Hybrid formation of multi-layer prepreg composite sheet layup

Patent metadata

Field	Value
Publication number	US-11919239-B2
Application number	US-202318129757-A
Country	US
Kind code	B2
Filing date	Mar 31, 2023
Priority date	Aug 7, 2018
Publication date	Mar 5, 2024
Grant date	Mar 5, 2024

Abstract

Methods, systems, and robots for multi-layer prepreg composite sheet layup. The robotic system may include a memory for storing a dataset including start and end point pairs of a mold of a 3D part that defines a layup sequence, a first robot or a first robot arm that is configured to conform a prepreg layer or sheet onto the mold of the 3D part, and a second robot or a second robot arm that is configured to hold or grasp the prepreg layer or sheet above the mold of the 3D part and stretch or relax the prepreg layer or sheet when the first robot or the first robot arm conforms the prepreg layer or sheet onto the mold. The robotic system may also include one or more processors connected to the first robot or the first robot arm and the second robot or the second robot arm.

First claim

What is claimed is:

1. A robotic system, comprising:
a memory for storing a dataset including start and end point pairs of a mold of a 3D part that defines a layup sequence;
a first robot or a first robot arm that is configured to conform a prepreg layer or sheet onto the mold of the 3D part;
a second robot or a second robot arm that is configured to hold or grasp the prepreg layer or sheet above the mold of the 3D part and stretch or relax the prepreg layer or sheet when the first robot or the first robot arm conforms the prepreg layer or sheet onto the mold; and
one or more processors connected to the first robot or the first robot arm and the second robot or the second robot arm and configured to:
generate a plurality of trajectories based on the layup sequence,
coordinate a plurality of collision free movements for the first robot or the first robot arm with a plurality of collision free movements of the second robot or the second robot arm based on the plurality of trajectories,
cause the first robot or the first robot arm to conform the prepreg layer or sheet onto the mold based on the plurality of collision free movements for the first robot or the first robot arm, and
cause the second robot or the second robot arm to hold, grasp, stretch or relax the prepreg layer or sheet based on the plurality of collision free movements for the second robot or the second robot arm.

2. The robot system of claim 1 , further comprising:
a third robot or a third robot arm having a laser and configured to scan, using the laser, an image of the prepreg layer or sheet on the mold; and
a display for displaying the image of the prepreg layer or sheet, the image showing a fiber alignment, a resin quality or a conformity of the prepreg layer or sheet on the mold;
wherein the one or more processors are configured to:
analyze the image to determine the fiber alignment, the resin quality or the conformity of the prepreg layer or sheet on the mold, and
render the image on the display.

3. The robot system of claim 2 , wherein the one or more processors are configured to cause the first robot or the first robot arm to conform the prepreg layer or sheet onto the mold further based on one or more parameters that result in the fiber alignment, the resin quality or the conformity of the prepreg layer or sheet on the mold.

4. The robot system of claim 3 , wherein the one or more parameters include at least one of a draping force, a dibbing force, a tool velocity, a temperature of airflow or a stiffness of the first robot or the first robot arm, wherein processor is configured to move the first robot or the first robot arm based on the one or more process parameters.

5. The robotic system of claim 1 , wherein the first robot or the first robot arm is a conforming robot or robot arm and the second robot or the second robot arm is a grasping robot or robot arm, wherein the conforming robot or robot arm is configured to press or place the prepreg layer or sheet onto the 3D part based on the plurality of trajectories and heat the prepreg layer or sheet to conform to the 3D part, and the grasping robot or robot arm is configured to hold the prepreg layer or sheet a threshold distance above the 3D part.

6. The robotic system of claim 1 , wherein the second robot or the second robot arm holds or grasps the prepreg layer or sheet at a point within a first area or region of the prepreg layer or sheet and outside a second area or region that encompasses the plurality of trajectories.

7. The robotic system of claim 1 , wherein the first robot or the first robot arm has one or more tools including at least one of a roller, a draping tool, a dibbing tool or a nozzle to blow air.

8. A robotic system, comprising:
a memory for storing a dataset including start and end point pairs of a mold of a 3D part that defines a layup sequence;
a first robot or a first robot arm that is configured to conform a prepreg layer or sheet onto the mold of the 3D part;
a second robot or a second robot arm that is configured to hold or grasp the prepreg layer or sheet above the mold of the 3D part when the first robot or the first robot arm conforms the prepreg layer or sheet onto the mold; and
one or more processors connected to the first robot or the first robot arm and the second robot or the second robot arm and configured to:
determine a location to place the 3D part within a workspace,
determine one or more grasp locations for the second robot or the second robot art to hold or grasp the prepreg layer or sheet,
generate a plurality of trajectories based on the layup sequence,
cause the first robot or the first robot arm to conform the prepreg layer or sheet onto the mold based on the plurality of trajectories, and
cause the second robot or the second robot art to hold or grasp the prepreg layer or sheet based on the one or more grasp locations.

9. The robotic system of claim 8 , wherein the one or more processors are configured to generate the plurality of trajectories further based on the one or more grasp locations.

Assignees

• Univ Southern California

Inventors

• Malhan Rishi
• Centea Timotei
• Gupta Satyandra
• Kabir Ariyan
• Shah Brual
• Shembekar Aniruddha

Classifications

• B29C64/379 Primary

  Handling of additively manufactured objects, e.g. using robots · CPC title

• B25J9/0087

  Dual arms (double SCARA arms B25J9/043) · CPC title

• B25J11/005

  Manipulators for mechanical processing tasks · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29C70/386

  Automated tape laying [ATL] · CPC title