Methods of forming a composite structure and associated automated manufacturing systems and components
A method for manufacturing a composite structure includes receiving measurements of properties of a composite sheet. The method further includes receiving historical properties of previous composite structures. The method also includes determining a number of composite plies for each section of the composite structure to achieve a desired final composite thickness based on the properties of the composite sheet and the historical properties of the previous composite structures. The method further includes laying up a plurality of composite plies to form an initial shape including the number of composite plies in each section determined to achieve the desired final composite thickness.
1 . An automated manufacturing system for controlling layup of a composite part, the automated manufacturing system comprising:
a layup system configured to receive one or more fiber tows as an input material and lay up the one or more fiber tows to form a composite structure of one or more laid up plies;
one or more sensors configured to measure properties of the one or more fiber tows while the layup system is feeding the one or more fiber tows to a substrate; and
a controller configured to:
receive the properties of the one or more fiber tows measured by the one or more sensors;
receive external measured data associated with the properties of the one or more fiber tows, the external measured data including one or more of a matrix density, a matrix percentage, a fiber percentage, a matrix composition, or a surface roughness;
compare the properties of the one or more fiber tows measured by the one or more sensors and the external measured data to historical data including data gathered from previous layup operations of composite parts; and
adjust a feed-through of the one or more fiber tows during the layup, including adjusting a number of plies being laid up to compensate for a variation in the layup as provided by the properties of the one or more fiber tows measured by the one or more sensors during the layup.
2 . The automated manufacturing system of claim 1 , wherein the one or more sensors are configured to measure a thickness of the one or more fiber tows.
3 . The automated manufacturing system of claim 1 , wherein the controller is configured to receive a layup program including initial instructions for the feed-through of the one or more fiber tows.
4 . The automated manufacturing system of claim 3 , wherein the layup program includes an initial number of plies for each section of the composite structure and a final desired thickness for each section of the composite structure.