Automated ply layup system

1. A method of automatically laying up plies on a tool, comprising:

providing a kit of plies to be placed in a predetermined order onto a tool wherein at least one of the plies is selected from one of filler plies, doubler plies, thermoplastics plies, prepreg plies, and metal foil plies;

using a robotically controlled end effector to select a first ply in the kit of plies and to lift the first ply from the kit of plies, including recording an image of the first ply with a first camera and using image recognition software and the recorded image to recognize the first ply from other plies in the kit of plies;

using a second camera to record an image of the first ply on the end effector, and using the image of the first ply on the end effector to determine a first position of the first ply on the end effector;

determining a second position of the first ply in a 3-D spatial coordinate system used by a robot controlling the end effector based on the first position of the first ply on the end effector;

using the end effector to move the first ply to an area of the tool;

using a 3-D laser scanner to detect features of a desired location on the tool where the first ply is to be placed, wherein the desired location comprises a pocket in the tool, the pocket having a number of edges, wherein the feature comprises one or more of the number of edges;

pre-inspecting, using the 3-D laser scanner, the desired location prior to ply placement to determine a location of the pocket on the tool and its location in the 3-D spatial coordinate system;

controlling movement of the end effector to precisely insert and place the first ply within boundaries of the pocket, and aligned with the number of edges of the pocket based on a the pre-inspection measurement by the 3-D laser scanner of the desired location, and using the end effector to compact the first ply against the tool;

wherein compacting the first ply comprises sensing a compaction force applied to the first ply during the compaction using a force sensor, and

adjusting the compaction force applied to the first ply based on the compaction force sensed by the force sensor.

2. A system for automatically laying up composite plies on a tool, comprising:

a kit of plies required to be laid up on the tool in a predetermined order, wherein at least one of the plies is selected from one of filler plies, doubler plies, thermoplastics plies, prepreg plies, and metal foil plies;

an end effector;

a robot for manipulating the end effector;

a vacuum gripper on the end effector for gripping a ply and to move plies to an area of the tool;

a first camera on the end effector for recording an image of plies in the kit, wherein the end effector is used to select a first ply in the kit of plies and to lift the first ply from the kit of plies, including recording an image of the first ply with the first camera, and using image recognition software and the recorded image to recognize the first ply from other plies in the kit of plies;

a second, stationary camera for recording an image of the ply on the vacuum gripper lifted from the kit by the end effector, and using the image of the first ply on the end effector to determine a first position of the first ply on the end effector and determining a second position of the first ply in a 3-D spatial coordinate system used by a robot controlling the end effector based on the first position of the first ply on the end effector;

a laser scanner on the end effector for detecting features of a desired location on the tool where the first ply is to be placed, wherein the desired location comprises a pocket in the tool, the pocket having a number of edges, wherein the feature comprises one or more of the number of edges, and for pre-inspecting, using the laser scanner, a location prior to ply placement to determine the location of the pocket on the tool and its location in the 3-D spatial coordinate system;

a force sensor on the end effector for sensing the force applied to the ply by the end effector when the end effector places the ply on the tool;

and

a controller for controlling the robot, the vacuum gripper, the first and second cameras, including image recognition software for recognizing images of plies recorded by the first camera, wherein the controller is configured to control movement of the end effector to precisely insert and place the first ply within boundaries of the pocket, and aligned with the number of edges of the pocket based on a pre-inspection measurement by the laser scanner of the location, and further using the end effector to compact the first ply against the tool, wherein compacting the first ply comprises sensing a compaction force applied to the first ply during the compaction using the force sensor and adjusting the compaction force applied to the first ply based on the compaction force sensed by the force sensor.