US 12,321,149 B2Granted

Method for computer analysis of as-programmed surface quality of composite structure

AssigneeThe Boeing Company

InventorsMatthew S. Stauffer, Kayley E. Seawright, Russell A. Strope, Michael S. Lindgren, Daniel E. Gonsor, Ashutosh Mani

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Abstract

A method for computer analysis of a quality of an as-programmed surface of a composite laminate. A first data set representing an as-programmed top surface is generated based on as-programmed ply definitions and a tool surface definition. Thereafter, a second data set representing coordinates of points of a first mesh on the as-programmed top surface is generated, which points form a first mesh. Then a third data set representing coordinates of points of a second mesh on a defined tool surface is generated. A respective angle of each mesh element of the first mesh relative to a corresponding mesh element of the second mesh is then calculated. Each angle is compared to a threshold of acceptable angle. In response to an acceptable number of angles exceeding a threshold of acceptable angle, a tow placement machine may be programmed to fabricate a composite structure using the as-programmed ply definitions.

Claims21

Dependent claims

A method for computer analysis of a quality of an as- programmed surface of a composite structure, the method comprising:

(a) generating a first data set representing a first as-programmed top surface of the composite structure based on an initial plurality of as-programmed ply definitions and a tool surface definition representing a defined tool surface;
(b) generating a second data set representing coordinates of a plurality of points on the first as-programmed top surface, the plurality of points being arranged to form a first mesh comprising a plurality of mesh elements;
(c) generating a third data set representing coordinates of a plurality of points on the defined tool surface, the plurality of points being arranged to form a second mesh comprising a plurality of mesh elements;
(d) calculating a respective angle of each mesh element of the first mesh relative to a corresponding mesh element of the second mesh;
(e) comparing each angle calculated in step (d) to a threshold of acceptable angle;
and
(f) programming a tow placement machine to fabricate the composite structure in accordance with the initial plurality of as-programmed ply definitions in response to an acceptable number of angles exceeding the threshold of acceptable angle in step (e),
wherein the composite structure in accordance with the initial plurality of as-programmed ply definitions has a ramp on an exterior and a ply drop-off region in an interior consisting of ply drops positioned and spaced in accordance with an as-programmed ply drop-off schedule.

5 more elements

A method for computer analysis of a quality of an as-programmed surface of a composite structure, the method comprising:

(a) generating a first data set representing a first as-programmed top surface of the composite structure based on an initial plurality of as-programmed ply definitions and a tool surface definition representing a defined tool surface;
(b) generating a second data set representing coordinates of a plurality of points on the first as-programmed top surface, the plurality of points being arranged to form a first mesh comprising a plurality of mesh elements;
(c) generating a third data set representing coordinates of a plurality of points on the defined tool surface, the plurality of points being arranged to form a second mesh comprising a plurality of mesh elements;
(d) calculating a respective angle of each mesh element of the first mesh relative to a corresponding mesh element of the second mesh;
(e) comparing each angle calculated in step (d) to a threshold of acceptable angle;
(f) generating a revised plurality of as-programmed ply definitions in response to an angle exceeding the threshold of acceptable angle;
(g) generating a fourth data set representing a second as-programmed top surface of the composite structure based on the revised plurality of as-programmed ply definitions and the tool surface definition;
(h) generating a fifth data set representing coordinates of a plurality of points on the second as-programmed top surface, the plurality of points being arranged to form a third mesh comprising a plurality of mesh elements;
(i) calculating a respective angle of each mesh element of the third mesh relative to the defined tool surface;
corresponding mesh element of the second mesh;
(j) comparing each angle calculated in step (i) to the threshold of acceptable angle;
and
(k) programming a tow placement machine to fabricate the composite structure in accordance with the revised plurality of as-programmed ply definitions in response to an acceptable number of angles exceeding the threshold of acceptable angle in step (j),
wherein the composite structure in accordance with the revised plurality of as- programmed ply definitions has a ramp on an exterior and a ply drop-off region in an interior consisting of ply drops positioned and spaced in accordance with an as-programmed ply drop-off schedule.

11 more elements

A method for computer analysis of a quality of an as-programmed surface of a composite structure, the method comprising:

(a) obtaining data representing a defined tool surface;
(b) obtaining as-designed geometric ply definitions for the composite structure from an engineering source, each ply definition including fiber orientation data and ply edge data;
(c) generating a tool path definition containing centerline data and a shape definition for each tow of each ply using the as-designed geometric ply definitions;
(d) generating an initial plurality of as-programmed ply definitions for each ply using the tool path and shape definitions;
(e) generating a first data set representing a first as-programmed top surface of the composite structure based on the initial plurality of as-programmed ply definitions and a tool surface definition;
(f) generating a second data set representing coordinates of a plurality of points on the first as-programmed top surface, the plurality of points being arranged to form a first mesh comprising a plurality of mesh elements;
(g) calculating a respective angle of each mesh element of the first mesh relative to the defined tool surface;
and
(h) comparing each angle calculated in step (g) to a threshold of acceptable angle. angle;
and
(i) programming a tow placement machine to fabricate the composite structure in accordance with a revised plurality of as-programmed ply definitions in response to an acceptable number of angles exceeding the threshold of acceptable angle in step (h),
wherein the composite structure in accordance with the initial plurality of as-programmed ply definitions has a ramp on an exterior and a ply drop-off region in an interior consisting of ply drops positioned and spaced in accordance with an as-programmed ply drop-off schedule.

9 more elements

A method for computer analysis of a quality of an as-programmed surface of a composite structure, the method comprising:

(a) obtaining data representing a defined tool surface;
(b) obtaining as-designed geometric ply definitions for the composite structure from an engineering source, each ply definition including fiber orientation data and ply edge data;
(c) generating a tool path definition containing centerline data and a shape definition for each tow of each ply using the as-designed geometric ply definitions;
(d) generating an initial plurality of as-programmed ply definitions for each ply using the tool path and shape definitions;
(e) generating a first data set representing a first as-programmed top surface of the composite structure based on the initial plurality of as-programmed ply definitions and a tool surface definition;
(f) generating a second data set representing coordinates of a plurality of points on the first as-programmed top surface, the plurality of points being arranged to form a first mesh comprising a plurality of mesh elements;
(g) calculating a respective angle of each mesh element of the first mesh relative to the defined tool surface;
(h) comparing each angle calculated in step (g) to a threshold of acceptable angle;
(i) generating a revised plurality of as-programmed ply definitions in response to an angle exceeding the threshold of acceptable angle;
(j) generating a third data set representing a second as-programmed top surface of the composite structure based on the revised plurality of as-programmed ply definitions and the tool surface definition;
(k) generating a fourth data set representing coordinates of a plurality of points on the second as-programmed top surface, the plurality of points being arranged to form a second mesh comprising a plurality of mesh elements;
(1) calculating a respective angle of each mesh element of the second mesh relative to the defined tool surface;
(m) comparing each angle calculated in step (1) to the threshold of acceptable angle;
and
(n) programming a tow placement machine to fabricate the composite structure in accordance with the revised plurality of as-programmed ply definitions in response to an acceptable number of angles exceeding the threshold of acceptable angle in step (m),
wherein the composite structure in accordance with the initial plurality of as-programmed ply definitions has a ramp on an exterior and a ply drop-off region in an interior consisting of ply drops positioned and spaced in accordance with an as-programmed ply drop-off schedule.

13 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/695,430Filed 15 Mar 2022 · us provisional application
Priority: 17 May 2021
Published: US 2022/0373992 A124 Nov 2022
Granted: 3 Jun 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification13 codes

G05B 19/4097
Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to…
G06F 30/20
Computer-aided design [CAD]: design optimisation, verification or simulation
B29C 70/386
Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns: automated tape laying [ATL]
B29C 70/54
Shaping operations therefor: component parts, details or accessories; Auxiliary operations , e.g. feeding or storage of prepregs or SMC after…