U.S. patent application number 16/787763 was filed with the patent office on 2021-08-12 for data-driven decisions for improved composite manufacturing.
The applicant listed for this patent is THE BOEING COMPANY. Invention is credited to John W. Adams, Sadie L. Fieni, Gary E. Georgeson, Seeran Prajapati, Russell A. Strope.
Application Number | 20210245457 16/787763 |
Document ID | / |
Family ID | 1000005735990 |
Filed Date | 2021-08-12 |
United States Patent
Application |
20210245457 |
Kind Code |
A1 |
Strope; Russell A. ; et
al. |
August 12, 2021 |
DATA-DRIVEN DECISIONS FOR IMPROVED COMPOSITE MANUFACTURING
Abstract
A method is provided that includes monitoring a process of
manufacturing a composite structure that includes introducing a
matrix material to a reinforcement material, applying the
reinforcement material into a mold cavity or onto a mold surface
with a first machine tool, subjecting the matrix material to a
melding event with a second machine tool, and inspecting the
composite structure. Data including at least one of first
measurement data, error data or second measurement data is
determined, and an analysis of the data is performed to summarize
the data and thereby produce feedback data including a summary of
the data. At least one of the process, the first machine tool or
the second machine tool is adjusted based on feedback including the
summary, and for manufacture of a next composite structure.
Inventors: |
Strope; Russell A.; (Mt.
Pleasant, SC) ; Georgeson; Gary E.; (Tacoma, WA)
; Prajapati; Seeran; (Summerville, SC) ; Fieni;
Sadie L.; (Ladson, SC) ; Adams; John W.;
(North Charleston, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
THE BOEING COMPANY |
Chicago |
IL |
US |
|
|
Family ID: |
1000005735990 |
Appl. No.: |
16/787763 |
Filed: |
February 11, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 70/54 20130101;
B29C 70/30 20130101 |
International
Class: |
B29C 70/54 20060101
B29C070/54; B29C 70/30 20060101 B29C070/30 |
Claims
1. A method comprising: monitoring a process of manufacturing a
composite structure that comprises: introducing a matrix material
to a reinforcement material; applying the reinforcement material
into a mold cavity or onto a mold surface with a first machine
tool; subjecting the composite structure, including the
reinforcement material and the matrix material, to a melding event
with a second machine tool, to set the composite structure
including the reinforcement material and the matrix material; and
inspecting the composite structure to evaluate properties of the
composite structure; and based on the monitoring, determining data
comprising at least one of first measurement data indicative of an
operating condition of at least one of the first machine tool or
the second machine tool, error data indicative of an error
associated with at least one of the first machine tool or the
second machine tool, or second measurement data indicative of a
property of the composite structure; performing an analysis of the
data to summarize the data and thereby produce feedback data
comprising a summary of the data; and adjusting at least one of the
process, the first machine tool or the second machine tool based on
the feedback data, and for manufacture of a next composite
structure.
2. The method of claim 1, wherein performing the analysis comprises
performing the analysis to produce the feedback data comprising the
summary of the data from which an outlier, trend or pattern in the
data is identifiable, and wherein adjusting at least one of the
process, the first machine tool or the second machine tool
comprises identifying an adjustment based on the outlier, trend or
pattern, and adjusting at least one of the process, the first
machine tool or the second machine tool according to the
adjustment.
3. The method of claim 1, wherein performing the analysis comprises
automatically producing infographics in a graphical user interface
(GUI) to visually summarize the data.
4. The method of claim 1, wherein when at least one of the first
machine tool or the second machine tool experiences a fault during
manufacture of the composite structure, the data comprises the
first measurement data, including measurements of a particular
operating condition of at least one of the first machine tool or
the second machine tool before the fault, wherein performing the
analysis comprises performing the analysis to summarize a change in
the measurements of the particular operating condition before the
fault, and wherein adjusting at least one of the process, the first
machine tool or the second machine tool comprises performing a
repair or replacement of at least one of the first machine tool or
the second machine tool that experienced the fault, and adjusting
the process to further monitor the particular operating condition
during manufacture of the next composite structure.
5. The method of claim 1, wherein the data comprises the error
data, including a particular error repeatedly reported during
manufacture of the composite structure, wherein performing the
analysis comprises performing the analysis to summarize repetition
of the particular error, and wherein adjusting at least one of the
process, the first machine tool or the second machine tool
comprises performing a root cause analysis to identify a root cause
of the repetition of the particular error, and adjusting at least
one of the first machine tool or the second machine tool to address
the root cause.
6. The method of claim 1, wherein the data comprises the second
measurement data, including particular measurements of a property
of the composite structure spatially referenced to locations on the
composite structure, and wherein performing the analysis further
comprises generating a three-dimensional (3D) model of the
composite structure with the particular measurements indicated on
the 3D model at the locations to which the particular measurements
are spatially referenced.
7. The method of claim 6, wherein the particular measurements
include measurements of cure state of the composite structure
referenced to locations on the composite structure.
8. The method of claim 6, wherein the particular measurements
include measurements of wrinkles or defects identified on the
composite structure.
9. The method of claim 8, wherein the particular measurements
include measurements of defects in the composite structure,
classified in a plurality of subclasses of defects, and wherein
generating the 3D model comprises generating a heat map including
the 3D model on which the subclasses of defects are indicated,
spatially referenced to locations on the composite structure.
10. The method of claim 6, wherein the particular measurements
include measurements that are out of tolerance or non-conforming,
and wherein generating the 3D model comprises generating a heat map
including the 3D model on which numbers of the measurements that
are out of tolerance or non-conforming are indicated, spatially
referenced to locations on the composite structure.
11. A computer comprising: a memory configured to store
computer-readable program code; and processing circuitry configured
to access the memory, and execute the computer-readable program
code to cause the computer to at least: monitor a process of
manufacturing a composite structure that comprises machine tools
configured to at least: introduce a matrix material to a
reinforcement material; apply the reinforcement material into a
mold cavity or onto a mold surface with a first machine tool of the
machine tools; subject the composite structure, including the
reinforcement material and the matrix material, to a melding event
with a second machine tool of the machine tools, to set the
composite structure; and inspect the composite structure to
evaluate properties of the composite structure; and based on the
monitor, determine data comprising at least one of first
measurement data indicative of an operating condition of at least
one of the first machine tool or the second machine tool, error
data indicative of an error associated with at least one of the
first machine tool or the second machine tool, or second
measurement data indicative of a property of the composite
structure; and perform an analysis of the data to summarize the
data and thereby produce feedback data comprising a summary of the
data, wherein at least one of the process, the first machine tool
or the second machine tool is adjustable based on the feedback
data, and for manufacture of a next composite structure.
12. The computer of claim 11, wherein the computer caused to
perform the analysis comprises the computer caused to perform the
analysis to produce the feedback data comprising the summary of the
data from which an outlier, trend or pattern in the data is
identifiable, and identify an adjustment based on the outlier,
trend or pattern, and wherein at least one of the process, the
first machine tool or the second machine tool is adjustable
according to the adjustment.
13. The computer of claim 11, wherein the computer caused to
perform the analysis comprises the computer caused to automatically
produce infographics in a graphical user interface (GUI) to
visually summarize the data.
14. The computer of claim 11, wherein when at least one of the
first machine tool or the second machine tool experiences a fault
during manufacture of the composite structure, the data comprises
the first measurement data, including measurements of a particular
operating condition of at least one of the first machine tool or
the second machine tool before the fault, wherein the computer
caused to perform the analysis comprises the computer caused to
perform the analysis to summarize a change in the measurements of
the particular operating condition before the fault, and wherein at
least one of the first machine tool or the second machine tool that
experienced the fault is repairable or replaceable, and the process
is adjustable to further monitor the particular operating condition
during manufacture of the next composite structure.
15. The computer of claim 11, wherein the data comprises the error
data, including a particular error repeatedly reported during
manufacture of the composite structure, wherein the computer caused
to perform the analysis comprises the computer caused to perform
the analysis to summarize repetition of the particular error, and
wherein the processing circuitry is configured to execute the
computer-readable program code to cause the computer to further
perform a root cause analysis to identify a root cause of the
repetition of the particular error, and at least one of the first
machine tool or the second machine tool is adjustable to address
the root cause.
16. The computer of claim 11, wherein the data comprises the second
measurement data, including particular measurements of a property
of the composite structure spatially referenced to locations on the
composite structure, and wherein the computer caused to perform the
analysis further comprises the computer caused to generate a
three-dimensional (3D) model of the composite structure with the
particular measurements indicated on the 3D model at the locations
to which the particular measurements are spatially referenced.
17. The computer of claim 16, wherein the particular measurements
include measurements of cure state of the composite structure
referenced to locations on the composite structure.
18. The computer of claim 16, wherein the particular measurements
include measurements of wrinkles or defects identified on the
composite structure.
19. The computer of claim 18, wherein the particular measurements
include measurements of defects in the composite structure,
classified in a plurality of subclasses of defects, and wherein the
computer caused to generate the 3D model comprises the computer
caused to generate a heat map including the 3D model on which the
subclasses of defects are indicated, spatially referenced to
locations on the composite structure.
20. The computer of claim 16, wherein the particular measurements
include measurements that are out of tolerance or non-conforming,
and wherein the computer caused to generate the 3D model comprises
the computer caused to generate a heat map including the 3D model
on which numbers of the measurements that are out of tolerance or
non-conforming are indicated, spatially referenced to locations on
the composite structure.
Description
TECHNOLOGICAL FIELD
[0001] The present disclosure relates generally to composite
manufacturing and, in particular, to using data analytics for
improved composite manufacturing.
BACKGROUND
[0002] Aircraft are being designed and manufactured with greater
and greater percentages of composite materials. Some aircraft may
have more than fifty percent of their primary structure made from
composite materials. Composite materials are used in aircraft to
decrease the weight of the aircraft. This decreased weight improves
performance features, such as payload capacities and fuel
efficiencies. Further, composite materials provide longer service
life for various components in an aircraft.
[0003] Composite materials are tough, light-weight materials,
created by combining two or more dissimilar components. For
example, a composite may include components such as a reinforcement
material (e.g., fibers) and matrix material (e.g., resin) that are
combined and cured to form a composite material.
[0004] By using composite materials, portions of an aircraft may be
created in larger pieces or sections. This is called integrated
structure. For example, a fuselage in an aircraft may be created in
cylindrical sections that may be put together to form the fuselage
of the aircraft. Other examples include, for example, without
limitation, wing skins, span-wise stiffeners, spars and chordwise
ribs joined to form a wing, stabilizer sections joined to form a
stabilizer, a stiffener, a fairing, a control surface, a skin, a
skin section, a door, a strut, and a tubular structure.
[0005] In manufacturing composite components, the materials are
typically formed using a mold with sufficient rigidity to maintain
the desired shape for the composite component when the composite
materials are applied into a cavity of the mold cavity or onto a
surface of the mold. A mold may be metallic or non-metallic in
composition to provide rigidity for supporting the composite
materials.
[0006] Currently, many composites in a manufactured aircraft employ
an autoclave to cure the composite components. Resins in
pre-impregnated plies of fibers typically need an elevated
temperature to achieve a chemical reaction that allows these resins
to flow and cure, and an elevated pressure to achieve ply
consolidation and expel gases contained within the pre-impregnated
plies, known as porosity. With large components, a large autoclave
is used to encompass the component and the tool for processing.
[0007] Conventional composite manufacturing processes are subject
to undesirable errors and inconsistency, which may in turn result
in reduced yield, increased scrap and rework, or performance/weight
penalties resulting from reduced design allowables (structural
knockdowns).
BRIEF SUMMARY
[0008] Example implementations of the present disclosure relate
generally to composite manufacturing and, in particular, to using
data analytics for improved composite manufacturing. In accordance
with example implementations, data recorded or reported during
manufacturing is collected, and an analysis of the data is
performed to summarize the data and thereby produce a summary of
the data. Feedback including the summary may suggest or otherwise
indicate one or more adjustments enhance the process or machine
tools, reduce undesirable errors and inconsistency, or otherwise
improve the process, machine tools or composite structures that are
manufactured. The process or a machine tool used in the process may
then be adjusted based on feedback including the summary, and a
next composite structure is manufactured according to or using the
process or machine tool, as adjusted.
[0009] The present disclosure thus includes, without limitation,
the following example implementations.
[0010] Some example implementations provide a method comprising
monitoring a process of manufacturing a composite structure that
comprises: introducing a matrix material to a reinforcement
material; applying the reinforcement material into a mold cavity or
onto a mold surface with a first machine tool; subjecting the
composite structure, including the reinforcement material and the
matrix material, to a melding event with a second machine tool, to
set the composite structure including the reinforcement material
and the matrix material; and inspecting the composite structure to
evaluate properties of the composite structure; and based on the
monitoring, determining data comprising at least one of first
measurement data indicative of an operating condition of at least
one of the first machine tool or the second machine tool, error
data indicative of an error associated with at least one of the
first machine tool or the second machine tool, or second
measurement data indicative of a property of the composite
structure; performing an analysis of the data to summarize the data
and thereby produce feedback data comprising a summary of the data;
and adjusting at least one of the process, the first machine tool
or the second machine tool based on the feedback data, and for
manufacture of a next composite structure.
[0011] In some example implementations of the method of any
preceding example implementation, or any combination of any
preceding example implementations, performing the analysis
comprises performing the analysis to produce the feedback data
comprising the summary of the data from which an outlier, trend or
pattern in the data is identifiable, and wherein adjusting at least
one of the process, the first machine tool or the second machine
tool comprises identifying an adjustment based on the outlier,
trend or pattern, and adjusting at least one of the process, the
first machine tool or the second machine tool according to the
adjustment.
[0012] In some example implementations of the method of any
preceding example implementation, or any combination of any
preceding example implementations, performing the analysis
comprises automatically producing infographics in a graphical user
interface (GUI) to visually summarize the data.
[0013] In some example implementations of the method of any
preceding example implementation, or any combination of any
preceding example implementations, when at least one of the first
machine tool or the second machine tool experiences a fault during
manufacture of the composite structure, the data comprises the
first measurement data, including measurements of a particular
operating condition of at least one of the first machine tool or
the second machine tool before the fault, wherein performing the
analysis comprises performing the analysis to summarize a change in
the measurements of the particular operating condition before the
fault, and wherein adjusting at least one of the process, the first
machine tool or the second machine tool comprises performing a
repair or replacement of at least one of the first machine tool or
the second machine tool that experienced the fault, and adjusting
the process to further monitor the particular operating condition
during manufacture of the next composite structure.
[0014] In some example implementations of the method of any
preceding example implementation, or any combination of any
preceding example implementations, the data comprises the error
data, including a particular error repeatedly reported during
manufacture of the composite structure, wherein performing the
analysis comprises performing the analysis to summarize repetition
of the particular error, and wherein adjusting at least one of the
process, the first machine tool or the second machine tool
comprises performing a root cause analysis to identify a root cause
of the repetition of the particular error, and adjusting at least
one of the first machine tool or the second machine tool to address
the root cause.
[0015] In some example implementations of the method of any
preceding example implementation, or any combination of any
preceding example implementations, the data comprises the second
measurement data, including particular measurements of a property
of the composite structure spatially referenced to locations on the
composite structure, and wherein performing the analysis further
comprises generating a three-dimensional (3D) model of the
composite structure with the particular measurements indicated on
the 3D model at the locations to which the particular measurements
are spatially referenced.
[0016] In some example implementations of the method of any
preceding example implementation, or any combination of any
preceding example implementations, the particular measurements
include measurements of cure state of the composite structure
referenced to locations on the composite structure.
[0017] In some example implementations of the method of any
preceding example implementation, or any combination of any
preceding example implementations, the particular measurements
include measurements of wrinkles or defects identified on the
composite structure.
[0018] In some example implementations of the method of any
preceding example implementation, or any combination of any
preceding example implementations, the particular measurements
include measurements of defects in the composite structure,
classified in a plurality of subclasses of defects, and wherein
generating the 3D model comprises generating a heat map including
the 3D model on which the subclasses of defects are indicated,
spatially referenced to locations on the composite structure.
[0019] In some example implementations of the method of any
preceding example implementation, or any combination of any
preceding example implementations, the particular measurements
include measurements that are out of tolerance or non-conforming,
and wherein generating the 3D model comprises generating a heat map
including the 3D model on which numbers of the measurements that
are out of tolerance or non-conforming are indicated, spatially
referenced to locations on the composite structure.
[0020] Some example implementations provide a computer comprising a
memory configured to store computer-readable program code; and
processing circuitry configured to access the memory, and execute
the computer-readable program code to cause the computer to at
least: monitor a process of manufacturing a composite structure
that comprises machine tools configured to at least: introduce a
matrix material to a reinforcement material; apply the
reinforcement material into a mold cavity or onto a mold surface
with a first machine tool of the machine tools; subject the
composite structure, including the reinforcement material and the
matrix material, to a melding event with a second machine tool of
the machine tools, to set the composite structure; and inspect the
composite structure to evaluate properties of the composite
structure; and based on the monitor, determine data comprising at
least one of first measurement data indicative of an operating
condition of at least one of the first machine tool or the second
machine tool, error data indicative of an error associated with at
least one of the first machine tool or the second machine tool, or
second measurement data indicative of a property of the composite
structure; and perform an analysis of the data to summarize the
data and thereby produce feedback data comprising a summary of the
data, wherein at least one of the process, the first machine tool
or the second machine tool is adjustable based on the feedback
data, and for manufacture of a next composite structure.
[0021] In some example implementations of the computer of any
preceding example implementation, or any combination of any
preceding example implementations, the computer caused to perform
the analysis comprises the computer caused to perform the analysis
to produce the feedback data comprising the summary of the data
from which an outlier, trend or pattern in the data is
identifiable, and identify an adjustment based on the outlier,
trend or pattern, and wherein at least one of the process, the
first machine tool or the second machine tool is adjustable
according to the adjustment.
[0022] In some example implementations of the computer of any
preceding example implementation, or any combination of any
preceding example implementations, the computer caused to perform
the analysis comprises the computer caused to automatically produce
infographics in a graphical user interface (GUI) to visually
summarize the data. In some example implementations of the computer
of any preceding example implementation, or any combination of any
preceding example implementations, when at least one of the first
machine tool or the second machine tool experiences a fault during
manufacture of the composite structure, the data comprises the
first measurement data, including measurements of a particular
operating condition of at least one of the first machine tool or
the second machine tool before the fault, wherein the computer
caused to perform the analysis comprises the computer caused to
perform the analysis to summarize a change in the measurements of
the particular operating condition before the fault, and wherein at
least one of the first machine tool or the second machine tool that
experienced the fault is repairable or replaceable, and the process
is adjustable to further monitor the particular operating condition
during manufacture of the next composite structure.
[0023] In some example implementations of the computer of any
preceding example implementation, or any combination of any
preceding example implementations, the data comprises the error
data, including a particular error repeatedly reported during
manufacture of the composite structure, wherein the computer caused
to perform the analysis comprises the computer caused to perform
the analysis to summarize repetition of the particular error, and
wherein the processing circuitry is configured to execute the
computer-readable program code to cause the computer to further
perform a root cause analysis to identify a root cause of the
repetition of the particular error, and at least one of the first
machine tool or the second machine tool is adjustable to address
the root cause.
[0024] In some example implementations of the computer of any
preceding example implementation, or any combination of any
preceding example implementations, the data comprises the second
measurement data, including particular measurements of a property
of the composite structure spatially referenced to locations on the
composite structure, and wherein the computer caused to perform the
analysis further comprises the computer caused to generate a
three-dimensional (3D) model of the composite structure with the
particular measurements indicated on the 3D model at the locations
to which the particular measurements are spatially referenced.
[0025] In some example implementations of the computer of any
preceding example implementation, or any combination of any
preceding example implementations, the particular measurements
include measurements of cure state of the composite structure
referenced to locations on the composite structure.
[0026] In some example implementations of the computer of any
preceding example implementation, or any combination of any
preceding example implementations, the particular measurements
include measurements of wrinkles or defects identified on the
composite structure.
[0027] In some example implementations of the computer of any
preceding example implementation, or any combination of any
preceding example implementations, the particular measurements
include measurements of defects in the composite structure,
classified in a plurality of subclasses of defects, and wherein the
computer caused to generate the 3D model comprises the computer
caused to generate a heat map including the 3D model on which the
subclasses of defects are indicated, spatially referenced to
locations on the composite structure.
[0028] In some example implementations of the computer of any
preceding example implementation, or any combination of any
preceding example implementations, the particular measurements
include measurements that are out of tolerance or non-conforming,
and wherein the computer caused to generate the 3D model comprises
the computer caused to generate a heat map including the 3D model
on which numbers of the measurements that are out of tolerance or
non-conforming are indicated, spatially referenced to locations on
the composite structure.
[0029] These and other features, aspects, and advantages of the
present disclosure will be apparent from a reading of the following
detailed description together with the accompanying figures, which
are briefly described below. The present disclosure includes any
combination of two, three, four or more features or elements set
forth in this disclosure, regardless of whether such features or
elements are expressly combined or otherwise recited in a specific
example implementation described herein. This disclosure is
intended to be read holistically such that any separable features
or elements of the disclosure, in any of its aspects and example
implementations, should be viewed as combinable unless the context
of the disclosure clearly dictates otherwise.
[0030] It will therefore be appreciated that this Brief Summary is
provided merely for purposes of summarizing some example
implementations so as to provide a basic understanding of some
aspects of the disclosure. Accordingly, it will be appreciated that
the above described example implementations are merely examples and
should not be construed to narrow the scope or spirit of the
disclosure in any way. Other example implementations, aspects and
advantages will become apparent from the following detailed
description taken in conjunction with the accompanying figures
which illustrate, by way of example, the principles of some
described example implementations.
BRIEF DESCRIPTION OF THE FIGURE(S)
[0031] Having thus described example implementations of the
disclosure in general terms, reference will now be made to the
accompanying figures, which are not necessarily drawn to scale, and
wherein:
[0032] FIGS. 1 and 2 illustrate various operations in methods of
manufacturing a composite structure that may benefit from at least
some example implementations of the present disclosure;
[0033] FIG. 3 illustrates a system for manufacturing composite
structures, according to some example implementations of the
present disclosure;
[0034] FIGS. 4 A, 4B, 4C and 4D are flowcharts illustrating various
operations in a method of manufacturing composite structures,
according to various example implementations; and
[0035] FIG. 5 illustrates a computer according to some example
implementations.
DETAILED DESCRIPTION
[0036] Some implementations of the present disclosure will now be
described more fully hereinafter with reference to the accompanying
figures, in which some, but not all implementations of the
disclosure are shown. Indeed, various implementations of the
disclosure may be embodied in many different forms and should not
be construed as limited to the implementations set forth herein;
rather, these example implementations are provided so that this
disclosure will be thorough and complete, and will fully convey the
scope of the disclosure to those skilled in the art. For example,
unless specified otherwise or clear from context, references to
first, second or the like should not be construed to imply a
particular order. A feature may be described as being above another
feature (unless specified otherwise or clear from context) may
instead be below, and vice versa; and similarly, features described
as being to the left of another feature else may instead be to the
right, and vice versa. As used herein, unless specified otherwise
or clear from context, the "or" of a set of operands is the
"inclusive or" and thereby true if and only if one or more of the
operands is true, as opposed to the "exclusive or" which is false
when all of the operands are true. Thus, for example, "[A] or [B]"
is true if [A] is true, or if [B] is true, or if both [A] and [B]
are true. Further, the articles "a" and "an" mean "one or more,"
unless specified otherwise or clear from context to be directed to
a singular form. To the extent that terms "includes," "including,"
"has," "contains," and variants thereof are used herein, such terms
are intended to be inclusive in a manner similar to the term
"comprises" as an open transition word without precluding any
additional or other elements. Like reference numerals refer to like
elements throughout.
[0037] Example implementations of the present disclosure relate
generally to composite manufacturing and, in particular, to using
data analytics for improved composite manufacturing. Example
implementations can be applied to pre-impregnated and resin infused
plies for any suitable manufacturing process, including, but not
limited to, in-autoclave, out-of-autoclave and/or resin infused
processes. The structure can be any of a number of different
structures composed of one or more layers (more specifically
"plies" in some examples), each of which in some examples can
include reinforcement material such as a bed of fibers (at times
more simply referred to as a ply or a ply of fibers).
[0038] The bed of fibers can be pre-impregnated with a matrix
material such as resin, or held together with a binder and to be
infused with resin. These composite structures can be composed of a
plurality of component elements including, for example, one or more
plies of fibers each ply of which can be pre-impregnated with resin
or held together with a binder (and to be infused with resin).
Examples of suitable structures include composites, laminated
composites and the like, such as laminated composites of
unidirectional tape plies, layered metallic structures, metallic or
composite skin and core (sandwich structures) and the like. These
structures can be put to use in a number of different manners, such
as on manned or unmanned vehicles (e.g., motor vehicles, railed
vehicles, watercraft, aircraft, spacecraft, etc.). Furthermore, it
should be understood that unless otherwise specified, the terms
"data," "content," "digital content," "information," and similar
terms may be at times used interchangeably.
[0039] FIG. 1 illustrates various operations in a process 100 of
manufacturing a composite structure that can benefit from at least
some example implementations of the present disclosure, although
example implementations can be equally applicable to other
processes of composite manufacturing. As shown at block 102, the
process includes introducing a matrix material such as resin, to a
reinforcement material such as a bed of fibers. This can include
pre-impregnating the fibers with resin, and forming a tow or tape
of the thereby pre-impregnated fibers.
[0040] The process 100 includes applying the reinforcement material
(e.g., fibers) into a mold cavity or onto a mold surface with a
first machine tool, as shown at block 104. In some examples, the
reinforcement material is applied onto the mold surface that is a
mandrel tool, and the first machine tool is an automated fiber
placement (AFP) or automated tape laying (ATL) machine. In these
examples, applying the reinforcement material includes applying the
tow or tape onto the mandrel tool with the AFP or ATL machine.
[0041] As shown at block 106, the process 100 also includes
subjecting the composite structure, including the reinforcement
material and the matrix material (e.g., resin), to a melding event
with a second machine tool such as an autoclave or oven, to set the
composite structure. And as shown at block 108, the process
includes inspecting the composite structure to evaluate properties
of the composite structure. In some examples, inspection of the
composite structure can include nondestructive inspection (NDI).
Examples of suitable machine tools useful for inspection of the
composite structure include various automated ultrasonic inspection
systems as well as measurement systems.
[0042] FIG. 2 illustrates more particularly various operations in a
process 200 of manufacturing a composite structure that can benefit
from at least some example implementations. As shown at block 202,
the process can include preparation of a tool (or mold), which can
include cleaning and applying a release agent chemical to the tool.
One or more plies of fibers can be cut to a desired size and/or
shape, and placed onto the tool in their correct order, as shown at
blocks 204 and 206. As indicated above, these plies can be
pre-impregnated with resin, or held together with a binder and to
be infused with resin.
[0043] The process 200 can include ply consolidation, as shown at
block 208. In the case of pre-impregnated plies, this ply
consolidation can include periodic consolidation (debulking) of the
plies by sealing the lay-up under a vacuum bag with a layer of
permeable material to provide an air path to evacuate volatiles.
The debulking can be accomplished by applying full vacuum for a
defined period of time (e.g., 5-10 minutes) to consolidate and
remove air from the plies.
[0044] In the case of resin infusion, ply consolidation is often
referred to as pre-forming. This involves laying up the plies,
placing the plies under vacuum to form them into the correct shape
and taking the plies up to a temperature (e.g., 330.degree. F.)
that melts the binder. This sets the plies into the correct shape.
In some examples, the plies can be trimmed and then transferred
from the pre-forming tooling onto an infusion tool. This
pre-forming can more often be performed where the geometry is
complex and the plies cannot be adequately laid up in-situ.
[0045] For both pre-impregnated plies and those to be infused with
resin, the process 200 can include a lay-up consumables and bagging
step, as shown at block 210. Here, a layer of release film can be
placed over the lay-up as a protective barrier over the plies, and
a layer of permeable material can be placed over the release film
to create an air path. For pre-impregnated plies, this air path can
be to remove gases and volatiles from the plies. For plies to be
infused with resin, the air path can create a path to infuse resin
into the plies (or more specifically their respective beds of
fibers). For both types of plies, the lay-up can be covered in a
vacuum bag that is sealed air tight to the tool.
[0046] The structure can then be cured, as shown at block 212. For
pre-impregnated plies, this can include placing the bagged lay-up
in an autoclave. For plies to be infused with resin, this can
include placing the bagged lay-up in an oven, and connecting the
lay-up to a resin source. Pressure and temperature profiles can be
applied according to a recommended cure cycle to cure the resin in
the case of pre-impregnated plies, or infuse the plies with resin
and cure the resin in the case of plies to be infused. After the
cure cycle, the composite structure can be de-bagged and trimmed,
as shown at block 214. This can include removal of the tool from
the autoclave (for pre-impregnated plies) or oven (for resin
infusion), and removal of consumables (vacuum bag, permeable
material and release film). The cured composite structure can be
de-molded from the tool, and trimmed to remove sharp edges and
create a desired final shape, which can then be inspected.
[0047] As described above in the process 200 of FIG. 2,
impregnating or infusing the plies of fibers with resin can
correspond to introducing a matrix material to a reinforcement
material, as shown at block 102 in the process 100 of FIG. 1.
Preparing the tool (block 202), cutting the plies and placing them
onto the tool (blocks 204 and 206), ply consolidation (block 208)
and lay-up consumables and bagging (block 210) can correspond to
applying the reinforcement material into the mold cavity or onto
the mold surface, as shown at block 104 in the process 100 of FIG.
1. And curing the structure (block 212) can correspond to
subjecting the matrix material to a melding event, as shown at
block 106 in the process 100 of FIG. 1.
[0048] Example implementations of the present disclosure provides a
system and method for improving composite manufacturing, such as
process 100, 200. Example implementations can be applied in-process
during manufacture of a composite structure to achieve one or more
certain defined quality. Example implementations can be applied
before, after or during any of a number of different operations of
the process of manufacturing a composite structure, or between the
manufacture of a composite structure and manufacture of a next
composite structure. In accordance with example implementations,
data recorded and/or reported during manufacturing may be
determined, and an analysis of the data may be performed to
summarize the data and thereby produce feedback data including a
summary of the data. The process and/or a machine tool used in the
process may be adjusted based on feedback including the summary,
and for manufacture of a next composite structure.
[0049] FIG. 3 illustrates a system 300 for manufacturing composite
structures, according to some example implementations. The system
can include any of a number of different subsystems (e.g., each an
individual system) for performing one or more functions or
operations. In some examples, the system includes machine tools 302
configured to manufacture a composite structure of the composite
structures. As shown, the machine tools include a first machine
tool 302A, second machine tool 302B and an n-th machine tool 302C.
As explained above, examples of suitable machine tools include a
mold such as a mandrel tool, an automated fiber placement (AFP)
machine, an automated tape laying (ATL) machine, an infusion tool,
an autoclave, an oven, a trim and drill machine, an automated
ultrasonic inspection system, measurement system, and the like.
[0050] The machine tools 302 are configured to manufacture the
composite structure according to a process such as, but not limited
to, processes 100 and/or 200. In this regard, the machine tools are
configured to introduce a matrix material to a reinforcement
material, and apply the reinforcement material into a mold cavity
or onto a mold surface with the first machine tool 302A (e.g.,
mandrel tool, AFP machine, ATL machine, infusion tool). The machine
tools are configured to subject the matrix material to a melding
event with a second machine tool 302B (e.g., autoclave, oven) to
set the composite structure including the reinforcement material
and the matrix material. And the machine tools 302 are configured
to inspect the composite structure to evaluate properties of the
composite structure.
[0051] As also shown, the first machine tool 302A, second machine
tool 302B and n-th machine tool 302C include sensors or systems 304
configured to record or report data during manufacture of the
composite structure. In some examples, this data includes
measurements of operating conditions of the first machine tool
and/or the second machine tool. Additionally or alternatively, for
example, the data includes errors reported by the first machine
tool and/or the second machine tool, recorded and/or reported by
sensors or systems of respectively the first machine tool and/or
the second machine tool during (and/or after) manufacture of the
composite structure. And in some examples, the data can
additionally or alternatively include measurements of the
properties of the composite structure recorded or reported during
(and/or after) manufacture of the composite structure, such as from
the inspection of the composite structure.
[0052] The system 300 of example implementations of the present
disclosure includes a computer 306 configured to monitor the
process of manufacturing the composite structure, and determine
data including first measurement data, error data and/or second
measurement data. The first measurement data may be indicative of
at least one operating condition of one or more of the machine
tools 302. The error data may be indicative of at least one error
associated with one or more for the machine tools, and the second
measurement data may be indicative of at least one property of the
composite structure. The data can include data for manufacture of
the composite structure or over a plurality of composite
structures. In some examples, the computer is co-located or
directly coupled to one or more of the machine tools. Additionally
or alternatively, in some examples, the computer can communicate
with one or more of the machine tools across one or more computer
networks 308.
[0053] The computer 306 is configured to perform an analysis of the
data to summarize the data and thereby produce feedback data 310
comprising a summary 312 of the data. In some examples, the
computer 306 is configured to automatically produce infographics
314 in a graphical user interface (GUI) 316 to visually summarize
the data. Examples of suitable analyses include exploratory data
analyses. More particular examples of suitable analyses include
univariate analysis, bivariate analysis, outlier detection,
correlation analysis, and the like. Examples of suitable
infographics include frequency distributions (e.g., histograms, bar
plots, kernel density estimation plots), descriptive statistics
(e.g., box plots, flight phase levels), data quality graphics
(e.g., table plots, summaries of distinct count), correlations
(e.g., heat maps), time-series plots, and the like.
[0054] According to example implementations of the present
disclosure, the feedback data 310 including the summary 312 can
suggest or otherwise indicate one or more adjustments to enhance
the process or machine tools 302, reduce undesirable errors and
inconsistency, or otherwise improve the process, machine tools or
composite structures that are manufactured. This can include an
adjustment to the process according to which the composite
structure is manufactured. Additionally or alternatively, the
adjustments can include an adjustment to one or more of the machine
tools (e.g., first machine tool 302A, second machine tool 302B,
n-th machine tool 302C). These adjustments can be made, and the
next and any subsequent composite structures manufactured.
[0055] In some examples, the computer 306 may be configured to
determine one or more adjustments either automatically, under
direct operator control, or some combination of thereof. In this
regard, in some examples, the computer is configured to determine
one or more adjustments automatically, that is, without being
directly controlled by an operator. This may be accomplished using
a number of suitable algorithms, such as machine learning
algorithms trained to determine one or more adjustments.
Additionally or alternatively, in some examples, the computer is
configured to determine one or more adjustments under direct
operator control. The computer may display one or more adjustments
for an operator to implement. Additionally or alternatively, in
some examples, the computer may be configured to send instructions
to one or more of the machine tools 302 to implement one or more
adjustments, automatically, under direct operator control, or some
combination thereof.
[0056] In some examples, the computer 306 is configured to perform
the analysis to produce the feedback data 310 including the summary
312 from which an outlier, trend or pattern in the data is
identifiable, and identify an adjustment based on the outlier,
trend or pattern, and according to which the process or one or more
of the machine tools 302 is adjustable.
[0057] In some examples in which the first machine tool 302A and/or
the second machine tool 302B experiences a fault during manufacture
of the composite structure, the data includes the first measurement
data, including measurements of a particular operating condition of
the first machine tool and/or the second machine tool before the
fault. In some of these examples, the computer 306 is configured to
perform the analysis to summarize a change in the measurements of
the particular operating condition before the fault. The first
machine tool and/or the second machine tool that experienced the
fault is repairable or replaceable, and the process is adjustable
to further monitor the particular operating condition during
manufacture of the next composite structure.
[0058] In some examples in which the data includes the error data,
the error data includes a particular error repeatedly reported
during manufacture of the composite structure, such as by the first
machine tool 302A and/or the second machine tool 302B. In some of
these examples, the computer 306 is configured to perform the
analysis to summarize repetition of the particular error. The
computer is further configured to perform a root cause analysis to
identify a root cause of the repetition of the particular error.
The first machine tool and/or the second machine tool, then, is
adjustable to address the root cause. In an AFP machine, for
example, repetition of certain error codes may be determined to be
caused by a faulty A/C unit, which may be replaced to address the
root cause. Repetition in other error codes may be caused by a
tensioner redirect roller and compliant roller not spinning freely,
which may be cleaned.
[0059] In some examples in which the data includes the second
measurement data, the second measurement data includes measurements
of a property of the composite structure spatially referenced to
locations on the composite structure. In some of these examples,
the computer 306 configured to perform the analysis further
includes the computer configured to generate a three-dimensional
(3D) model 318 of the composite structure with the particular
measurements indicated on the 3D model at the locations to which
the particular measurements are spatially referenced. Examples of
suitable particular measurements include measurements of cure state
of the composite structure referenced to locations on the composite
structure, measurements of wrinkles or defects identified on the
composite structure, measurements that are out of tolerance or
non-conforming, and the like.
[0060] In some further examples in which the particular
measurements include measurements of defects in the composite
structure, the measurements are classified in a plurality of
subclasses of defects. In some of these examples, the computer 306
configured to generate the 3D model includes the computer
configured to generate a heat map 320 including the 3D model on
which the subclasses of defects are indicated, spatially referenced
to locations on the composite structure. Additionally or
alternatively, in some examples in which the particular
measurements include measurements that are out of tolerance or
non-conforming, the computer is configured to generate the heat map
or another heat map including the 3D model on which numbers of the
measurements that are out of tolerance or non-conforming are
indicated, spatially referenced to locations on the composite
structure.
[0061] FIGS. 4A, 4B, 4C and 4C are flowcharts illustrating various
operations in a method 400 according to example implementations of
the present disclosure. As shown at block 402 of FIG. 4A, the
method includes monitoring a process of manufacturing a composite
structure, such as process 100, 200. The process includes
introducing a matrix material to a reinforcement material, and
applying 104 the reinforcement material into a mold cavity or onto
a mold surface with a first machine tool 302A. The process includes
subjecting the composite structure, including the reinforcement
material and the matrix material, to a melding event with a second
machine tool 302B, to set the composite structure. And the process
includes inspecting 108 the composite structure to evaluate
properties of the composite structure.
[0062] As shown at block 404, based on the monitoring, the method
400 includes determining 404 data comprising first measurement
data, error data and/or second measurement data. The first
measurement data is indicative of an operating condition of the
first machine tool 302A and/or the second machine tool 302B, and
the error data is indicative of an error associated with the first
machine tool and/or the second machine tool, which may be recorded
or reported by sensors or systems 304 of respectively the first
machine tool and/or the second machine tool during manufacture of
the composite structure. The second measurement data is indicative
of a property of the composite structure, which may also be
recorded or reported during manufacture of the composite
structure.
[0063] The method 400 includes performing an analysis of the data
to summarize the data and thereby produce feedback data 310
comprising a summary 312 of the data, as shown at block 406. The
method includes adjusting the process, the first machine tool 302A
and/or the second machine tool 302B based on the feedback data, as
shown at block 408, and for manufacture of a next composite
structure. And in some examples, the method includes manufacturing
the next composite structure according to or using the process, the
first machine tool or the second machine tool, as adjusted.
[0064] In some examples, the analysis is performed to produce the
feedback data 310 comprising the summary 312 of the data from which
an outlier, trend or pattern in the data is identifiable, as shown
at block 406' of FIG. 4B. In some of these examples, adjusting the
process, the first machine tool 302A and/or the second machine tool
302B includes identifying an adjustment based on the outlier, trend
or pattern, and adjusting the process, the first machine tool
and/or the second machine tool according to the adjustment, as
shown at blocks 408A' and 408B'.
[0065] In some examples, when the first machine tool 302A or the
second machine tool 302B experiences a fault during manufacture of
the composite structure, the data includes the first measurement
data, including measurements of a particular operating condition of
the first machine tool and/or the second machine tool before the
fault. In some of these examples, performing the analysis includes
performing the analysis to summarize a change in the measurements
of the particular operating condition before the fault, as shown at
block 406'' of FIG. 4C. Also in some of these examples, adjusting
the process, the first machine tool and/or the second machine tool
includes performing a repair or replacement of the first machine
tool and/or the second machine tool that experienced the fault, and
adjusting the process to further monitor the particular operating
condition during manufacture of the next composite structure, as
shown at blocks 408A'' and 408B''.
[0066] In some examples, the data includes the error data,
including a particular error repeatedly reported during manufacture
of the composite structure. In some of these examples, performing
the analysis includes performing the analysis to summarize
repetition of the particular error, as shown at block 406''' of
FIG. 4D. Also in some of these examples, adjusting the process, the
first machine tool and/or the second machine tool includes
performing a root cause analysis to identify a root cause of the
repetition of the particular error, and adjusting the first machine
tool and/or the second machine tool to address the root cause, as
shown at blocks 408A''' and 408B'''.
[0067] Returning to FIG. 4A, in some examples in which the data
includes the second measurement data, the second measurement data
includes particular measurements of a property of the composite
structure spatially referenced to locations on the composite
structure. In some of these examples, performing the analysis
further includes generating a three-dimensional (3D) model 318 of
the composite structure with the particular measurements indicated
on the 3D model at the locations to which the particular
measurements are spatially referenced, as shown at block 412. As
indicated above, examples of suitable particular measurements
include measurements of cure state of the composite structure
referenced to locations on the composite structure, measurements of
wrinkles or defects identified on the composite structure,
measurements that are out of tolerance or non-conforming, and the
like.
[0068] In some examples in which the particular measurements
include measurements of defects in the composite structure, the
measurements are classified in a plurality of subclasses of
defects. In some of these examples, generating the 3D model 318
includes generating a heat map 320 including the 3D model on which
the subclasses of defects are indicated, spatially referenced to
locations on the composite structure, as shown at block 414.
Additionally or alternatively, in some examples in which the
particular measurements include measurements that are out of
tolerance or non-conforming, generating the 3D model includes
generating a heat map including the 3D model on which numbers of
the measurements that are out of tolerance or non-conforming are
indicated, spatially referenced to locations on the composite
structure.
[0069] According to example implementations of the present
disclosure, the computer 306 can be implemented or otherwise
executed by various means. These means can include hardware, alone
or under direction of one or more computer programs from a
computer-readable storage medium. In some examples, more than one
computer can be configured to function as or otherwise implement
the computer shown and described herein.
[0070] FIG. 5 illustrates the computer 306 according to some
example implementations of the present disclosure. Generally, the
computer of example implementations of the present disclosure can
comprise, include or be embodied in one or more fixed, portable or
mobile electronic devices. The computer can include one or more of
each of a number of components such as, for example, processing
circuitry 502 (e.g., processor unit) connected to a memory 504
(e.g., storage device).
[0071] The processing circuitry 502 can be composed of one or more
processors alone or in combination with one or more memories. The
processing circuitry is generally any piece of computer hardware
that is capable of processing information such as, for example,
data, computer programs and/or other suitable electronic
information. The processing circuitry is composed of a collection
of electronic circuits some of which can be packaged as an
integrated circuit or multiple interconnected integrated circuits
(an integrated circuit at times more commonly referred to as a
"chip"). The processing circuitry can be configured to execute
computer programs, which can be stored onboard the processing
circuitry or otherwise stored in the memory 504 (of the same or
another computer).
[0072] The processing circuitry 502 can be a number of processors,
a multi-core processor or some other type of processor, depending
on the particular implementation. Further, the processing circuitry
can be implemented using a number of heterogeneous processor
systems in which a main processor is present with one or more
secondary processors on a single chip. As another illustrative
example, the processing circuitry can be a symmetric
multi-processor system containing multiple processors of the same
type. In yet another example, the processing circuitry can be
embodied as or otherwise include one or more ASICs, FPGAs or the
like. Thus, although the processing circuitry can be capable of
executing a computer program to perform one or more functions, the
processing circuitry of various examples can be capable of
performing one or more functions without the aid of a computer
program. In either instance, the processing circuitry can be
appropriately programmed to perform functions or operations
according to example implementations of the present disclosure.
[0073] The memory 504 is generally any piece of computer hardware
that is capable of storing information such as, for example, data,
computer programs (e.g., computer-readable program code 506) and/or
other suitable information either on a temporary basis and/or a
permanent basis. The memory can include volatile and/or
non-volatile memory, and can be fixed or removable. Examples of
suitable memory include random access memory (RAM), read-only
memory (ROM), a hard drive, a flash memory, a thumb drive, a
removable computer diskette, an optical disk, a magnetic tape or
some combination of the above. Optical disks can include compact
disk-read only memory (CD-ROM), compact disk-read/write (CD-R/W),
DVD or the like. In various instances, the memory can be referred
to as a computer-readable storage medium. The computer-readable
storage medium is a non-transitory device capable of storing
information, and is distinguishable from computer-readable
transmission media such as electronic transitory signals capable of
carrying information from one location to another.
Computer-readable medium as described herein can generally refer to
a computer-readable storage medium or computer-readable
transmission medium.
[0074] In addition to the memory 504, the processing circuitry 502
can also be connected to one or more interfaces for displaying,
transmitting and/or receiving information. The interfaces can
include communications interface(s) 508 (e.g., communications unit)
and/or one or more user interfaces. The communications interface
can be configured to transmit and/or receive information, such as
to and/or from other computer(s), network(s) or the like. The
communications interface can be configured to transmit and/or
receive information by physical (wired) and/or wireless
communications links. Examples of suitable communication interfaces
include a network interface controller (NIC), wireless NIC (WNIC)
or the like.
[0075] The user interfaces can include a display 510 and/or user
input interface(s) 512 (e.g., input/output unit). The display can
be configured to present or otherwise display information to a
user, suitable examples of which include a liquid crystal display
(LCD), light-emitting diode display (LED), plasma display panel
(PDP) or the like. The user input interfaces can be wired or
wireless, and can be configured to receive information from a user
into the computer, such as for processing, storage and/or display.
Suitable examples of user input interfaces include a microphone,
image or video capture device, keyboard or keypad, joystick,
touch-sensitive surface (separate from or integrated into a
touchscreen), biometric sensor or the like. The user interfaces can
further include one or more interfaces for communicating with
peripherals such as printers, scanners or the like.
[0076] As indicated above, program code instructions can be stored
in memory, and executed by processing circuitry that is thereby
programmed, to implement functions of the systems, subsystems,
tools and their respective elements described herein. As will be
appreciated, any suitable program code instructions can be loaded
onto a computer or other programmable apparatus from a
computer-readable storage medium to produce a particular machine,
such that the particular machine becomes a means for implementing
the functions specified herein. These program code instructions can
also be stored in a computer-readable storage medium that can
direct a computer, a processing circuitry or other programmable
apparatus to function in a particular manner to thereby generate a
particular machine or particular article of manufacture. The
instructions stored in the computer-readable storage medium can
produce an article of manufacture, where the article of manufacture
becomes a means for implementing functions described herein. The
program code instructions can be retrieved from a computer-readable
storage medium and loaded into a computer, processing circuitry or
other programmable apparatus to configure the computer, processing
circuitry or other programmable apparatus to execute operations to
be performed on or by the computer, processing circuitry or other
programmable apparatus.
[0077] Retrieval, loading and execution of the program code
instructions can be performed sequentially such that one
instruction is retrieved, loaded and executed at a time. In some
example implementations, retrieval, loading and/or execution can be
performed in parallel such that multiple instructions are
retrieved, loaded, and/or executed together. Execution of the
program code instructions can produce a computer-implemented
process such that the instructions executed by the computer,
processing circuitry or other programmable apparatus provide
operations for implementing functions described herein.
[0078] Execution of instructions by a processing circuitry, or
storage of instructions in a computer-readable storage medium,
supports combinations of operations for performing the specified
functions. In this manner, the computer 306 can include a
processing circuitry 502 and a computer-readable storage medium or
memory 504 coupled to the processing circuitry, where the
processing circuitry is configured to execute computer-readable
program code 506 stored in the memory. It will also be understood
that one or more functions, and combinations of functions, can be
implemented by special purpose hardware-based computer systems
and/or processing circuitry s which perform the specified
functions, or combinations of special purpose hardware and program
code instructions.
[0079] Many modifications and other implementations of the
disclosure set forth herein will come to mind to one skilled in the
art to which the disclosure pertains having the benefit of the
teachings presented in the foregoing description and the associated
figures. Therefore, it is to be understood that the disclosure is
not to be limited to the specific implementations disclosed and
that modifications and other implementations are intended to be
included within the scope of the appended claims. Moreover,
although the foregoing description and the associated figures
describe example implementations in the context of certain example
combinations of elements and/or functions, it should be appreciated
that different combinations of elements and/or functions can be
provided by alternative implementations without departing from the
scope of the appended claims. In this regard, for example,
different combinations of elements and/or functions than those
explicitly described above are also contemplated as can be set
forth in some of the appended claims. Although specific terms are
employed herein, they are used in a generic and descriptive sense
only and not for purposes of limitation.
* * * * *