System and method for validating and inspecting composite parts

Patent metadata

Field	Value
Publication number	US-11314228-B2
Application number	US-201615006230-A
Country	US
Kind code	B2
Filing date	Jan 26, 2016
Priority date	Jan 26, 2016
Publication date	Apr 26, 2022
Grant date	Apr 26, 2022

Abstract

A part analysis tool is used to analyze aspects of a composite part. The part analysis tool includes a verification control unit that compares numerical control data used to control operation of a forming system that is used to form the composite part to computer-aided design (CAD) data that includes an authoritative part definition for the composite part. The verification control unit determines whether the numerical control data is within one or more conformance thresholds related to the CAD data. The part analysis tool may also include an inspection control unit that compares inspection data of one or more plies of the composite part to the CAD data. The inspection control unit determines whether the inspection data is within the conformance threshold(s) related to the CAD data.

First claim

What is claimed is:

1. A part analysis tool for analyzing aspects of a composite part, the part analysis tool comprising:
a verification control unit that compares numerical control data used to control operation of a forming system that is used to form the composite part to computer-aided design (CAD) data that includes an authoritative part definition for the composite part, wherein the verification control unit determines whether the numerical control data is within one or more conformance thresholds related to the CAD data before the forming system uses numerical control data to form the composite part.

2. The part analysis tool of claim 1 , wherein the verification control unit disregards non-essential data within the numerical control data.

3. The part analysis tool of claim 2 , wherein the non-essential data is unrelated to laying up plies of composite material that form the composite part.

4. The part analysis tool of claim 1 , wherein the numerical control data comprises structural and geometric data of the composite part.

5. The part analysis tool of claim 4 , wherein the structural and geometric data of the composite part comprises part length, number of plies of composite material, ply boundary areas, stagger between plies, ply orientation, and angular deviation between plies.

6. The part analysis tool of claim 1 , further comprising an inspection control unit that compares inspection data of one or more plies of the composite part to the CAD data, wherein the inspection control unit determines whether the inspection data is within the one or more conformance thresholds related to the CAD data.

7. The part analysis tool of claim 6 , wherein the inspection control unit compares the inspection data to the CAD data after the verification control unit compares the numerical control data to the CAD data.

8. The part analysis tool of claim 6 , wherein the inspection control unit compares the inspection data to the CAD data as the verification control unit compares the numerical control data to the CAD data.

9. The part analysis tool of claim 6 , wherein the inspection control unit analyzes the inspection data of a virtual representation of the composite part.

10. A composite part forming system configured to form a composite part, wherein the composite part forming system comprises:
a computer-aided design (CAD) system operable to generate CAD data that includes an authoritative part definition for the composite part;
a forming system operable to form the composite part based on numerical control data;
an inspection system operable to inspect the composite part before, during, or after formation of the composite part and generate inspection data that relates to inspection of the composite part; and
a part analysis tool comprising one or more processors including: (a) a verification control unit that compares the numerical control data used to control operation of the forming system to the CAD data before the forming system operates to form the composite part, wherein the verification control unit determines whether the numerical control data is within one or more conformance thresholds related to the CAD data, and (b) an inspection control unit that compares the inspection data to the CAD data, wherein the inspection control unit determines whether the inspection data is within the one or more conformance thresholds related to the CAD data.

11. The composite part forming system of claim 10 , wherein the verification control unit disregards non-essential data within the numerical control data, wherein the non-essential data is unrelated to laying up plies of composite material that form the composite part, and wherein the numerical control data comprises structural and geometric data of the composite part.

12. The composite part forming system of claim 11 , wherein the structural and geometric data of the composite part comprises part length, number of plies of composite material, ply boundary areas, stagger between plies, ply orientation, and angular deviation between plies.

13. The composite part forming system of claim 11 , wherein the inspection control unit compares the inspection data to the CAD data after the verification control unit compares the numerical control data to the CAD data.

14. The composite part forming system of claim 11 , wherein the inspection control unit compares the inspection data to the CAD data as the verification control unit compares the numerical control data to the CAD data.

15. The composite part forming system of claim 11 , wherein the inspection control unit analyzes the inspection data of a virtual representation of the composite part.

16. A method for analyzing aspects of a composite part, the method comprising:
generating computer-aided design (CAD) data that includes an authoritative part definition for the composite part;
receiving numerical control data used to control operation of a forming system that is used to form the composite part;
comparing the numerical control data to the CAD data before the forming system operates based on numerical control data to form the composite part;
determining, through the comparing the numerical control data to the CAD data, whether the numerical control data is within one or more conformance thresholds related to the CAD data;
receiving inspection data of one or more plies of the composite part;
comparing the inspection data to the CAD data; and
determining, through the comparing the inspection data to the CAD data, whether the inspection data is within the one or more conformance thresholds related to the CAD data.

17. The method of claim 16 , wherein the comparing the numerical control data to the CAD data comprises disregarding non-essential data within the numerical control data, wherein the non-essential data is unrelated to laying up plies of composite material that form the composite part, and wherein the numerical control data comprises structural and geometric data of the composite part.

18. The method of claim 17 , wherein the structural and geometric data of the composite part comprises part length, number of plies of composite material, ply boundary areas, stagger between plies, ply orientation, and angular deviation between plies.

19. The method of claim 16 , wherein the comparing the inspection data to the CAD data is concurrent with the comparing the numerical control data to the CAD data.

20. The method of claim 16 , wherein the receiving the inspection data comprises receiving the inspection data of a virtual representation of the composite part.

Assignees

• Boeing Co

Inventors

• Dostert Stephen
• Miller Jeffrey L
• Honea Michael

Classifications

• G06F30/00 Primary

  Computer-aided design [CAD] · CPC title

• G05B19/4065

  Monitoring tool breakage, life or condition · CPC title

• G05B2219/50206

  Tool monitoring integrated in nc control · CPC title

• G05B2219/35012

  Cad cam · CPC title

• G05B19/4097 Primary

  characterised by using design data to control NC machines, e.g. CAD/CAM (G05B19/4093 takes precedence) · CPC title