Manufacturing system for composite structures

Patent metadata

Field	Value
Publication number	US-9782938-B2
Application number	US-201414221343-A
Country	US
Kind code	B2
Filing date	Mar 21, 2014
Priority date	Mar 21, 2014
Publication date	Oct 10, 2017
Grant date	Oct 10, 2017

Abstract

A system for manufacturing a composite part. The system comprises fiber placement devices, an overhead track system, and a scheduling controller. The fiber placement devices are configured to operate in a coordinated manner to place fibers at locations on a tool used for manufacturing the composite part. The overhead track system comprises a linear track running co-axial to the tool. The overhead track system is associated with the fiber placement devices and configured to move the fiber placement devices to the locations along a length of the tool. The scheduling controller is configured to coordinate operation of the fiber placement devices such that the fiber placement devices perform tasks simultaneously to place the fibers in a desired configuration on the tool.

First claim

What is claimed is:

1. A system for manufacturing a composite part comprising:
fiber placement devices configured to operate in a coordinated manner to place fibers at locations on a tool used for manufacturing the composite part;
an overhead track system comprising a first linear track running parallel to an axis of the tool, wherein the overhead track system is associated with the fiber placement devices and configured to move the fiber placement devices to the locations along a length of the tool;
an overhead conveyor system comprising a second linear track running parallel to the axis of the tool to receive one or more of the fiber placement devices and to provide one or more replacement fiber placement devices;
a scheduling controller configured to coordinate operation of the fiber placement devices such that the fiber placement devices perform tasks simultaneously to place fibers in a desired configuration on the tool;
wherein the fiber placement devices are mounted on robotic positioning arms configured to move using the first linear track and to affix a fiber placement device onto a first receiver of the overhead conveyor system and to pick up a replacement fiber placement device from a second receiver of the conveyor system; and
wherein the first receiver and the second receiver are moveably engaged to the second linear track system.

2. The system of claim 1 , wherein the fiber placement devices are configured to operate independently of one another and wherein the second linear track system is a gravity roller system.

3. The system of claim 1 , wherein the scheduling controller is configured to identify an order for the tasks performed by the fiber placement devices and assign each of the tasks to one of the fiber placement devices based on the order of the tasks.

4. The system of claim 1 , wherein the scheduling controller is configured to modify the operation of at least one of the fiber placement devices based on an availability of another of the fiber placement devices.

5. The system of claim 4 , wherein the scheduling controller is configured to reassign the tasks when one of the fiber placement devices becomes unavailable.

6. The system of claim 1 , wherein a robotic positioning arm in the robotic positioning arms is configured to move about the tool such that the robotic positioning arm accesses substantially all of a surface of the tool.

7. The system of claim 1 , wherein the fiber placement devices are configured to place a continuous fiber along the length of the composite part.

8. The system of claim 1 , wherein the composite part has a thickness that changes between locations along the length of the composite part and wherein the fiber placement devices are configured to move about the tool such that the fibers are placed in the desired configuration with respect to the thickness at the locations.

9. The system of claim 1 , wherein each of the fiber placement devices is configured to move along the first linear track over the length of the tool to place the fibers in the desired configuration.

10. A method for manufacturing a composite part, the method comprising:
assigning tasks to fiber placement devices configured to place fibers at locations on a tool used for manufacturing the composite part;
coordinating operation of the fiber placement devices such that the fiber placement devices perform the tasks simultaneously to place the fibers in a desired configuration on the tool;
moving the fiber placement devices to the locations along a length of the tool using an overhead track system comprising a first linear track that parallel to the length of the tool;
providing a replacement fiber placement device on an overhead conveyor system comprising a second linear track running parallel to the length of the tool;
placing the fibers in the locations on the tool using the fiber placement devices;
wherein a robotic positioning arm mounted on the first linear track system is configured to place a fiber placement device onto a first receiver movably affixed to the second linear track and to pick up the replacement fiber placement device from a second receiver movably affixed to the second linear track.

11. The method of claim 10 further comprising:
identifying the tasks to be performed by the fiber placement devices;
identifying an order for the tasks;
assigning the tasks to the fiber placement devices based on the order of the tasks; and
moving the fiber placement devices along the first linear track to perform the tasks in a coordinated manner.

12. The method of claim 10 further comprising:
modifying the operation of at least one of the fiber placement devices based on an availability of another of the fiber placement devices.

13. The method of claim 10 further comprising:
performing the tasks to manufacture the composite part.

14. The method of claim 10 , wherein the fiber placement devices are mounted on robotic positioning arms configured to move using the overhead track system and further comprising:
moving a robotic positioning arm in the robotic positioning arms about the tool such that the robotic positioning arm accesses substantially all of the tool to place the fibers in the desired configuration.

15. The method of claim 10 further comprising:
placing a continuous fiber along the length of the composite part using the fiber placement devices.

16. A composite fiber placement system comprising:
robotic positioning arms configured to move along a first linear track positioned over and parallel to an axis of a tool used for manufacturing a composite part;
one or more fiber placement devices associated with the robotic positioning arms and configured to operate in a coordinated manner to place fibers at locations on the tool;
a second linear track positioned over and parallel to the axis of the tool and configured to receive a fiber placement device on a first receiver and to provide a replacement fiber placement device on a second receiver;
a scheduling controller configured to identify an order for tasks performed by the fiber placement devices, assign each of the tasks to one of the fiber placement devices based on the order of the tasks, and coordinate operation of the fiber placement devices such that the fiber placement devices perform the tasks simultaneously to place the fibers in a desired configuration on the tool;
wherein the robotic positioning arms are configured to place the fiber placement device onto the first receiver and to pick up the replacement fiber placement device from the second receiver;
wherein the first receiver and the second receiver are moveably engaged to a second linear track system.

17. The composite fiber placement system of claim 16 , wherein the first linear track system is a gravity roller system.

18. The composite fiber placement system of claim 16 , wherein the fiber placement devices are configured to place a continuous fiber along a length of the composite part.

19. The composite fiber placement system of claim 16 , wherein a first fiber placement device, responsive to a second fiber placement device going offline, is configured to assume tasks assigned to the second fiber placement device.

Assignees

• Boeing Co

Inventors

• Pedigo Samuel Francis
• Johnson Brice Aaron

Classifications

• G05B19/41865

  characterised by job scheduling, process planning, material flow · CPC title

• Y02P90/20

  Cross-Sectional Technologies · mapped topic

• B29C70/386

  Automated tape laying [ATL] · CPC title

• B29C70/16

  using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} · CPC title

• B29C70/384

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