# US 12,109,764 B2 · Automated placement of composite material

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- Number: US 12,109,764 B2
- Document ID: US12109764B2
- Status: Granted
- Kind: B2
- Application number: 15/951,165
- Filed: 2018-04-11
- Published: 2019-10-17
- Granted: 2024-10-08
- Earliest claimed: 2018-04-11
- Assignees: Textron Innovations Inc.
- Applicants: Bell Helicopter Textron Inc.
- Inventors: Sébastien Duval; Pascal Flynn-Robitaille
- Web page: https://patentgrep.com/patent/US12109764B2

## CPC

- B29C 70/382: {Automated fiber placement [AFP]}
- B29C 70/205: {the structure being shaped to form a three-dimensional configuration}
- B29C 70/88: characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
- B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 7/03: with respect to the orientation of features (direction of fibres or filaments B32B5/12)
- B64C 1/06: Frames; Stringers; Longerons {; Fuselage sections}
- B64F 5/10: Manufacturing or assembling aircraft, e.g. jigs therefor
- G06F 30/15: Vehicle, aircraft or watercraft design
- G06F 30/23: using finite element methods [FEM] or finite difference methods [FDM]
- B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)}
- B32B 2307/514: Oriented
- B32B 2307/708: Isotropic
- B32B 2605/18: Aircraft
- B64C 2001/0072: {from composite materials}
- G06F 2113/26: Composites
- Y02T 50/40: Weight reduction
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B64C: AEROPLANES; HELICOPTERS
- B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
- G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

Methods and systems for automated placement of composite material on a surface of a component, the composite material including unidirectional fibers, is provided. A set of fiber paths along the surface is established, the set of fiber paths comprising at least one ply, each ply comprising a respective plurality of fiber paths being substantially aligned with a respective direction. An isotropy factor for the component is determined based on the set of fiber paths, the isotropy factor being indicative of a distribution of the plurality of fiber paths on the surface. When the isotropy factor exceeds a predetermined threshold, a respective layer of composite material is applied to the surface of the component using an automated fiber placement machine and for each of the at least one ply, wherein the unidirectional fibers of the composite material are applied along the set of fiber paths.

## Claims

### Claim 1

A method for automated placement of composite material on a surface for manufacturing a component, the composite material including unidirectional fibers, the method comprising:
establishing an initial set of fiber paths along the surface, the initial set of fiber paths comprising at least one ply, each ply comprising a respective plurality of fiber paths being substantially aligned with a respective direction;
determining an isotropy factor for the component based on the initial set of fiber paths, the isotropy factor being a measure of a distribution of the plurality of fiber paths on the surface, the isotropy factor determined, via a finite element analysis, by:
dividing the component into a plurality of elements;
evaluating, for each of the plurality of elements, an angular distance between the plurality of fiber paths and a mechanical strength provided by the plurality of fiber paths to obtain one or more local isotropy factors; and
combining the one or more local isotropy factors into the isotropy factor;
comparing the isotropy factor to a predetermined threshold;
determining that the isotropy factor exceeds the predetermined threshold;
using an automated fiber placement machine for applying, for each of the at least one ply, a respective layer of composite material to the surface of the component, wherein the unidirectional fibers of the composite material are applied along the initial set of fiber paths; and
validating the initial set of fiber paths by inspecting, for each of the at least one ply, the respective layer of composite material as applied to the surface, the validating comprising:
projecting a reference shape on the respective layer of composite material as applied to the surface;
determining an angle between a line portion of the reference shape and an orientation of the unidirectional fibers composing the respective layer of composite material;
comparing the angle to a predetermined value;
validating the respective layer of composite material when the angle is lower than the predetermined value; and
when the angle exceeds the predetermined value, adjusting at least one of a position and an orientation of at least some of plurality of fiber paths, thereby producing a first adjusted set of fiber paths, and repeating, using the first adjusted set of fiber paths as the initial set of fiber paths, the determining, the comparing, the applying, and the validating until the isotropy factor is below the predetermined threshold or the angle is lower than the predetermined value.

### Claim 2 (depends on 1)

The method of claim 1, further comprising:
adjusting the at least one of the position and the orientation of the at least some of the plurality of fiber paths to achieve a given stress profile for at least one region of the surface, thereby producing a second adjusted set of fiber paths, the at least one region identified via the finite element analysis; and
updating the isotropy factor for the component based on the second adjusted set of fiber paths.

### Claim 3 (depends on 1)

The method of claim 1, wherein the at least one ply comprises a first ply substantially aligned with a first direction and a second ply aligned with a second direction different from the first direction.

### Claim 4 (depends on 3)

The method of claim 3, wherein the second direction is different from the first direction substantially by one of 90°, 60°, 45°, 30°, −30°, −45° and −60° from the first direction.

### Claim 5 (depends on 1)

The method of claim 1, wherein the at least one ply comprises a first ply substantially aligned with a first direction, the first direction corresponding to a 0° orientation for the unidirectional fibers.

### Claim 6 (depends on 1)

The method of claim 1, wherein the at least one ply comprises at least two subsequent plies, wherein the respective direction of each of the at least two plies is a common direction.

### Claim 7

A method for automated placement of composite material on a surface for manufacturing a component, the composite material including unidirectional fibers, the method comprising:
establishing an initial set of fiber paths along the surface, the initial set of fiber paths comprising at least one ply, each ply comprising a respective plurality of fiber paths being substantially aligned with a respective direction;
determining an isotropy factor for the component based on the initial set of fiber paths, the isotropy factor being a measure of a distribution of the plurality of fiber paths on the surface, the isotropy factor determined, via a finite element analysis, by:
dividing the component into a plurality of elements;
evaluating, for each of the plurality of elements, an angular distance between the plurality of fiber paths and a mechanical strength provided by the plurality of fiber paths to obtain one or more local isotropy factors; and
combining the one or more local isotropy factors into the isotropy factor;
comparing the isotropy factor to a predetermined threshold;
determining that the isotropy factor is below the predetermined threshold;
identifying at least one region of the surface where the angular distance of at least some of the plurality of fiber paths is greater than a predetermined maximum angular distance or lower than a predetermined minimum angular distance;
adjusting at least one of a position and an orientation of the at least some of the plurality of fiber paths to maintain the angular distance between adjacent fiber paths of the plurality of fiber paths above the predetermined minimum angular distance or below the predetermined maximum angular distance, thereby producing an adjusted set of fiber paths;
updating the isotropy factor for the component based on the adjusted set of fiber paths;
repeating the steps of comparing, identifying, adjusting, and updating until the isotropy factor exceeds the predetermined threshold; and
using an automated fiber placement machine for applying, for each of the at least one ply, a respective layer of composite material to the surface of the component, wherein the unidirectional fibers of the composite material are applied along the adjusted set of fiber paths.

### Claim 8 (depends on 7)

The method of claim 7, wherein identifying the at least one region comprises highlighting the at least one region on a virtual rendering of the component.

### Claim 9 (depends on 7)

The method of claim 7, further comprising receiving input indicative of an adjustment to the set of fiber paths, wherein adjusting the position of the at least some fiber paths is based on the input.

### Claim 10 (depends on 7)

The method of claim 7, wherein adjusting the position of the at least some of the plurality of fiber paths comprises employing artificial intelligence.

### Claim 11 (depends on 7)

The method of claim 7, wherein the at least one ply comprises a first ply substantially aligned with a first direction and a second ply aligned with a second direction different from the first direction.

### Claim 12 (depends on 11)

The method of claim 11, wherein the second direction is different from the first direction substantially by one of 90°, 60°, 45°, 30°, −30°, −45° and −60° from the first direction.

### Claim 13 (depends on 7)

The method of claim 7, wherein the at least one ply comprises a first ply substantially aligned with a first direction, the first direction corresponding to a 0° orientation for the unidirectional fibers.

### Claim 14 (depends on 7)

The method of claim 7, wherein the at least one ply comprises at least two subsequent plies, wherein the respective direction of each of the at least two plies is a common direction.