There is described herein a process for assigning location-specific correction factors to composite components using data obtained from the simulation of an automated manufacturing process, and correlating the location-specific correction factors to safety margins across the surface of the composite component, in order to quantify the impact of features introduced by the manufacturing process.

Systems and methods are provided for verifying the placement of tows by a robot. One embodiment includes a robot that includes an end effector that lays up tows, actuators that reposition the end effector, a memory storing a Numerical Control (NC) program, and a robot controller that directs the actuators to reposition the end effector based on the NC program, and instructs the end effector to lay up tows based on the NC program. The system also includes a sensor system comprising an imaging device that acquires images of the tows as the tows are laid-up, a measuring device that generates input as tows are laid-up by the end effector, and a sensor controller that receives images from the imaging device and the input from the measuring device, and updates stored data to correlate the images with instructions in the NC program, based on the input.

A novel method designs and analyzes composite parts including optimal manufacturing strategies. The invention analyzes part design including curvatures and other surface topology to formulate an optimal strategy for material layup, number of plies, initial orientation angle, and towpath steering vectors. The method computes an optimum starting point for each fiber path and a stagger offset for each successive fiber path to as to eliminate or minimize gaps and overlaps between adjacent plies. Intermediate surfaces are generated by a polynomial discretization method which generates large computational time savings and enhances blending of adjacent zones to control surface smoothness. The method further calculates a variable steering path for the layer taking into account material parameters and limitations such that plies originating in the same location have a variable orientation angle and follow any reference curve generated by the method to maximize strength and minimize weight of the component.

A novel method designs and analyzes composite parts including optimal manufacturing strategies. The invention analyzes part design including curvatures and other surface topology to formulate an optimal strategy for material layup, number of plies, initial orientation angle, and towpath steering vectors. The method computes an optimum starting point for each fiber path and a stagger offset for each successive fiber path to as to eliminate or minimize gaps and overlaps between adjacent plies. Intermediate surfaces are generated by a polynomial discretization method which generates large computational time savings and enhances blending of adjacent zones to control surface smoothness. The method further calculates a variable steering path for the layer taking into account material parameters and limitations such that plies originating in the same location have a variable orientation angle and follow any reference curve generated by the method to maximize strength and minimize weight of the component.

A method and system for assisting in the manufacture of composite parts such as those used for various high-strength assemblies such as aircraft wings, vertical stabilizers, racing car shells, boat hulls, and other parts which are required to have a very high strength to weight ratio. The system uses laser technology to measure the resultant surfaces of a first manufactured composite part. A computer system analyzes and compares the as-built dimensions with the required production specifications. Supplemental composite filler plies are designed including shape and dimensions. These plies are nested together into a single composite sheet and manufactured to minimize wasted material. The plies are then cut out and applied to the first part guided by a laser projection system for locating the plies on the part. The part is then re-cured. The final assembly is then re-measured for compliance with production dimensions.

A method and system for assisting in the manufacture of composite parts such as those used for various high-strength assemblies such as aircraft wings, vertical stabilizers, racing car shells, boat hulls, and other parts which are required to have a very high strength to weight ratio. The system uses laser technology to measure the resultant surfaces of a first manufactured composite part. A computer system analyzes and compares the as-built dimensions with the required production specifications. Supplemental composite filler plies are designed including shape and dimensions. These plies are nested together into a single composite sheet and manufactured to minimize wasted material. The plies are then cut out and applied to the first part guided by a laser projection system for locating the plies on the part. The part is then re-cured. The final assembly is then re-measured for compliance with production dimensions.

The present disclosure provides an attachment system of a weather strip, including: a supply unit configured to unwind the weather strip that winds with a predetermined length and to supply the weather strip, an attaching unit configured to attach the weather strip to a surface of a component by the adhesive layer and to cut the weather strip at a predetermined position, a tag provided in the supply unit that is configured to store position information of the defective portion of the weather strip detected during the weather strip extruding process, a reader antenna provided during the weather strip assembling process that is configured to receive the position information of the defective portion, and a controller configured to control a cutting position of the weather strip discharging side of the attaching unit based on the position information of the defective portion.

Systems and methods are provided for verifying the placement of tows by a robot. One embodiment includes a robot that includes an end effector that lays up tows, actuators that reposition the end effector, a memory storing a Numerical Control (NC) program, and a robot controller that directs the actuators to reposition the end effector based on the NC program, and instructs the end effector to lay up tows based on the NC program. The system also includes a sensor system comprising an imaging device that acquires images of the tows as the tows are laid-up, a measuring device that generates input as tows are laid-up by the end effector, and a sensor controller that receives images from the imaging device and the input from the measuring device, and updates stored data to correlate the images with instructions in the NC program, based on the input.

A method for defining trajectories of fibers on a layup surface for producing at least one ply having a given theoretical orientation, by laying up fibers, including the steps of providing the definition of the constraint curves and/or the definition of at least one constraint grid with association of at least one constraint vector to each node of the constraint grid, the direction of a fiber at an analysis point of the layup surface, being obtained by calculation of the normalized weights of the constraint vectors of the constraint curves and/or by calculation by of the normalized weights of the constraint vectors of the constraint grid, and by weighting by the normalized weights of the constraint vectors.

A method and apparatus for laying composite tape. The method may comprise driving a plurality of robots, each having a respective movement system across a movement surface, in which the movement surface faces a workpiece, and laying composite tape from the plurality of robots in a coordinated manner on the workpiece.