US 12,321,149 B2
Method for computer analysis of as-programmed surface quality of composite structure
Matthew S. Stauffer, Ladson, SC (US); Kayley E. Seawright, Charleston, SC (US); Russell A. Strope, Mount Pleasant, SC (US); Michael S. Lindgren, Ravenal, SC (US); Daniel E. Gonsor, Summerville, SC (US); and Ashutosh Mani, Summerville, SC (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Mar. 15, 2022, as Appl. No. 17/695,430.
Claims priority of provisional application 63/189,241, filed on May 17, 2021.
Prior Publication US 2022/0373992 A1, Nov. 24, 2022
Int. Cl. G05B 19/4097 (2006.01)
CPC G05B 19/4097 (2013.01) [G05B 2219/32177 (2013.01); G05B 2219/35117 (2013.01)] 21 Claims
OG exemplary drawing
 
1. 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.