associate the master file 114 with the lamination tool 108.

The master file 114 includes master target data 118 and master surface data 116. Master file 114 correlates master target data 118 with master surface data 116 and establishes a spatial relationship therebetween. In other words, the master file 114 establishes a fixed spatial relationship between the target positions of the first positioning target 112 and the second positioning target 152 represented by the master target data 118 and the contour position of the line contour 154 represented by the master surface data 116.

More specifically, the master file 114 establishes a fixed relationship of the contour position of each line contour 154 represented by the master surface data 116 relative to the target positions of a corresponding one of the target pairs 156 (e.g., one of the first positioning targets 112 and one of the second positioning targets 152) represented by the master target data 118. As an example, the master file 114 establishes a spatial relationship between a portion of the master target data 118 representing target positions of the first positioning target 112A and the second positioning target 152A and a portion of the master surface data 116 representing contour positions of the line contour 154A, establishes a spatial relationship between a portion of the master target data 118 representing target positions of the first positioning target 112B and the second positioning target 152B and a portion of the master surface data 116 representing contour positions of the line contour 154B, and so forth.

It is understood that localized variations in tool position may occur entirely along the length of the laminating tool 108 (e.g., as shown in fig. 4). However, relatively small discrete sections of the lamination tool 108 do not generate these localized variations. Thus, the profile position of any one line profile 154 relative to the target position of the corresponding target pair 156 is not affected by local variations along the length of the lamination tool 108.

Using the line profile 154 as a specific portion of the laminated surface 110 to be measured and generating the primary surface data 116 representing the line profile 154 advantageously reduces the time required to measure the laminated surface 110, reduces the amount of data required to adequately represent the laminated surface 110, and reduces the processing resources required for the converting operation for machine compensation, as compared to conventional techniques requiring measurement and data collection of an entire or large area of the laminated surface 110.

The use of the first positioning target 112 and the second positioning target 152 provides a fixed reference location on the lamination tool 108 for initial measurement of the line profile 154 of the lamination surface 110 to the computer-aided measurement system 126.

The use of the relationship between the primary surface data 116 and the primary target data 118 established by the primary file 114 enables the contour position of the line contour 154, and thus the surface position of the laminating surface 110, to be determined from subsequent re-measurements of the first and second positioning targets 112, 152 without requiring subsequent measurements of the laminating surface 110.

In one or more examples, the master file 114 is created when the lamination tool 108 is initially loaded in the work unit 104 (e.g., as shown in fig. 11). As an example, when laying down the lamination tool 108 in the work cell 104, the computer-aided measurement system 126 measures the lamination tool 108 and generates the primary target data 118 and the primary surface data 116. The computing device 134 generates the master file 114 and associates the master file 114 with the laminating tool 108. In one or more examples, the master file 114 represents an initial or baseline measurement of the lamination tool 108. In one or more examples, the master file 114 is used to represent the nominal position of the lamination tool 108 or to replace a design specification (e.g., CAD model) that originally represented the nominal position of the lamination tool 108.

In one or more examples, at the initial measurement of the lamination tool 108, the master file 114 is used to determine the transformation and compensate for the NC composite layup machine 102.

In one or more examples, computing device 134 compares the contour position of line contour 154 represented by major surface data 116 of main file 114 with the nominal position of line contour 154 and determines a deviation 176 (shown in fig. 1) between the contour position of line contour 154 and the nominal position of line contour 154. The bias 176 represents a global rigid body transformation and may be algebraically represented using a transformation coordinate matrix and calculated or determined using a best fit analysis (e.g., least squares) between the primary surface data 116 representing the contour position of the line contour 154 and the data representing the nominal position of the line contour 154.

The computing device 134 communicates the deviation 176 to the NC composite material placement machine 102. The NC composite material placement machine 102 compensates the NC program path 222 based on the deviation 176.

Referring now to FIG. 6, an example of a virtual representation of the lamination tool 108 represented by the collected data (e.g., the primary surface data 116 and the primary target data 118 of the primary file 114) is schematically illustrated. In one or more examples, computing device 134 is configured to divide main file 114 into a plurality of partitions 158. The computing device 134 is configured to associate the partitions 158 with corresponding portions or sections of the laminating surface 110. As an example, the computing device 134 associates each partition 158 with a corresponding portion or section of the laminating surface 110.

In one or more examples, each partition 158 includes a portion of the primary surface data 116 representing three line contours 154 and a portion of the primary target data 118 representing three target pairs 156 associated with or corresponding to the three line contours 154. In other examples, the one or more partitions 158 may include a portion of the primary surface data 116 representing more than three line profiles 154 and a portion of the primary target data 118 representing more than three target pairs 156 associated with or corresponding to more than three line profiles 154.

In one or more examples, each partition 158 overlaps with a directly adjacent one of the partitions 158 such that a portion of the primary surface data 116 representing one line profile 154 and a portion of the primary target data 118 representing one target pair 156 associated with the one line profile 154 are shared by the directly adjacent pair of partitions 158. As an example, partition 158A includes a portion of primary surface data 116 representing line contours 154A, 154B, 154C and a portion of primary target data 118 representing target pairs 156A, 156B, 156C. Partition 158B overlaps partition 158A and includes a portion of primary surface data 116 representing line contours 154C, 154D, 154E and a portion of primary target data 118 representing target pairs 156C, 156D, 156E. The partition 158C overlaps the partition 158B and includes a portion of the primary surface data 116 representing the line profiles 154E, 154F, 154G and a portion of the primary target data 118 representing the target pairs 156E, 156F, 156G, and so on.

Referring now to fig. 7 and 8, examples of virtual representations of the lamination tool 108 represented by the collected data (e.g., the primary surface data 116 and the primary target data 118 of the primary file 114) are schematically illustrated. In fig. 7 and 8, the lamination tool 108 includes one or more localized variations in the surface position of the lamination surface 110 (e.g., as shown in fig. 3) due to bending and/or twisting of the lamination tool 108 when the lamination tool 108 is laid down in the work unit 104.

As shown in fig. 7, in one or more examples, the computing device 134 compares the contour position of the line contour 154 represented by the major surface data 116 of the master file 114 for each partition 158 to the nominal position of the line contour 154 of the corresponding portion or section of the laminating surface 110, and determines a plurality of local deviations 178 (shown in fig. 1) between the contour position and the nominal position. The local biases 178 represent local rigid body transformations, and may be calculated or determined using a best fit analysis (e.g., least squares) between the primary surface data 116 representing the contour position of the line contour 154 of each partition 158 and the data representing the nominal position of the line contour 154.

As shown in fig. 8, the computing device 134 then determines the total deviation 180 from the local deviation 178. As an example, the computing device 134 interpolates the local bias 178 along one or more axes to smooth a step-wise function between each partition 158 and a directly adjacent one of the partitions 158 (e.g., nearest neighbor).

The computing device 134 communicates the total deviation 180 to the NC composite material placement machine 102. The NC composite material placement machine 102 compensates the NC program path 222 based on the total deviation 180.

In one or more examples, when the lamination tool 108 is subsequently loaded in the work cell 104, the master file 114 is reused to determine the transformation and compensate for the NC composite layup machine 102. It will be appreciated that each time the laminating tool 108 is laid down in the work unit 104, the tool position of the laminating tool 108, and more particularly the surface position of the laminating surface 110, may vary. Thus, while the master file 114 represents a known spatial relationship between the first positioning target 112, the second positioning target 152, and the line profile 154 of the laminating surface 110, the master file 114 may not provide a known tool position of the laminating tool 108 in the tool space.

In one or more examples, the computer-aided measurement system 126 re-measures the first positioning target 112 and the second positioning target 152 and generates measured target data 128. The measured target data 128 represents target positions of the first positioning target 112 and the second positioning target 152. After re-measurement, the target positions of the first positioning target 112 and the second positioning target 152 represented by the measured target data 128 are known in the tool space.

The computing device 134 is configured to determine a contour position of the line contour 154 of the laminating surface 110 from the measured target data 128 based on the spatial relationship between the primary target data 118 and the primary surface data 116 established by the master file 114. For example, the measured target data 128 is compared to the master target data 118. The contour position of the line contour 154 is determined based on the measured coordinate difference between the target data 128 and the main target data 118. Thus, using the measured target data 128 enables the contour position of the line contour 154 represented by the primary surface data 116 to be determined from the re-measurements of the first positioning target 112 and the second positioning target 152 or otherwise transmitted to be known in the tool space. In these examples, fig. 7 and 8 schematically illustrate examples of virtual representations of the lamination tool 108 represented by collected data (e.g., the primary surface data 116 of the primary file 114 adjusted in space based on the measured target data 128) subsequent to loading the lamination tool 108 in the work unit 104.

As described above, the computing device 134 compares the newly determined contour position of the line contour 154 represented by the primary surface data 116 of the primary file 114 and adjusted based on the measured target data 128 with the nominal position of the line contour 154. In an example, a deviation 176 between the contour position of the line contour 154 and the nominal position of the line contour 154 is determined globally, and the NC composite material placement machine 102 is compensated for by the deviation 176. In another example, a plurality of local deviations 178 between the contour position and the nominal position of the line contour 154 of each zone 158 are determined locally, a total deviation 180 is determined from the local deviations 178, and the NC composite material placement machine 102 is compensated for by the total deviation 180.

Thus, each time the laminating tool 108 is loaded in the work unit 104, the system 100 enables determining the tool position of the laminating tool 108 (more specifically, the surface position of the laminating surface 110) in the tool space and compensating the NC composite material placement machine 102 based on the actual tool position without requiring subsequent full surface measurements of the laminating tool 108.

In one or more examples, the system 100 also facilitates in-flight or real-time adjustment or correction of the compensation of the NC composite material placement machine 102. As an example, the computer-aided measurement system 126 re-measures the selected first positioning target 112 and second positioning target 152 corresponding to one partition 158. The computer-aided measurement system 126 generates measured target data 128. The measured target data 128 represents the newly acquired target positions of the first positioning target 112 and the second positioning target 152. After re-measurement, the newly acquired target positions of the first positioning target 112 and the second positioning target 152, represented by the measured target data 128, are now known in the tool space.

The computing device 134 determines, from the measured target data 128, a contour position of the line contour 154 of the laminating surface 110 associated with the selected first and second positioning targets 112, 152 and corresponding to one of the partitions 158 based on the spatial relationship between the primary target data 118 and the primary surface data 116 established by the primary file 114. The computing device 134 compares the newly determined contour position of the selected line contour 154 represented by the primary surface data 116 for one of the partitions 158 with the nominal position of the line contour 154 for the corresponding portion of the laminating surface 110. The computing device 134 determines a local deviation 178 between the contour position of the line contour 154 of the selected one of the zones 158 and the nominal position of the line contour 154 of the corresponding section of the laminating surface 110. The computing device 134 then corrects the total deviation 180 using the value of the newly determined local deviation 178. The total deviation 180 corrected by the value of the newly determined local deviation 178 is transmitted to the NC composite material placement machine 102. The NC composite material placement machine 102 compensates the NC program path 222 based on the total deviation 180 corrected by the local deviation 178.

Referring to fig. 1 and 11, in one or more examples, the system 100 includes a vision system 242. The vision system 242 is configured to visually inspect the composite laminate 240 formed on the laminating surface 110 of the laminating tool 108 during a composite lay-up operation performed by the NC composite lay-up machine 102. In one or more examples, the computing device 134 is configured to detect anomalies or other failures in the composite laminate 240 from information provided by the vision system 242. The computing device 134 is also configured to determine or select one of the zones 158 corresponding to the portion of the laminating surface 110 associated with the anomaly location. The computing device 134 selects the first positioning target 112 and the second positioning target 152 corresponding to the determined one of the partitions 158 to be re-measured by the computer-aided measurement system 126.

Referring again to fig. 1, in one or more examples, the system 100 may be extended for use with multiple lamination tools 108. In one or more examples, one or more lamination tools 108 are a different type of tool than another lamination tool 108. For example, the lamination tool 108 may have different sizes and/or shapes, or may be used to form different types of composite laminates 240. In other examples, two or more lamination tools 108 are the same type of tool (e.g., have the same size and/or shape or are used to form the same type of composite laminate 240). However, different lamination tools 108 of the same type may have minor differences based on manufacturing tolerances.

In one or more examples, each lamination tool 108 includes an identifier 168. As described above, at the initial measurement, the computer-aided measurement system 126 measures a series of line profiles 154 for the first positioning target 112, the second positioning target 152, and the laminating surface 110 for each lamination tool 108. The computer-aided measurement system 126 generates primary surface data 116 and primary target data 118 for each lamination tool 108. The computing device 134 generates, for each lamination tool 108, a master file 114 that establishes a spatial relationship between the master target data 118 and the master surface data 116. The computing device 134 is also configured to associate the master file 114 with an identifier 168 of a corresponding one of the lamination tools 108.

Referring now to fig. 9, an example of a composite manufacturing method 1000 (also referred to herein as method 1000) is shown. The method 1000 enables efficient collection of data representative of the laminating tool 108. The method 1000 can also automatically compensate the NC composite material placement machine 102 based on the actual position and/or actual shape of the lamination tool 108 represented by the collected data. The method 1000 is also capable of reusing previously collected data during subsequent machine compensation operations. In one or more examples, some or all of method 1000 is implemented using system 100 (e.g., shown in fig. 1).

In one or more examples, the method 1000 includes the step of positioning the lamination tool 108 in the work cell 104. In one or more examples, the method 1000 includes the step of measuring a series of line contours 154 of the laminating surface 110 of the laminating tool 108, the first positioning target 112, the second positioning target 152, and the second positioning target 112 (block 1002). The method 1000 includes the step of generating primary surface data 116 and primary target data 118 (block 1004). The method 1000 includes the step of generating the master file 114 (block 1006). The step of generating the master file 114 (block 1006) includes the step of correlating the master target data 118 with the master surface data 116 and the step of establishing a spatial relationship between the master target data 118 and the master surface data 116. The method 1000 includes the step of associating the master file 114 with the lamination tool 108 (block 1008).

In one or more examples, the method 1000 includes a step of comparing the contour position of the line contour 154 represented by the major surface data 116 of the master file 114 to the nominal position of the line contour 154 (block 1010). The method 1000 includes the step of determining a deviation 176 between the contour position of the line contour 154 and the nominal position of the line contour 154 (block 1012). The method 1000 includes the step of transmitting the deviation 176 to an NC composite material placement machine. The method 1000 includes the step of compensating the NC composite material placement machine 102 based on the deviation 176 (block 1014).

In one or more examples, the deviation 176 represents a global rigid body transformation between the primary surface data 116 representing the contour position of the line contour 154 and the data representing the nominal position of the line contour 154.

In one or more examples, the bias 176 is a total bias 180 determined from the plurality of local biases 178. The local deviation 178 represents a local rigid body transformation between the primary surface data 116 representing the contour position of the line contour 154 of each zone 158 and the data representing the nominal position of the line contour 154 of each section of the laminating surface 110. Thus, in one or more examples, the method 1000 includes the step of dividing the master file 114 into a plurality of partitions 158 (block 1016). The method 1000 includes the step of associating the partitions 158 with corresponding portions of the laminating surface 110 (block 1018).

The method 1000 includes the step of performing a composite layup operation using the NC composite layup machine 102 according to the NC program path 222 compensated based on the bias 176 (e.g., the total bias 180) (block 1020).

In one or more examples, the method 1000 facilitates compensating the NC composite material placement machine 102 when subsequently loading the lamination tool 108 in the work unit 104 (e.g., before performing a subsequent composite material placement operation). In these examples, method 1000 includes the step of re-measuring the first positioning target 112 and the second positioning target 152 (block 1022). The method 1000 includes the step of generating measured target data 128 (block 1024). Method 1000 includes the step of determining a contour position of line contour 154 of laminating surface 110 from measured target data 128 based on the spatial relationship between primary target data 118 and primary surface data 116 established by primary file 114 (block 1026).

In determining the contour position of the newly acquired line contour 154, the method 1000 includes the step of comparing the newly determined contour position of the line contour 154 represented by the primary surface data 116 of the primary file 114 with the nominal position of the line contour 154 (block 1010). The method 1000 includes the step of determining a deviation 176 between the contour position of the line contour 154 and the nominal position of the line contour 154 (block 1012).

As an example, the step of comparing (block 1010) includes the step of comparing the contour position of the line contour 154 represented by the major surface data 116 of the master file 114 of each partition 158 with the nominal position of the line contour 154 of the corresponding portion of the laminating surface 110. The determining step (block 1012) includes the step of determining a plurality of local deviations 178 between the profile position and the nominal position of the laminating surface 110. In these examples, method 1000 includes the step of determining total deviation 180 from the local deviation.

The method 1000 includes the step of transmitting the bias 176 (e.g., the total bias 180) to the NC composite material placement machine 102. The method 1000 includes the step of compensating the NC program path 222 of the NC composite material placement machine 102 based on the deviation 176 (block 1014). The method 1000 includes the step of performing a composite layup operation using the NC composite layup machine 102 according to the NC program path 222 compensated based on the bias 176 (e.g., the total bias 180) (block 1020).

In one or more examples, the method 1000 facilitates point correction and re-compensation of the NC composite material placement machine 102, for example, during a composite material placement operation (e.g., block 1020). In these examples, method 1000 includes the step of remeasuring the selected first positioning target 112 and second positioning target 152 corresponding to the at least one partition 158 (block 1028). The method 1000 includes the step of generating measured target data 128 (block 1030). In these examples, the measured target data 128 represents the newly acquired and determined target locations of the selected first positioning target 112 and second positioning target 152 corresponding to the at least one partition 158. The method 1000 includes a new contour location step of determining a line contour 154 of the laminating surface 110 associated with the selected first positioning target 112 and second positioning target 152 corresponding to the at least one partition 158 from the measured target data 128 based on the spatial relationship between the primary target data 118 and the primary surface data 116 established by the primary file 114 (block 1032).

In determining the contour position of the newly acquired line contour 154, the method 1000 includes the step of comparing the newly determined contour position of the line contour 154 represented by the major surface data 116 for the at least one zone 158 with the nominal position of the line contour 154 for the corresponding portion of the laminating surface 110 (block 1010). In these examples, the step of determining the deviation 176 (block 1012) includes the steps of determining a local deviation 178 between the contour position and the nominal position and correcting the total deviation 180 using the local deviation 178.

The method 1000 includes the step of transmitting the total deviation 180 corrected by the local deviation 178 to the NC composite material placement machine 102. The method 1000 includes the step of compensating the NC program path 222 based on the corrected total deviation 180 (block 1014). The method 1000 includes the step of performing a composite layup operation using the NC composite layup machine 102 according to the NC program path 222 compensated based on the corrected total deviation 180 (block 1020).

In one or more examples, the point correction and re-compensation of the NC composite material placement machine 102 is performed in response to identifying anomalies or other disqualification in the composite material laminate 240 formed on the laminating surface 110 by the NC composite material placement machine 102. By way of example, anomalies may be introduced due to inaccuracies or errors in the machine compensation operation, such as wrinkles in the composite layup 208, gaps between directly adjacent composite layups 208, and the like. Thus, in one or more examples, the method 1000 includes a step of inspecting the composite laminate 240 formed on the laminating surface 110 of the laminating tool 108 during a composite lay-up operation (e.g., block 1020) performed by the NC composite lay-up machine 102 (block 1034).

In these examples, the method 1000 includes a step of detecting anomalies in the composite laminate 240 (block 1036). The method 1000 includes the step of determining a partition 158 corresponding to a portion of the laminating surface 110 associated with the anomaly location (block 1038). In these examples, the selected first positioning target 112 and second positioning target 152 of the re-measurement (e.g., block 1028) correspond to one partition 158.

The method 1000 may also be extended for use with multiple lamination tools 108. As an example, in one or more examples, the method 1000 includes the step of measuring a series of line contours 154 of the laminating surface 110 of each of the first positioning target 112, the second positioning target 152, and the plurality of laminating tools 108 (block 1002). The method 1000 includes the step of generating primary surface data 116 and primary target data 118 for each lamination tool 108 (block 1004). The method 1000 includes the step of generating, for each lamination tool 108, a master file 114 that establishes a spatial relationship between the master target data 118 and the master surface data 116 (block 1006). In these examples, the method 1000 includes the step of associating the master file 114 with the identifier 168 of the corresponding one of the lamination tools 108 (block 1008).

In one or more examples, according to the method 1000, each lamination tool 108 includes an identifier 168. Each of the plurality of master files 114 is associated with an identifier 168 of a corresponding one of the laminating tools 108. In one or more examples, the method 1000 includes the steps of: reading the identifier 168; accessing the master file 114; and selecting the master document 114 associated with the identifier 168 corresponding to one of the lamination tools 108.

Referring now to FIG. 10, an example of a computing device 134 for use with the system 100 or by the system 100 is shown. In one or more examples, implementation of one or more operational steps of method 1000 (shown in fig. 9) is performed using computing device 134.

In one or more examples, the computing device 134 includes a processor unit 904 coupled to a storage 916. The storage 916 includes program code 918 executable by the processor unit 904 to instruct the computer-aided measurement system 126 to measure a series of line profiles 154 (e.g., as shown in fig. 5) of the first positioning target 112, the second positioning target 152, and the laminating surface 110 of the laminating tool 108. The storage 916 includes program code 918 executable by the processor unit 904 to generate the primary surface data 116 and the primary target data 118 (shown in fig. 1). The storage 916 includes program code 918 executable by the processor unit 904 to generate the master file 114 establishing a spatial relationship between the master target data 118 and the master surface data 116. The storage 916 includes program code 918 executable by the processor unit 904 to associate the master file 114 with the laminating tool 108.

In one or more examples, the storage 916 includes program code 918 executable by the processor unit 904 to correlate the primary target data 118 and the primary surface data 116 for the lamination tool 108 and create the primary file 114.

In one or more examples, the storage 916 includes program code 918 executable by the processor unit 904 to divide the main file 114 into a plurality of partitions 158 (e.g., as shown in fig. 6). The storage 916 includes program code 918 executable by the processor unit 904 to associate the partitions 158 with corresponding portions of the laminating surface 110.

In one or more examples, the storage 916 includes program code 918 executable by the processor unit 904 to retrieve the master file 114 associated with the lamination tool 108, for example, after reading the identifier 168, when the lamination tool 108 is laid down in the work unit 104. Master file 114 is associated with an identifier 168. The storage 916 includes program code 918 executable by the processor unit 904 to select a master file 114 from a plurality of master files 114 (e.g., stored in the database 246 shown in fig. 1) corresponding to a plurality of lamination tools 108.

In one or more examples, the storage 916 includes program code 918 executable by the processor unit 904 to instruct the computer-aided measurement system 126 to re-measure the first positioning target 112 and the second positioning target 152 and generate measured target data 128. The storage 916 includes program code 918 executable by the processor unit 904 to determine a contour position of the line contour 154 of the laminating surface 110 from the measured target data 128 based on the spatial relationship between the primary target data 118 and the primary surface data 116 established by the primary file 114.

In one or more examples, the storage 916 includes program code 918 executable by the processor unit 904 to compare the contour position of the line contour 154 of the partition 158 represented by the major surface data 116 to the nominal position of the line contour 154 of the corresponding portion of the laminating surface 110. The storage 916 includes program code 918 executable by the processor unit 904 to determine a plurality of local deviations between the contour position and the nominal position. The storage 916 includes program code 918 executable by the processor unit 904 to determine a total deviation from the local deviations. The memory device 916 includes program code 918 executable by the processor unit 904 to communicate the total deviation to the NC composite material placement machine 102, the NC composite material placement machine 102 configured to perform a composite material placement operation based on the nominal position of the laminating tool 108. The NC composite material placement machine 102 compensates the NC program path 222 based on the total deviation.

In one or more examples, the storage 916 includes program code 918 executable by the processor unit 904 to instruct the computer-aided measurement system 126 to re-measure the selected first positioning target 112 and second positioning target 152 corresponding to the at least one partition 158 and generate measured target data 128. The storage 916 includes program code 918 executable by the processor unit 904 to determine a contour position of the line contour 154 of the laminating surface 110 associated with the selected first positioning target 112 and second positioning target 152 corresponding to the at least one partition 158 from the measured target data 128 based on the spatial relationship between the primary target data 118 and the primary surface data 116 established by the primary file 114. The storage 916 includes program code 918 executable by the processor unit 904 to compare the contour position of the line contour 154 represented by the major surface data 116 for the at least one partition 158 to the nominal position of the line contour 154 for a corresponding portion of the laminating surface 110. The storage 916 includes program code 918 executable by the processor unit 904 to determine a local deviation between the contour position and the nominal position. The storage 916 includes program code 918 executable by the processor unit 904 to correct the total deviation using the local deviation. The memory device 916 includes program code 918 executable by the processor unit 904 to communicate the total deviation to the NC composite material placement machine 102. The NC composite material placement machine 102 compensates the NC program path 222 based on the total deviation corrected by the local deviation.

In one or more examples, the storage 916 includes program code 918 executable by the processor unit 904 to instruct the computer-aided measurement system 126 to measure the series of line profiles 154 of the first positioning target 112, the second positioning target 152, and the laminating surface 110 and generate the primary surface data 116 and the primary target data 118 for each of the plurality of laminating tools 108. The storage 916 includes program code 918 executable by the processor unit 904 to generate, for each lamination tool 108, the master file 114 establishing a spatial relationship between the master target data 118 and the master surface data 116. The storage 916 includes program code 918 executable by the processor unit 904 to associate the master file 114 with the identifier 168 of a corresponding one of the laminating tools 108.

In other examples, storage 916 includes program code 918 executable by processor unit 904 to perform one or more additional operations described herein, for example, in accordance with method 1000 (shown in fig. 9) and/or system 100 (shown in fig. 1).

Still referring to FIG. 10, computing device 134 includes any suitable data processing system 900. In one or more examples, the data processing system 900 includes a communication framework 902 that provides communications between at least one processor unit 904, one or more storage devices 916 (e.g., memory 906 and/or persistent storage 908), a communication unit 910, an input/output (I/O) unit 912, and a display 914. In this example, communication framework 902 may take the form of a bus system.

The processor unit 904 is configured to execute software instructions that may be loaded into the memory 906. The processor unit 904 may be a plurality of processors, a multi-processor core, or some other type of processor, depending on the particular implementation.

Memory 906 and persistent storage 908 are examples of storage 916. A storage device is any hardware capable of temporarily, permanently, or both temporarily and permanently storing information, such as, but not limited to, at least one of data, program code in functional form, or other suitable information. The storage 916 may also be referred to as computer-readable storage. Memory 906 may be, for example, random access memory or any other suitable volatile or non-volatile storage. Persistent storage 908 may take various forms depending on the particular implementation. Persistent storage 908 may contain one or more components or devices. For example, persistent storage 908 may be a hard drive, a solid state drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The medium used by persistent storage 908 also may be removable. For example, a removable hard drive may be used for persistent storage 908.

The communication unit 910 provides for communication with other data processing systems or devices, such as with the control unit 210 of the NC composite material placement machine 102 (shown in fig. 1). In one or more examples, the communication unit 910 is a network interface card.

Input/output unit 912 allows data to be input and output with other devices that may be connected to data processing system 900. For example, input/output unit 912 may provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, the input/output unit 912 may send output to a printer. Display 914 provides a mechanism to display information to a user.

Instructions for the operating system, applications, or programs may be located on storage 916, which is in communication with processor unit 904 via communications framework 902. The processing of the various examples and operations described herein may be performed by processor unit 904 using computer implemented instructions, which may be located in a memory (e.g., memory 906).

The instructions are referred to as program code, computer usable program code, or computer readable program code (e.g., program code 918) that may be read and executed by the processor unit 904. Program code in different examples may be embodied on different physical or computer readable storage media (e.g., memory 906 or persistent storage 908).

In one or more examples, program code 918 is located in a functional form on a selectively removable computer readable medium 920 and may be loaded onto data processing system 900 or transferred to data processing system 900 for execution by processor unit 904. In one or more examples, the program code 918 and the computer readable medium 920 form a computer program product 922. In one or more examples, computer-readable medium 920 is a computer-readable storage medium 924.

Examples of program code 918 include program code or instructions for operation of the NC composite material placement machine 102 (e.g., NC program 220), operation of the computer-aided measurement system 126, processing and analysis of the primary surface data 116, the primary target data 118, and the measured target data 128 (shown in fig. 1), generation of the primary file 114, determination of deviations for global and local tool transforms, compensation of the NC program path 222, and the like.

In one or more examples, the computer-readable storage medium 924 is a physical or tangible storage device for storing the application code 918, rather than a medium that propagates or transmits the application code 918.

Alternatively, the application code 918 may be transferred to the data processing system 900 using a computer readable signal medium. The computer readable signal medium may be, for example, a propagated data signal with application code 918. For example, the computer-readable signal medium may be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals may be transmitted via at least one communication link, such as a wireless communication link, a fiber optic cable, a coaxial cable, an electrical wire, or any other suitable type of communication link.

The different components illustrated for data processing system 900 are not intended to provide architectural limitations to the manner in which different examples may be implemented. Different examples may be implemented in data processing system 900 including components in addition to or in place of those shown in FIG. 10. Other components shown in fig. 10 may differ from the example shown. The different examples may be implemented using any hardware device or system capable of executing program code 918. By way of example, the operational steps described herein may be implemented in a dedicated module or by a dedicated software application.

Referring to fig. 11, an example of a manufacturing environment 200 that measures a lamination tool 108 and manufactures a composite laminate 240 using an NC composite layup machine 102 is shown. The NC composite layup machine 102 is compensated by the system 100 for the position (e.g., position, orientation, and shape) of the lamination tool 108.

In one or more examples, the system 100 includes a work unit 104. The tool position of the laminating tool 108 in the work cell 104 is determined by the system 100 in the tool space (e.g., relative to the tool coordinate system 106). NC program 220 utilizes instructions that reference the nominal position of lamination tool 108 in machine space (e.g., relative to machine coordinate system 150). As described herein above, NC program 220 compensates NC program path 222 based on the deviation between the nominal position and the tool position.

In one or more examples, the lamination tool 108 is positioned in the work cell 104 prior to the machine compensation and composite lay-up operations. In one or more examples, the lamination tool 108 is laid on and supported by a plurality of tool holders 218 in the work unit 104. As an example, the tool holder 218 may extend at least a portion of the length of the laminating tool 108 along the longitudinal axis A1. Typically, the tool holder 218 sets the X, Y and Z coordinates of the laminating tool 108 in the work cell coordinate system 106.

Each time the lamination tool 108 is positioned in the work cell 104, the tool position may be different from the nominal position. As an example, the equipment used to deposit the laminating tool 108 on the tool holder 218 may not accurately position the laminating tool 108 in the nominal position. As another example, the tool geometry of the lamination tool 108 (e.g., lamination surface 110) may not exactly match the nominal geometry of the lamination tool 108. As another example, once the lamination tool 108 is supported by the tool holder 218, the geometry, shape, and/or position of at least a portion of the lamination tool 108 may be varied. For example, lamination tools 108 having relatively high aspect ratios (e.g., those used to form elongated composite aircraft structures (e.g., wings, stringers, etc.) may bend, twist, sag, or otherwise locally deform at one or more regions along a longitudinal axis A1 of the lamination tool 108. Such deformation may cause the tool position (e.g., surface position) of at least a portion of the lamination tool 108 to be different from the nominal position.

Thus, the system 100, method 1000, and/or computing device 134 utilize the first positioning target 112, the second positioning target 152, and the line profile 154 of the lamination surface 110 as key reference features to quickly and efficiently determine the tool position of the lamination tool 108, and thus the surface position of the lamination surface 110, within an acceptable level of accuracy in manufacturing the composite laminate 240. Advantageously, this process significantly reduces the processing time required to accurately position the laminating tool 108 and compensate for the NC composite layup machine 102 prior to laying up the composite layup 208.

In one or more examples, the master document 114 is generated and provided by the manufacturer of the lamination tool 108. In one or more examples, the master file 114 is generated by the system 100, for example, when initially measuring the lamination tool 108 in the work cell 104. In any of these examples, master file 114 is generated by taking measurements of line profile 154 of lamination surface 110 and measurements of first positioning target 112 and second positioning target 152.

The primary surface data 116 takes the form of a collection of data points representing the relative position, orientation, and shape of the line profile 154 of the laminating surface 110. The primary target data 118 takes the form of a collection of data points representing the relative positions and orientations of the first positioning target 112 and the second positioning target 152. Each data point has its own set of cartesian (X, Y, Z) values. The primary target data 118 is correlated with the primary surface data 116. The relative fixing of the primary target data 118 and the primary surface data 116 or relates to the position of each data point relative to any other data point. For example, the correlation of the primary target data 118 and the primary surface data 116 fixes and preserves the distance (e.g., euclidean distance) between each pair of data points.

In one or more examples, the computing device 134 is coupled to or in communication with the computer-aided measurement system 126. The computer-aided measurement system 126 is or includes any suitable type of computer-aided metrology device or instrument capable of taking dimensional measurements of an object and generating data points representing the three-dimensional geometry of the object surface and the position in space. In one or more examples, the computer-aided measurement system 126 includes at least one measurement device 164. In one or more examples, the computer-aided measurement system 126 includes a plurality of measurement devices 164 (e.g., measurement device 164A, measurement device 164B, and measurement device 164C shown in fig. 11).

In one or more examples, the computer-aided measurement system 126 utilizes contact three-dimensional measurements or scans. By way of example, the measurement device 164 includes or takes the form of a probe or coordinate measuring machine. In these examples, one or more of the first positioning target 112 and the second positioning target 152 include or take the form of features that can be physically measured using a contact measurement device.

In one or more examples, the computer-aided measurement system 126 utilizes non-contact three-dimensional measurements or scans. By way of example, the measurement device 164 includes or takes the form of a laser scanner, a structured light scanner, or photogrammetry. In these examples, one or more of the first positioning target 112 and the second positioning target 152 include or take the form of features that enable optical measurements using a non-contact measurement device.

In one or more examples, the computer-aided measurement system 126 utilizes both contact and non-contact three-dimensional measurements or scans. As an example, initial measurements for generating the first positioning target 112, the second positioning target 152, and the line profile 154 for the primary surface data 116 and the primary target data 118 of the primary file 114 may be performed via non-contact three-dimensional measurements or scans. When the lamination tool 108 is subsequently loaded in the work unit 104, subsequent measurements of the first positioning target 112 and the second positioning target 152 for generating the measured target data 128 may be performed via contact three-dimensional measurements or scanning. In addition, during real-time correction of machine compensation, re-measurement of the selected first positioning target 112 and second positioning target 152 for generating measured target data 128 may be performed via contact three-dimensional measurement or scanning.

In one or more examples, one or more of the first positioning target 112 and the second positioning target 152 are removably coupled to (e.g., removable from) the lamination tool 108. As an example, the first positioning target 112 and the second positioning target 152 are coupled to the lamination tool 108 through custom bushings. This configuration enables the type of object (e.g., optical or physical) used by either of the first positioning object 112 and the second positioning object 152 to be removed (e.g., when not needed), replaced (e.g., when damaged), and/or swapped (e.g., with a different type of object). This configuration also allows one portion of the first positioning target 112 and the second positioning target 152 to be optical targets and the other portion of the first positioning target 112 and the second positioning target 152 to be physical targets. Before curing (e.g., via heat and/or pressure) the composite laminate 240 on the lamination tool 108, it may be desirable and beneficial to remove the first and second locating targets 112, 152, for example, from the bushings.

In one or more examples, the types (e.g., optical or physical) of the first positioning target 112 and the second positioning target 152 may be switched between an initial measurement (e.g., generating the primary surface data 116 and the primary target data 118 and creating the primary file 114) and a subsequent measurement (e.g., generating the measured target data 128). For example, the types of first positioning target 112 and second positioning target 152 may be switched while maintaining the positions of first positioning target 112 and second positioning target 152 relative to line profile 154.

To reduce cycle time and increase efficiency each time the lamination tool 108 is loaded in the work unit 104 for alignment and compensation of the NC composite material placement machine 102, the system 100 utilizes the computer-aided measurement system 126 to determine (e.g., measure) only the characteristic positions of the first positioning target 112 and the second positioning target 152. The system 100 then registers the data points in the master file 114 (e.g., master target data 118) representing the first and second positioning targets 112, 152 to the newly measured data points (e.g., measured target data 128) representing the first and second positioning targets 112, 152. Thus, this registration process provides the location of data points (e.g., major surface data 116) representing the line profile 154 of the laminating surface 110, thereby providing the actual surface location of the laminating surface 110 (e.g., within acceptable tolerances) without requiring a full measurement of the laminating surface 110.

In one or more examples, measurement data generated by the computer-aided measurement system 126 is provided to and processed by the computing device 134. The computing device 134 is operable to process the primary surface data 116 and the primary target data 118 and create a primary file 114 for the lamination tool 108. The computing device 134 is also operable to process the measured target data 128 as subsequent measurement data for determining the contour position of the line contour 154.

In one or more examples, the computer-aided measurement system 126 also includes a mobile system 228. The movement system 228 supports the measurement device 164 and is relative to the laminating tool 108. In one or more examples, the movement system 228 is configured to move each measurement device 164 independently with respect to the lamination tool 108 and with respect to each other.

In one or more examples, the movement system 228 includes or takes the form of an overhead gantry configured to move one or more measurement devices 164 (e.g., measurement device 164A and measurement device 164B) along the lamination tool 108. In these examples, measurement device 164A and measurement device 164B are non-contact measurement devices. The non-contact measurement (e.g., scanning) operation of the measurement lamination tool 108 may be performed automatically using instructions provided to the mobile system 228.

In one or more examples of the measurement device 164 being a non-contact measurement device, the system 100 includes a support structure 230. The support structure 230 includes a plurality of reference targets 234. Each reference target 234 is located at a known reference target location in the tool space. In one or more examples, the movement system 228 of the computer-aided measurement system 126 is coupled to the support structure 230 or otherwise supported by the support structure 230, e.g., such that the at least one measurement device 164 is positioned above the lamination tool 108.

The measurement data collected by the computer-aided measurement system 126 includes reference target data representing a known (e.g., fixed) location of the reference target 234. As an example, reference target data is collected and/or included as primary surface data 116 and primary target data 118 are collected. As another example, reference target data is collected and/or included when the measured target data 128 is collected. Thus, the reference target data is used to register the measurement data and determine the actual tool position of the laminating tool 108.

Although in the illustrative example the reference target data of the reference target 234 is utilized to determine the relative position of the laminating tool 108 in the work unit 104, it is understood that any of a variety of other known methods or techniques for determining the relative position of the measurement data may be used.

In one or more examples, the movement system 228 includes or takes the form of a programmable robotic arm or other machine configured to move one or more measurement devices 164 (e.g., measurement device 164C) along the lamination tool 108. In these examples, measurement device 164C is a contact measurement device. In one or more examples, one measurement device 164 (e.g., measurement device 164C) is coupled to the platform 212 of the NC composite material placement machine 102. As an example, during measurement of the lamination tool 108, the measurement device 164C forms or is otherwise attached to the tool head 238 of the NC composite material placement machine 102. At machine compensation and prior to the composite lay-up operation, the measurement device 164C is removed and replaced with the lay-up head 206. The contact measurement (e.g., probing) operation of the measurement lamination tool 108 may be performed automatically using instructions provided to the movement system 228 (e.g., the platform 212 of the NC composite material placement machine 102).

In one or more examples, the vision system 242 is or includes any suitable machine vision device capable of (e.g., configured to) inspecting the composite layup 208 while being laid down by the NC composite layup machine 102. In one or more examples, the vision system 242 is operable to detect a failure in the composite layup 208. Failure may indicate an error in the alignment or compensation of the NC composite layup machine 102 with the lamination tool 108.

Referring to fig. 1, in one or more examples, the system 100 includes a plurality of lamination tools 108. Each lamination tool 108 includes an identifier 168. The identifier 168 takes any of a variety of forms. By way of example, the identifier 168 is or takes the form of an alphanumeric code, a bar code, a radio frequency identification ("RFID") code, or the like.

In these examples, system 100 also includes a plurality of master files 114. Each master file 114 includes primary surface data 116 and primary target data 118 (e.g., as shown in fig. 1) corresponding to one of the lamination tools 108. Each master document 114 is associated with an identifier 168 of a corresponding one of the lamination tools 108.

Referring to fig. 1, in one or more examples, the system 100 includes a database 246. Database 246 stores a plurality of master files 114 and a plurality of identifiers 168 corresponding to a plurality of lamination tools 108.

Still referring to fig. 1, in one or more examples, the system 100 includes a reader 248. For example, before or after the laminating tool 108 is positioned in the work unit 104, the reader 248 may be operable (e.g., suitably configured) to detect and/or read the identifier 168 of the laminating tool 108. The reader 248 takes any of a variety of forms. By way of example, the reader 248 is or takes the form of an optical scanner, a bar code scanner, a radio frequency identification scanner, or the like.

In one or more examples, the reader 248 provides the identifier 168 to the computing device 134. The computing device 134 is operable to access the database 246 and retrieve the master file 114 associated with the identifier 168.

Referring now to fig. 12 and 13, examples of the system 100, method 1000, and computing device 134 may relate to an aircraft manufacturing and service method 1100 as shown in the flowchart of fig. 12 and an aircraft 1200 as schematically shown in fig. 13 or used in the context thereof. For example, the aircraft 1200 and/or the aircraft production and service method 1100 may utilize a composite structure fabricated on the lamination tool 108 using the NC composite layup machine 102. The actual position of the laminating tool 108 is determined using the system 100 and/or the computing device 134 or according to the method 1000. The NC composite material placement machine 102 is spatially compensated using the system 100 and/or the computing device 134 or according to the method 1000.

Referring to fig. 13, an example of an aircraft 1200 includes a fuselage 1202 having an interior 1206. The aircraft 1200 also includes a plurality of on-board (e.g., advanced) systems 1204. Examples of on-board systems 1204 include one or more of propulsion system 1208, electrical system 1210, hydraulic system 1212, environmental system 1214, and communication system 1216. In other examples, aircraft 1200 may include any number of other types of systems, such as flight control systems, guidance systems, weapon systems, and the like. In one or more examples, the composite structure (e.g., formed from the composite laminate 240) forms a component of the fuselage 1202, such as the wing 1220, the airframe 1218, a horizontal stabilizer, a vertical stabilizer or panel, a stringer, a spar, or the like.

Referring to fig. 12, prior to production, method 1100 includes specification and design of aircraft 1200 (block 1102) and material procurement (block 1104). During production of aircraft 1200, component and subassembly manufacturing (block 1106) and system integration (block 1108) of aircraft 1200 are performed. Thereafter, the aircraft 1200 is authenticated and dispatched (block 1110) to be placed in service (block 1112). Routine maintenance and service (block 1114) includes modification, reconfiguration, reconstruction, etc. of one or more systems of the aircraft 1200.

The various processes of method 1100 shown in fig. 12 may be performed or completed by a system integrator, a third party, and/or an operator (e.g., a customer). For purposes of this specification, a system integrator may include, but is not limited to, any number of spacecraft manufacturers and major-system subcontractors; third parties may include, but are not limited to, any number of sellers, subcontractors, and suppliers; the operators may be airlines, leasing companies, military entities, service organizations, etc.

Examples of the system 100, method 1000, and computing device 134 shown and described herein may be employed during any one or more stages of the manufacturing and service method 1100 shown in the flow chart shown in fig. 12. In an example, components and sub-assembly fabrication (block 1106) and/or system integration (block 1108) may be formed using the system 100 and/or composite structures fabricated according to the method 1000. Further, composite structures fabricated using the system 100 and/or according to the method 1000 may be utilized in a manner similar to components or sub-assemblies concurrently prepared in the aircraft 1200 service (block 1112). In addition, composite structures fabricated using the system 100 and/or according to the method 1000 may be utilized during system integration (block 1108) and authentication and distribution (block 1110). Similarly, composite structures fabricated using system 100 and/or according to method 1000 may be utilized, for example, but not limited to, while in service (block 1112) of aircraft 1200 and during repair and maintenance (block 1114). For example, spare and/or replacement composite parts may be manufactured and installed due to a specified maintenance cycle or after damage to the composite parts.

Although an aerospace example is shown, the examples and principles disclosed herein may be applied to other industries, such as the automotive industry, the space industry, the construction industry, and other design and manufacturing industries. Accordingly, in addition to aircraft, the examples and principles disclosed herein may be applicable to composite assemblies and systems for other types of vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.) and independent structures, and methods of making the same.

Throughout this disclosure, the term "composite" refers to a tough, lightweight material produced by combining two or more functional components. For example, the composite material may include reinforcing fibers incorporated into a polymer resin matrix. The fibers may be unidirectional or may take the form of a woven cloth or fabric. After the composite layers are laid up on the tool, the composite layers may be consolidated or cured (e.g., exposed to temperature and/or pressure), thus forming the final composite structure.

Composite structures may be used as components in many types of platforms. For example, platforms having composite components may be mobile platforms, stationary platforms, land-based structures, aquatic structures, and space-based structures. More specifically, the platform may be an aircraft, a surface vessel, a tank, a troop, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, a building, and any other suitable type of platform.

The foregoing detailed description makes reference to the accompanying drawings, which illustrate specific examples described in this disclosure. Other examples having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same features, elements, or components in different drawings. Any of the plurality of items may be referred to individually throughout this disclosure as items, and the plurality of items may be collectively referred to as items and may be denoted by like reference numerals. Furthermore, as used herein, a feature, element, component, or step recited in the accompanying drawings should be understood as not excluding plural features, elements, components, or steps, unless such exclusion is explicitly recited.

The foregoing provides illustrative, non-exhaustive examples, which may but are not necessarily claimed, in accordance with the subject matter of this disclosure. Reference herein to "an example" means that one or more features, structures, elements, components, characteristics, and/or operational steps described in connection with the example are included in at least one aspect, embodiment, and/or implementation of the subject matter according to this disclosure. Thus, the phrases "example," "another example," "one or more examples," and similar language throughout this disclosure may, but do not necessarily, refer to the same example. Moreover, characterizing the subject matter of any one example may, but need not, include characterizing the subject matter of any other example. Furthermore, the subject matter that characterizes any one example may, but need not, be combined with the subject matter that characterizes any other example.

As used herein, a system, device, apparatus, structure, article, element, component, or hardware "configured to" perform a specified function is actually able to perform the specified function without any change, rather than merely that it is possible to perform the specified function after further modification. In other words, a system, device, apparatus, structure, article, element, component, or hardware "configured to" perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed to perform the specified function. As used herein, "configured to" means an existing characteristic of the system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform a specified function without further modification. For the purposes of this disclosure, a system, device, apparatus, structure, article, element, component, or hardware described as "configured to" perform a particular function may additionally or alternatively be described as "adapted" and/or "operable to" perform that function.

Unless otherwise indicated, the terms "first," "second," "third," and the like herein are used merely as labels, and are not intended to impose order, position, or hierarchical requirements on the items to which these terms refer. Furthermore, reference to an item such as "second" does not require or exclude the presence of items such as "first" or lower numbered items and/or items such as "third" or higher numbered items.

As used herein, the phrase "at least one of …" when used with a list of items means that different combinations of one or more of the listed items can be used and that only one may be required for each item in the list. For example, "at least one of item a, item B, and item C" may include, but is not limited to, item a or item a and item B. This example may also include item a, item B, and item C or item B and item C. In other examples, "at least one of …" may be, for example, but not limited to, two items a, one item B, and ten items C; four items B and seven items C; as well as other suitable combinations. As used herein, the term "and/or" and "/" symbols include any and all combinations of one or more of the associated listed items.

For the purposes of this disclosure, the term "couple" and similar terms refer to two or more elements that are engaged, linked, fastened, attached, connected, in communication, or otherwise associated (e.g., mechanical, electrical, fluid, optical, electromagnetic) with each other. In various examples, elements may be directly or indirectly related. As an example, element a may be directly associated with element B. As another example, element a may be indirectly associated with element B (e.g., via another element C). It will be understood that not all of the associations between the various disclosed elements are necessarily presented. Thus, couplings other than those depicted in the figures may also be present.

As used herein, the term "about" refers to or refers to a condition that is close to, but not entirely, the condition, yet performs the desired function or achieves the desired result. By way of example, the term "about" refers to a condition within an acceptable predetermined tolerance or precision, such as a condition within 10% of the condition. However, the term "about" does not exclude conditions that are entirely said conditions. As used herein, the term "substantially" refers to a condition that is substantially the condition that performs the desired function or achieves the desired result.

For purposes of this disclosure, an item positioned along an axis (e.g., extending along an axis) refers to one or more items that are coaxial with, or at least approximately parallel to, the axis.

For purposes of this disclosure, unless explicitly stated otherwise, the "position" of an item refers to the position of the item in three-dimensional space, the angular orientation of the item in three-dimensional space, and/or the shape of the item.

Throughout this disclosure and the drawings, the term "numerical control" may also be referred to simply as "NC".

As used herein, the terms "having," "including," and variations thereof, are intended to be inclusive in a manner similar to the term "comprising" as an open-ended transition word without excluding any additional or other elements.

The above-referenced figures 1-8, 10, 11 and 13 may represent functional elements, features, or components thereof without necessarily implying any particular structure. Accordingly, modifications, additions and/or omissions may be made to the structures illustrated. In addition, those skilled in the art will appreciate that not all of the elements, features, and/or components described and illustrated in fig. 1-8, 10, 11, and 13 referred to above need be included in each example, and that not all of the elements, features, and/or components described herein are necessarily depicted in the various illustrative examples. Thus, some of the elements, features, and/or components described and illustrated in fig. 1-8, 10, 11, and 13 may be combined in various ways without the inclusion of other features described and illustrated in fig. 1-8, 10, 11, and 13, other figures, and/or the accompanying disclosure, even if such a combination or combinations are not explicitly illustrated herein. Similarly, additional features not limited to the examples presented may be combined with some or all of the features shown and described herein. The schematic diagrams of the examples depicted in fig. 1-8, 10, 11, and 13 referenced above are not intended to imply architectural limitations with respect to the illustrative examples unless explicitly stated otherwise. Rather, while one exemplary structure is indicated, it will be appreciated that the structure may be modified as appropriate. Accordingly, modifications, additions and/or omissions may be made to the structures illustrated. Furthermore, elements, features and/or components in each of fig. 1-8, 10, 11 and 13 that serve similar or at least substantially similar purposes are labeled with similar numbers and will not be discussed in detail herein with reference to each of fig. 1-8, 10, 11 and 13. Similarly, not all elements, features, and/or components are labeled in each of fig. 1-8, 10, 11, and 13, but for consistency, reference numerals associated therewith may be used herein.

In the above-referenced fig. 9 and 12, blocks may represent operations, steps, and/or portions thereof, and the lines connecting the various blocks do not imply any particular order or dependency of the operations or portions thereof. It will be understood that not necessarily all dependencies between the various disclosed operations are represented. Fig. 9 and 12, and the accompanying disclosure describing the operations of the disclosed methods set forth herein, should not be construed as necessarily determining the order in which the operations are to be performed. Rather, although one exemplary order is indicated, it will be appreciated that the order of operations may be modified as appropriate. Accordingly, the illustrated operations may be modified, added, and/or omitted, and certain operations may be performed in a different order or concurrently. In addition, those skilled in the art will appreciate that not all of the operations described need be performed.

1. A composite manufacturing system (100), comprising:

laminating tool (108) comprising

A lamination surface (110);

a plurality of first positioning targets (112) extending the lamination surface (110) along a first side (172) of the lamination tool (108); and

a plurality of second positioning targets (152) extending the lamination surface (110) along a second side (174) of the lamination tool (108) opposite the first side (172);

A computer-aided measurement system (126) adapted to measure a series of line contours (154) of the first positioning target (112), the second positioning target (152) and the laminating surface (110) and to generate primary surface data (116) and primary target data (118), wherein:

the primary target data (118) represents target positions of the first positioning target (112) and the second positioning target (152); the main surface data (116) represents a contour position of a line contour (154) of the lamination surface (110);

each line profile (154) is associated with and extends between one of a plurality of target pairs (156); and is also provided with

Each target pair (156) includes a first positioning target (112) and an opposing second positioning target (152); and

-computing means (134) adapted to:

generating a master file (114) establishing a spatial relationship between master target data (118) and primary surface data (116); and is also provided with

The master file (114) is associated with the lamination tool (108).

2. The composite manufacturing system (100) of clause 1, wherein:

the computing means (134) is adapted to:

dividing the main file (114) into a plurality of partitions (158); and is also provided with

Associating the zones (158) with corresponding portions of the laminating surface (110),

each partition (158) includes a portion of the primary surface data (116) representing three line contours (154) and a portion of the primary target data (118) representing three target pairs (156) associated with the three line contours (154); and is also provided with

Each partition (158) overlaps with a directly adjacent one of the partitions (158) such that a portion of the primary surface data (116) representing one line profile (154) and a portion of the primary target data (118) representing one target pair (156) associated with the one line profile (154) are shared by the directly adjacent pair of partitions (158).

3. The composite manufacturing system (100) of clause 2, wherein:

the computer-aided measurement system (126) is adapted to re-measure the first (112) and second (152) positioning targets and to generate measured target data (128);

the measured target data (128) represents target positions of the first positioning target (112) and the second positioning target (152); and is also provided with

The computing device (134) is adapted to determine a contour position of a line contour (154) of the laminating surface (110) from the measured target data (128) based on a spatial relationship between the main target data (118) and the main surface data (116) established by the main file (114).

4. The composite manufacturing system (100) of clause 3, further comprising a numerical control composite placement machine (102) configured to perform a composite placement operation based on a nominal position of the lamination surface (110),

wherein:

the computing means (134) is adapted to:

Comparing a contour position of a line contour (154) of the laminating surface (110) represented by the main surface data (116) of the partition (158) with a nominal position of a corresponding portion of the laminating surface (110);

determining a plurality of local deviations (178) between the contour position and the nominal position;

determining a total deviation (180) from the local deviation (178); and is also provided with

Transmitting the total deviation (180) to a numerical control composite lay-up machine (102); and is also provided with

The numerical control composite lay-up machine (102) compensates the numerical control program path (222) based on the total deviation (180).

5. The composite manufacturing system (100) of clause 4, wherein:

the computer-aided measurement system (126) is adapted to re-measure the selected first (112) and second (152) positioning targets corresponding to one partition (158) and to generate measured target data (128); and is also provided with

The computing means (134) is adapted to:

determining, from the measured target data (128), a contour position of a line contour (154) of the laminating surface (110) represented by the main surface data (116) and associated with the selected first positioning target (112) and second positioning target (152) corresponding to the one partition (158) based on a spatial relationship between the main target data (118) and the main surface data (116) established by the main file (114);

Comparing the contour position of the line contour (154) represented by the main surface data (116) of the one partition (158) with the nominal position of the corresponding portion of the laminating surface (110);

determining a local deviation (178) between the contour position and the nominal position;

correcting the total deviation (180) using the local deviation (178); and is also provided with

The numerical control composite layup machine (102) compensates the numerical control program path (222) based on the total deviation (180) corrected by the local deviation (178).

6. The composite manufacturing system (100) of clause 5, further comprising a vision system (242) configured to visually inspect the composite laminate (240) formed on the laminating surface (110) of the laminating tool (108) during a composite lay-up operation performed by the digitally controlled composite lay-up machine (102),

wherein:

the computing means (134) is adapted to:

detecting anomalies in the composite laminate (240); and is also provided with

Determining a zone (158) corresponding to a portion of the laminating surface (110) associated with the anomaly location; and is also provided with

The selected first (112) and second (152) positioning targets re-measured by the computer-aided measuring system (126) correspond to the one partition (158).

7. The composite manufacturing system (100) of any of clauses 1-6, further comprising a plurality of lamination tools (108), each lamination tool (108) further comprising an identifier (168),

wherein:

the computer-aided measurement system (126) is adapted to measure a series of line contours (154) of the first positioning target (112), the second positioning target (152) and the laminating surface (110) and to generate main surface data (116) and main target data (118) for each laminating tool (108); and is also provided with

The computing means (134) is adapted to:

generating, for each lamination tool (108), a master file (114) establishing a spatial relationship between master target data (118) and master surface data (116); and is also provided with

The master file (114) is associated with an identifier (168) corresponding to one of the lamination tools (108).

8. A method (1000) of manufacturing a composite material, comprising the steps of:

measuring a series of line profiles (154) of the lamination surface (110) of the first positioning target (112), the second positioning target (152) and the lamination tool (108);

generating primary surface data (116) and primary target data (118), wherein:

Each target pair (156) includes a first positioning target (112) and an opposing second positioning target (152);

generating a master file (114) establishing a spatial relationship between master target data (118) and primary surface data (116); and

the master file (114) is associated with the lamination tool (108).

9. The composite manufacturing method (1000) of clause 8, further comprising the steps of:

dividing the main file (114) into a plurality of partitions (158); and

wherein:

10. The composite manufacturing method (1000) of clause 9, further comprising the steps of:

re-measuring the first positioning target (112) and the second positioning target (152);

generating measured target data (128), wherein the measured target data (128) represents target positions of the first positioning target (112) and the second positioning target (152); and

a contour position of a line contour (154) of the lamination surface (110) is determined from the measured target data (128) based on a spatial relationship between the primary target data (118) and the primary surface data (116) established by the primary file (114).

11. The composite manufacturing method (1000) of clause 10, further comprising the steps of:

comparing the contour position of the line contour (154) represented by the main surface data (116) of the partition (158) with the nominal position of the corresponding portion of the laminating surface (110);

determining a total deviation (180) from the local deviation (178);

transmitting the total deviation (180) to a numerical control composite lay-up machine (102);

compensating a numerical control program path (222) of the numerical control composite material placement machine (102) based on the total deviation (180); and

a composite lay-up operation is performed using a numerical control composite lay-up machine (102) according to a numerical control program path (222) compensated based on the total deviation (180).

12. The composite manufacturing method (1000) of clause 11, further comprising the steps of:

re-measuring the selected first (112) and second (152) positioning targets corresponding to one partition (158);

generating measured target data (128);

determining a contour position of a line contour (154) of the lamination surface (110) associated with the selected first positioning target (112) and second positioning target (152) corresponding to the one partition (158) from the measured target data (128) based on a spatial relationship between the main target data (118) and the main surface data (116) established by the main file (114);

correcting the total deviation (180) using the local deviation (178);

compensating the nc program path (222) based on the total deviation (180); and

13. The composite manufacturing method (1000) of clause 12, further comprising the steps of:

inspecting the composite laminate (240) formed on the laminating surface (110) of the laminating tool (108) during a composite lay-up operation performed by the digitally controlled composite lay-up machine (102);

detecting anomalies in the composite laminate (240); and

determining a zone (158) corresponding to a portion of the laminating surface (110) associated with the anomaly location,

wherein the re-measured selected first (112) and second (152) positioning targets correspond to the one partition (158).

14. The composite manufacturing method (1000) according to any one of clauses 8 to 13, further comprising the steps of:

measuring a series of line profiles (154) of the lamination surface (110) of each of the first positioning target (112), the second positioning target (152), and the plurality of lamination tools (108);

generating primary surface data (116) and primary target data (118) for each lamination tool (108);

generating, for each lamination tool (108), a master file (114) establishing a spatial relationship between master target data (118) and master surface data (116); and

15. A computer system (134) for a composite manufacturing system (100), the computer system (134) comprising a processor unit (904) coupled to a storage (916) comprising program code (918), the program code (918) being executable by the processor unit (904) to:

a computer-aided measurement system (126) is instructed to measure a series of line contours (154) of a lamination surface (110) of a plurality of first positioning targets (112), a plurality of second positioning targets (152), and a lamination tool (108) and generate primary surface data (116) and primary target data (118), wherein:

the primary target data (118) represents target positions of the first positioning target (112) and the second positioning target (152);

the main surface data (116) represents a contour position of a line contour (154) of the lamination surface (110);

The master file (114) is associated with the lamination tool (108).

16. The computer system (134) of clause 15, wherein the program code (918) is executable by the processor unit (904) to:

wherein:

17. The computer system (134) of clause 16, wherein the program code (918) is executable by the processor unit (904) to:

instructing the computer-aided measurement system (126) to re-measure the first positioning target (112) and the second positioning target (152) and generating measured target data (128), wherein the measured target data (128) represents target positions of the first positioning target (112) and the second positioning target (152); and is also provided with

18. The computer system (134) of clause 17, wherein:

program code (918) is executable by the processor unit (904) to:

comparing the profile position represented by the main surface data (116) of the zone (158) with the nominal position of the corresponding portion of the laminating surface (110);

Transmitting the total deviation (180) to a numerical control composite lay-up machine (102) configured to perform a composite lay-up operation based on the nominal position; and is also provided with

19. The computer system (134) of clause 18, wherein:

program code (918) is executable by the processor unit (904) to:

instructing the computer-aided measurement system (126) to re-measure the selected first (112) and second (152) positioning targets corresponding to one partition (158) and to generate measured target data (128);

comparing the contour position represented by the main surface data (116) of the one section (158) with the nominal position of the corresponding portion of the laminating surface (110);

Transmitting the total deviation (180) to a numerical control composite material laying machine (102),

20. The computer system (134) of any of clauses 15 or 19, wherein the program code (918) is executable by the processor unit (904) to:

instructing the computer-aided measurement system (126) to measure a series of line contours (154) of the first positioning target (112), the second positioning target (152), and the lamination surface (110) and generate primary surface data (116) and primary target data (118) for each of the plurality of lamination tools (108);

Furthermore, references throughout this specification to features, advantages, or similar language in use herein do not imply that in any single example, all of the features and advantages that may be realized with the examples disclosed herein. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussion of the features and advantages, and similar language, throughout this disclosure may, but do not necessarily, refer to the same example.

The features, advantages, and characteristics described in one example may be combined in any suitable manner in one or more other examples. One skilled in the relevant art will recognize that the examples described herein may be practiced without one or more of the specific features or advantages of a particular example. In other instances, additional features and advantages may be recognized in certain examples that may not be present in all examples. Further, while various examples of the system 100, method 1000, and computing device 134 are shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

Priority

The present application claims priority to U.S. Ser. No. 63/366,783, filed on 22, 6, 2022.

Claims

1. A composite manufacturing system (100), the composite manufacturing system (100) comprising:

a lamination tool (108), the lamination tool (108) comprising:

a lamination surface (110);

-extending a plurality of first positioning targets (112) of the laminating surface (110) along a first side (172) of the laminating tool (108); and

-extending a plurality of second positioning targets (152) of the laminating surface (110) along a second side (174) of the laminating tool (108) opposite the first side (172);

a computer-aided measurement system (126), the computer-aided measurement system (126) being adapted to measure a series of line profiles (154) of the first positioning target (112), the second positioning target (152) and the laminating surface (110) and to generate main surface data (116) and main target data (118), wherein:

-the primary target data (118) represents target positions of the first positioning target (112) and the second positioning target (152);

-the main surface data (116) represents a contour position of the line contour (154) of the laminating surface (110);

each of the line profiles (154) is associated with and extends between one of a plurality of target pairs (156); and is also provided with

Each of said target pairs (156) includes one of said first positioning targets (112) and an opposite one of said second positioning targets (152); and

-a computing device (134), the computing device (134) being adapted to:

generating a master file (114) establishing a spatial relationship between the master target data (118) and the primary surface data (116); and is also provided with

-associating the master document (114) with the lamination tool (108).

2. The composite manufacturing system (100) of claim 1, wherein:

the computing device (134) is adapted to:

dividing the master file (114) into a plurality of partitions (158); and is also provided with

each of the partitions (158) includes a portion of the primary surface data (116) representing three of the line profiles (154) and a portion of the primary target data (118) representing three of the target pairs (156) associated with the three of the line profiles (154); and is also provided with

Each of the partitions (158) overlaps with a directly adjacent one of the partitions (158) such that a portion of the primary surface data (116) representing one of the line profiles (154) and a portion of the primary target data (118) representing one of the target pairs (156) associated with the one of the line profiles (154) are shared by the directly adjacent pair of the partitions (158).

3. The composite manufacturing system (100) of claim 2, wherein:

the computer-aided measurement system (126) is adapted to re-measure the first positioning target (112) and the second positioning target (152) and to generate measured target data (128);

the measured target data (128) represents the target positions of the first positioning target (112) and the second positioning target (152); and is also provided with

The computing device (134) is adapted to determine the contour position of the line contour (154) of the laminating surface (110) from the measured target data (128) based on the spatial relationship between the main target data (118) and the main surface data (116) established by the main file (114).

4. The composite manufacturing system (100) of claim 3, the composite manufacturing system (100) further comprising a numerically controlled composite placement machine (102) configured to perform a composite placement operation based on a nominal position of the lamination surface (110),

wherein:

the computing device (134) is adapted to:

comparing the contour position of the line contour (154) of the laminating surface (110) represented by the main surface data (116) of the partition (158) with a nominal position of a corresponding portion of the laminating surface (110);

Determining a plurality of local deviations (178) between the contour position and the nominal position of the corresponding portion;

-transmitting the total deviation (180) to the numerical control composite material placement machine (102); and is also provided with

The numerical control composite lay-up machine (102) compensates a numerical control program path (222) based on the total deviation (180).

5. The composite manufacturing system (100) of claim 4, wherein:

the computer-aided measurement system (126) is adapted to re-measure the first (112) and second (152) positioning targets selected corresponding to one of the partitions (158) and to generate measured target data (128); and is also provided with

The computing device (134) is adapted to:

determining from the measured target data (128) the contour position of the line contour (154) of the laminating surface (110) represented by the main surface data (116) and associated with the selected first positioning target (112) and the second positioning target (152) corresponding to the one partition (158) based on the spatial relationship between the main target data (118) and the main surface data (116) established by the main file (114);

Comparing the contour position of the line contour (154) represented by the main surface data (116) of the one of the partitions (158) with the nominal position of a corresponding portion of the laminating surface (110);

determining a local deviation (178) between the contour position and the nominal position of the corresponding portion;

-correcting said total deviation (180) with said local deviation (178); and is also provided with

The numerical control composite placement machine (102) compensates the numerical control program path (222) based on the total deviation (180) corrected by the local deviation (178).

6. A composite manufacturing method (1000), the composite manufacturing method (1000) comprising the steps of:

generating primary surface data (116) and primary target data (118), wherein:

Each of said target pairs (156) includes one of said first positioning targets (112) and an opposite one of said second positioning targets (152);

generating a master file (114) establishing a spatial relationship between the master target data (118) and the primary surface data (116); and

-associating the master document (114) with the lamination tool (108).

7. The composite manufacturing method (1000) according to claim 6, the composite manufacturing method (1000) further comprising the steps of:

dividing the master file (114) into a plurality of partitions (158); and

wherein:

8. The composite manufacturing method (1000) according to claim 7, the composite manufacturing method (1000) further comprising the steps of:

generating measured target data (128), wherein the measured target data (128) represents the target positions of the first positioning target (112) and the second positioning target (152); and

the contour position of the line contour (154) of the laminating surface (110) is determined from the measured target data (128) based on the spatial relationship between the main target data (118) and the main surface data (116) established by the main file (114).

9. The composite manufacturing method (1000) according to claim 8, the composite manufacturing method (1000) further comprising the steps of:

comparing the contour position of the line contour (154) represented by the main surface data (116) of the partition (158) with a nominal position of a corresponding portion of the laminating surface (110);

determining a total deviation (180) from the local deviation (178);

-performing a composite lay-up operation using the numerical control composite lay-up machine (102) according to the numerical control program path (222) compensated based on the total deviation (180).

10. The composite manufacturing method (1000) according to claim 9, the composite manufacturing method (1000) further comprising the steps of:

re-measuring the selected first (112) and second (152) positioning targets corresponding to one of the partitions (158);

generating measured target data (128);

determining the contour position of the line contour (154) of the laminating surface (110) associated with the selected first positioning target (112) and the second positioning target (152) corresponding to the one partition (158) from the measured target data (128) based on the spatial relationship between the main target data (118) and the main surface data (116) established by the main file (114);

-correcting said total deviation (180) with said local deviation (178);

-transmitting the total deviation (180) to the numerical control composite material placement machine (102);

compensating the nc program path (222) based on the total deviation (180); and

-performing the composite lay-up operation using the numerical control composite lay-up machine (102) according to the numerical control program path (222) compensated based on the total deviation (180).

11. The composite manufacturing method (1000) according to claim 10, the composite manufacturing method (1000) further comprising the steps of:

inspecting a composite laminate (240) formed on the laminating surface (110) of the laminating tool (108) during the composite lay-up operation performed by the digitally controlled composite lay-up machine (102);

detecting anomalies in the composite laminate (240); and

determining one of said zones (158) corresponding to the portion of said laminating surface (110) associated with the location of said anomaly,

wherein the selected first (112) and second (152) positioning targets re-measured correspond to the one of the partitions (158).

12. The composite manufacturing method (1000) according to any one of claims 6 to 11, the composite manufacturing method (1000) further comprising the steps of:

measuring a series of the line profiles (154) of the laminating surface (110) of each of the first positioning target (112), the second positioning target (152), and a plurality of laminating tools (108);

generating the primary surface data (116) and the primary target data (118) for each of the lamination tools (108);

generating for each of the lamination tools (108) the master document (114) establishing the spatial relationship between the master target data (118) and the master surface data (116); and

-associating said master document (114) with an identifier (168) of a corresponding one of said laminating tools (108).

13. A computer system (134) for a composite manufacturing system (100), the computer system (134) comprising a processor unit (904) coupled to a storage (916) comprising program code (918), the program code (918) being executable by the processor unit (904) to:

-associating the master document (114) with the lamination tool (108).

14. The computer system (134) of claim 13, wherein the program code (918) is executable by the processor unit (904) to:

wherein:

15. The computer system (134) of claim 13 or 14, wherein the program code (918) is executable by the processor unit (904) to:

-instructing the computer-aided measurement system (126) to measure a series of the line profiles (154) of the first positioning target (112), the second positioning target (152) and the laminating surface (110), and generating the primary surface data (116) and the primary target data (118) for each of a plurality of laminating tools (108);

generating for each of the lamination tools (108) the master document (114) establishing the spatial relationship between the master target data (118) and the master surface data (116); and is also provided with