Machine configured to form a composite structure

Patent metadata

Field	Value
Publication number	US-11911977-B2
Application number	US-202117313074-A
Country	US
Kind code	B2
Filing date	May 6, 2021
Priority date	May 11, 2018
Publication date	Feb 27, 2024
Grant date	Feb 27, 2024

Abstract

An illustrative example of the present disclosure provides a machine configured to form a composite structure. The machine includes a composite placement machine, measuring equipment, a tool path generator, and compaction equipment. The composite placement machine lays up composite plies. The measuring equipment measures surfaces of the composite plies to form measurements during layup of the composite plies. A computer includes a model of the composite plies for a structure. The tool path generator forms a modified tool path based upon a difference between the measurements and expected measurements for the composite plies in the model.

First claim

What is claimed is:

1. A machine that comprises:
a composite placement machine programmed with a tool path defining a laydown surface of a single build composite structure comprising a plurality of composite plies;
measuring equipment configured to produce a measurement of an intermediate surface of the composite structure defined by at least one of the composite plies, wherein an accuracy of the measurement of the intermediate surface is within a tolerance for the composite structure; and
a tool path generator configured to modify the tool path, the modified tool path corresponding to a modified laydown surface for the composite placement machine, wherein formation of the modified tool path depends upon whether a difference between the measurement of the intermediate surface and an expected measurement of the intermediate surface exceeds a threshold, and wherein the modified laydown surface matches the measurement of the intermediate surface;
wherein the composite placement machine is configured to continue laying down, based upon the modified tool path, the composite plies on the intermediate surface.

2. The machine of claim 1 , wherein the accuracy of the measurement of the intermediate surface is at least within 0.001″.

3. The machine of claim 1 , wherein the measuring equipment comprises a laser tracker.

4. The machine of claim 1 , further comprising compaction equipment configured to apply heat and pressure to the intermediate surface.

5. The machine of claim 1 , wherein the intermediate surface is of a set of composite plies and wherein the measurement of the intermediate surface of the composite structure and the formation of the modified tool path is performed during layup of the composite structure.

6. A machine that comprises:
a composite placement machine;
a tool path generator and a model within a computer, wherein the model is for a single build composite structure that comprises a set of plies,
and wherein the tool path generator is in communication with the composite placement machine and is configured to:
cause the composite placement machine to lay up the set of plies such that the set of plies comprises a first outer ply;
form a modified tool path based upon a difference between a first set of measurements and expected measurements for the first outer ply if the difference exceeds a threshold, wherein the modified tool path matches the first set of measurements; and
cause the composite placement machine to continue to lay up the set of plies on a surface of the first outer ply based on the modified tool path;

measuring equipment configured to measure the surface of the first outer ply of the set of plies during formation of the composite structure to form the first set of measurements; and
compaction equipment configured to apply heat and/or pressure to the first outer ply.

7. The machine of claim 6 , wherein the first set of measurements comprises a size and a shape of the first outer ply.

8. The machine of claim 6 , wherein the measuring equipment comprises a laser tracker.

9. The machine of claim 6 , wherein the measuring equipment comprises a laser tracker that comprises an accuracy of at least 0.001″.

10. The machine of claim 6 , wherein the compaction equipment is configured to apply the heat and the pressure to the first outer ply.

11. The machine of claim 6 , wherein the set of plies comprises a quantity of plies between 10 and 20.

12. The machine of claim 6 , wherein the model comprises the expected measurements for the first outer ply.

13. The machine of claim 6 , wherein the model comprises: a ply geometry, a quantity of plies, an order of plies, and fiber orientations for the composite structure that comprises the set of plies.

14. A machine configured to form a single build composite structure that comprises composite plies, such that the machine comprises:
a composite placement machine configured to lay up the composite plies based on a tool path for the composite structure;
measuring equipment configured to measure a plurality of intermediate surfaces of the composite plies during the layup of the composite plies and form a plurality of measurements;
a computer that comprises a model for the composite structure and configured to control a tool path generator; and
the tool path generator configured to form a modified tool path for the composite placement machine in response to a difference between a set of measurements in the plurality of measurements and expected measurements of an intermediate surface of the plurality of intermediate surfaces that exceeds a threshold, wherein the modified tool path matches the set of measurements;
wherein the composite placement machine is further configured to continue laying up the composite plies on the intermediate surface of the plurality of intermediate surfaces based on the modified tool path.

15. The machine of claim 14 , further comprising compaction equipment configured to apply at least one of: heat, and pressure, onto an intermediate surface of the plurality of intermediate surfaces of the composite plies.

16. The machine of claim 14 , wherein the set of measurements comprises a size and a shape of a first set of the composite plies.

17. The machine of claim 14 , further configured to form the structure to comprise dimensions within 0.001 inches of the model.

18. The machine of claim 14 , wherein the measuring equipment comprises a laser tracker.

19. The machine of claim 14 , wherein the composite placement machine comprises a placement head.

20. The machine of claim 14 , wherein the measuring equipment is further configured to make the set of measurements of the plurality of intermediate surfaces with the composite plies located on a layup tool.

Assignees

• Boeing Co

Inventors

• Louie Michael Kenneth-Que
• Albers Robert Graham
• Moore Jeron D
• Perla Luis A
• Saini Gagandeep
• Johnson Brice A
• Rabiega Marcin A

Classifications

• B29C70/38 Primary

  Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)} · CPC title

• B29C70/388

  Tape placement heads, e.g. component parts, details or accessories · CPC title

• B29C70/54

  Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing} · CPC title

• B32B41/00

  Arrangements for controlling or monitoring lamination processes; Safety arrangements · CPC title

• G05B19/182

  characterised by the machine tool function, e.g. thread cutting, cam making, tool direction control (G05B19/21 - G05B19/40 take precedence) · CPC title