US 12,472,703 B2
Automated fiber placement of plies with staggering
Joseph G. Kirchhoff, Tukwila, WA (US); and Brice A. Johnson, Seattle, WA (US)
Assigned to The Boeing Company, Chicago, IL (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Jan. 7, 2022, as Appl. No. 17/647,434.
Prior Publication US 2023/0219305 A1, Jul. 13, 2023
Int. Cl. B29C 70/30 (2006.01); B29C 70/38 (2006.01); G05B 19/4155 (2006.01)
CPC B29C 70/302 (2021.05) [B29C 70/382 (2013.01); G05B 19/4155 (2013.01); G05B 2219/35113 (2013.01)] 22 Claims
OG exemplary drawing
 
1. A method for fabricating a hollow composite body comprising ply layers and a central axis, the method comprising:
executing, using a computer system, the following steps:
determining a number of tows in each course and a number of courses in a ply layer to be laid up around the central axis, wherein the number of tows reduces a sum of arc distances between edges of each course in the ply layer to a value less than a thickness of a tow in the number of tows; and
determining, iteratively for each ply layer from a furthest ply layer from the central axis to a ply layer closest to the central axis, a radial position around the central axis of an arc between edges of courses adjacent in the ply layer, wherein the radial position forms a radial alignment of the arc with a least number possible of gaps between edges of courses, respectively, in all of the ply layers previously laid up around the central axis; and
fabricating, by controlling fabricating equipment, the hollow composite body with steps of:
laying up a number of tows in each course and the number of courses in the ply layer around the central axis as determined by the computer system, wherein the number of tows reduces the sum of arc distances between edges of each course in the ply layer to the value less than the thickness of the tow in the number of tows; and
laying up each ply layer as determined by the computer system from a furthest ply layer from the central axis to the ply layer closest to the central axis, at the radial position around the central axis of the arc between edges of courses adjacent in the ply layer as determined by the computer system, wherein the radial position forms the radial alignment of the arc with the least number possible of gaps between edges of courses, respectively, in all of the ply layers previously laid up around the central axis.