Patent Description:
Composite materials are used in a wide variety of applications due to their favorable properties such as high specific strength, high specific stiffness, and high corrosion resistance. Composite materials in one example are comprised of fibrous material (e.g., carbon fibers) pre-impregnated with a resin (e.g., epoxy). Composite materials such as composite fabrics are generally produced in a flat or planar shape, and require secondary forming to produce functional end products. Several methods have developed for secondary forming of composite material.

One method of secondary forming is a manual operation in which one or more technicians pick up sheets or plies of composite material after being cut out of raw material using a ply cutter. The technicians manually transport each ply one-by-one from the ply cutter to a layup tool, where each ply is carefully positioned on the tooling surface of the layup tool. The technicians manually form each ply to the contours of the tooling surface. The forming process is largely unplanned, and is time-consuming and can result in wrinkles in the formed product due to manual handling of the plies.

Another method involves the use of automated lamination machines (ALMs), such as automatic fiber placement machines, contour tape laminating machines, or fabric dispensing machines, for automated application of unidirectional tape or fabric onto a layup tool. Such ALMs include mechanisms for conforming the composite material to the contours of a tooling surface. However, the shear strength of composite material and the bulkiness of the ALMs can limit the shapes of layup tools that composite materials can be successively formed over. In addition, the material deposition rates of ALMs generally decreases with increased complexity of the tooling surface.

Stamp and diaphragm forming are methods for single-plane forming of composite materials, or for small degrees of complex forming. The shear strength of composite materials can be a limiting factor in the complexity of shapes that can be formed using stamp or diaphragm forming. For example, material shear strength can limit the magnitude of force that can be applied to the composite material during the forming process. Complex shapes can be successively formed using stamp or diaphragm forming if the composite material is highly formable, which may come at the expense of material strength.

Other methods of forming composite materials are available. However, such methods can present challenges such as bridging or uncontrolled extension of the composite material in critical areas, and can potentially result in wrinkles and other undesirable features in the formed product. Although approaches have been developed to overcome the bridging problem, such approaches are limited in the shapes of layup tools over which composite material can be successfully formed.

<CIT>, in accordance with its abstract, states a preform for producing fiber composite components, wherein a plurality of additional fibers are arranged in the preform in addition to the fibers that constitute the preform. The additional fibers comprise a paramagnetic or ferromagnetic material. The invention further relates to a preform processing device for preforms, comprising at least one forming tool having a die for accommodating the preform. A plurality of electromagnets is arranged in the die near a surface of the die that forms a forming contour, and the magnetic fields produced by the electromagnets can be developed according to the arrangement of the magnetic additional fibers of the preform in the forming contour. The preform processing device comprises a control device, which is coupled to the electromagnets in order to control the electromagnets. The invention further relates to a method that is suitable for the large-scale production of fiber composite components from the preforms.

<CIT>, in accordance with its abstract, states effector for picking up, handling and/or depositing textile structures, in particular in the production of fiber composite material components, the effector having a base module, a plurality of active modules which can be moved in a controlled manner relative to the base module and actuation modules for the controlled displacement of the active modules, in which the actuation modules are each passively adaptive, device for picking up, handling and / or depositing textile structures, in particular when producing fiber composite material components, the device having a manipulator, in particular a Industrial robot, and such an effector, and method for picking up, handling and/or depositing textile structures, in particular in the production of fiber composite material components, such a device being used and the active modules being moved in a coordinated manner pick up, handle and/or put down textile structures.

<CIT>, in accordance with its abstract, states an electropermanent magnet array is provided. The electropermanent magnet array includes one or more of a plurality of electropermanent magnets of common length, arranged in a parallel fashion, and a planar pole piece, coupled to the first ends of the plurality of electropermanent magnets. Each electropermanent magnet includes a first and a second end opposite the first end.

As can be seen, there exists a need in the art for a system and method for automated forming of composite material into complex shapes in an accurate, wrinkle-free, and time-efficient manner.

The above-noted needs associated with automated forming of composite materials are addressed by the present disclosure, which provides a manufacturing system as defined by the independent claim <NUM> with preferred embodiments defined in the appended dependent claims. The manufacturing system comprising a stator base having a planar stator surface covering an array of electrical coils configured to generate an electromagnetic field. In addition, the manufacturing system includes a plurality of movers, each containing multiple permanent magnets configured to cause the movers to levitate and move relative to the stator surface in response to the electromagnetic field. The manufacturing system also includes one or more end effectors coupled to the movers. Each end effector is configured to perform one or more functions in relation to a material sheet. Additionally, the manufacturing system includes a controller configured to selectively activate the electrical coils in a manner causing independent, coordinated movement of the movers over the stator surface, and causing the end effectors to engage with and operate on the material sheet.

Also disclosed is a manufacturing system having a base transport system. In addition, the manufacturing system includes a stator base that is movably supported by the base transport system, and which has a planar stator surface covering an array of electrical coils configured to generate an electromagnetic field. Also, the manufacturing system includes a plurality of movers associated with the stator base. Each mover contains multiple permanent magnets configured to cause levitated movement of the mover relative to the stator surface in response to the electromagnetic field. Furthermore, the manufacturing system includes a plurality of end effectors coupled to the movers, and which are configured to perform one or more functions in relation to a material sheet. The manufacturer system additionally includes a controller configured to perform the following: selectively activate the electrical coils in a manner causing independent, coordinated movement of the movers over the stator surface, and causing the end effectors to engage with the material sheet at a material pickup station, and cause the base transport system to move the stator base through an envelope of motion to thereby transport the material sheet from the material pickup station to a material placement station.

Also disclosed is a method of processing a material sheet as defined by the independent claim <NUM> with preferred embodiments defined in the appended dependent claims. The method includes activating an array of electrical coils in a stator base having a planar stator surface, and thereby generating an electromagnetic field. In addition, the method includes levitating and moving a plurality of movers in a coordinated manner over the stator surface in response to multiple permanent magnets in each mover reacting to the electromagnetic field. The method also includes performing one or more functions on a material sheet using a plurality of end effectors coupled to the movers.

The features, functions, and advantages that have been discussed can be achieved independently in various versions of the disclosure or may be combined in yet other versions, further details of which can be seen with reference to the following description and drawings.

The disclosure can be better understood with reference to the following detailed description taken in conjunction with the accompanying drawings, which illustrate preferred and exemplary versions, but which are not necessarily drawn to scale. The drawings are examples and not meant as limitations on the description or the claims.

The figures shown in this disclosure represent various aspects of the versions presented, and only differences will be discussed in detail.

Disclosed versions will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all of the disclosed examples are shown. Indeed, several different examples or versions may be provided and should not be construed as limited to the examples set forth herein. Rather, these examples are provided so that this disclosure will be thorough and fully convey the scope of the disclosure to those skilled in the art.

Referring now to the drawings, shown in <FIG> is an example of a manufacturing system <NUM> configured to perform pick and place operations on a material sheet <NUM>. In the example shown, the manufacturing system <NUM> includes a base transport system <NUM>, a planar motor system <NUM>, and a controller <NUM>. The planar motor system <NUM> includes a stator base <NUM>, and one or more movers <NUM> (<FIG>). The movers <NUM> are configured to move in levitated, non-contact relation to the stator base <NUM>.

As shown in <FIG> and described in greater detail below, the planar motor system <NUM> includes one or more end effectors <NUM> coupled to the movers <NUM>. Each end effector <NUM> is configured to perform one or more functions in relation to a material sheet <NUM>. For example, the end effectors <NUM> can be configured as grippers <NUM> (<FIG>) configured to engage (e.g., grip) and pick up a material sheet <NUM> at a material pickup station <NUM> (e.g., <FIG>), transport the material sheet <NUM> to a material placement station <NUM> via the base transport system <NUM> (e.g., <FIG>), and place the material sheet <NUM> onto a layup tool <NUM> at the material placement station <NUM> (e.g., <FIG>), after which the grippers <NUM> disengage from the material sheet <NUM> (e.g., <FIG>). For example, each gripper <NUM> can engage the material sheet <NUM> at a predefined engagement point <NUM> (<FIG>) on the material sheet <NUM>. The material sheet <NUM> includes a plurality of predefined control points <NUM> (<FIG>) that enable tracking of the movement of the material sheet <NUM> during pickup, placement, and/or forming onto the tooling surface <NUM>, as shown in <FIG> and described in greater detail below.

In this regard, the planar motor system <NUM> provides a means for independent planar and out-of-plane movement of multiple end effectors <NUM> performing one or more functions in a coincident and/or sequential manner, as part of pick and place operations performed on a material sheet <NUM>. For example, in addition to pick and place capability, the planar motor system <NUM> provides a means for measuring, compacting, tacking, and/or shearing of individual material sheets <NUM>. The material sheets <NUM> can be composite plies, and the manufacturing system <NUM> can form each composite ply over a layup tool <NUM> as part of the process of laying up a composite laminate (not shown).

Referring to the example of <FIG>, the base transport system <NUM> is shown as an overhead gantry <NUM> configured to support and transport the planar motor system <NUM>. The gantry <NUM> has a pair of overhead beams <NUM>. The stator base <NUM> is fixedly coupled to the overhead beams <NUM>. The overhead beams <NUM> are coupled at opposite ends to gantry posts <NUM>. The overhead beams <NUM> are vertically movable along the gantry posts <NUM> for positioning the vertical height of the planar motor system <NUM>. The gantry posts <NUM> are movable along gantry tracks <NUM>, which may be embedded in the shop floor. The vertical movement of the overhead beams <NUM> and the horizontal movement of the gantry <NUM> is controlled by the controller <NUM>.

As an alternative to a gantry <NUM>, the base transport system <NUM> can be provided as one or more robotic devices <NUM> (<FIG>). As described in greater detail below, each robotic device <NUM> is configured to support and move one or more planar motor systems <NUM>. However, the base transport system <NUM> is not limited to a gantry <NUM> or robotic devices <NUM>, and can include any one of a variety of alternative base transport systems <NUM> for supporting and transporting the planar motor systems <NUM>.

In <FIG>, the base transport system <NUM> is described in the context of transporting a single planar motor system <NUM> (and material sheet <NUM>) between a material pickup station <NUM> containing a material cutting table <NUM>, and a material placement station <NUM> containing a layup tool <NUM>. However, the base transport system <NUM> may be configured to transport any number of planar motor systems <NUM> between any one of a variety of different locations within a manufacturing facility, and is not limited to movement between a material pickup station <NUM> and a material placement station <NUM>.

Referring to <FIG>, the planar motor system <NUM> includes a stator base <NUM> and one or more movers <NUM>, as mentioned above. <FIG> shows four movers <NUM> on the stator base <NUM>, each supporting an end effector <NUM> configured as a gripper <NUM> for engaging or gripping a material sheet <NUM>. In the example of <FIG>, the material sheet <NUM> has four engagement points <NUM> for engagement respectively by the four grippers <NUM> (<FIG>). Although <FIG> shows four movers <NUM> and four end effectors <NUM>, a manufacturing system <NUM> can include any number of movers <NUM> and any number of end effectors <NUM>.

The stator base <NUM> has a planar stator surface <NUM> covering an array of electrical coils <NUM>, as shown in <FIG>. The electrical coils <NUM> are arranged in an array (e.g., a Halbach array or other arrangement), and are configured to generate electromagnetic fields (not shown) when energized via command of the controller <NUM>. Although the stator base <NUM> is shown having a square shape, the stator base <NUM> can have any one of a variety of different shapes including, but not limited to, rectangular, linear, triangular, disc shaped, or other shapes.

Referring to <FIG>, each of the movers <NUM> contains multiple permanent magnets <NUM> arranged in a horizontal plane, as shown in <FIG>. The permanent magnets <NUM> cause the movers <NUM> to levitate and move in contact-free relation to the stator surface <NUM> in response to the electromagnetic fields generated by the electrical coils <NUM> when activated by the controller <NUM>. Advantageously, the non-contact movement of the movers <NUM> over the stator surface <NUM> eliminates frictional energy losses and wear associated with conventional pick-and-place systems. Although shown in <FIG> as having a square shape, the mover <NUM> may be provided in any one of a variety of alternative shapes including, but not limited to, rectangular, triangular, disc shaped, or other shapes.

In <FIG>, each mover <NUM> has a mover x-axis <NUM>, a mover y-axis <NUM>, and a mover z-axis <NUM>. Each mover <NUM> is configured to move with at least two degrees-of-freedom, including planar motion parallel to the stator surface <NUM> within the plane of the mover x-axis <NUM> (e.g., left-right) and the mover y-axis <NUM> (e.g., forward-backward). The controller <NUM> is configured to precisely manipulate the electromagnetic fields in a manner to independently guide each mover <NUM> across the stator surface <NUM> along an infinite number of freely programmable mover paths (not shown). In one example, the movers <NUM> can be configured to travel at speeds of up to <NUM> meters-per-second or more. In addition, the movers <NUM> can be stopped at any location on the stator surface <NUM> with repeat positional accuracy on the order of tens of microns (e.g., less than <NUM> microns).

In addition to movement parallel to the stator surface <NUM>, each mover <NUM> is configured to rotate <NUM> degrees in either direction about the mover z-axis <NUM>. As shown in <FIG>, the movers <NUM> are additionally configured to levitate at a controllable mover-stator gap <NUM> (e.g., up to <NUM>) relative to the stator surface <NUM>. Additionally, the movers <NUM> can be configured for a small amount of tilting motion (e.g., up to <NUM> degrees) about the mover x-axis <NUM> and/or a small amount of tilting motion (e.g., up to <NUM> degrees) about the mover y-axis <NUM>.

Referring to <FIG>, shown is an example of a stator base <NUM> comprised of multiple tiles <NUM> positioned in side-by-side relation to each other. The tiles <NUM> are mounted to a tile support frame <NUM>, which is preferably a rigid structure fabricated of rigid material such as metallic material (e.g., aluminum), composite material (e.g., carbon fiber), or other material. The tile support frame <NUM> can be coupled to the base transport system <NUM> to allow the multi-tile stator base <NUM> to be moved during pick-and-place operations.

In <FIG>, each tile <NUM> has a tile top surface <NUM>, and contains an array of electrical coils <NUM> (<FIG>). When assembled in side-by-side relation, the tiles <NUM> collectively form a stator base <NUM> having a planar stator surface <NUM>. The tiles <NUM> are modular, allowing any number of tiles <NUM> to be positioned in side-by-side relation to form a stator surface <NUM> having any one of a variety of different shapes. Although <FIG> shows the tiles <NUM> arranged to form a stator base <NUM> having a square shape, the tiles <NUM> may be arranged to form a stator base <NUM> having a rectangular shape, a linear shape, or any other shape. One example of a planar motor system <NUM> that contains modular tiles <NUM> is the XPlanar motor system <NUM>™, commercially available from Beckhoff Automation, of Savage, MN.

As shown in <FIG>, the manufacturing system <NUM> includes one or more end effectors <NUM> coupled to the movers <NUM>. In the example shown, each mover <NUM> supports a single end effector <NUM>. However in other examples not shown, a single mover <NUM> may support two or more end effectors <NUM>. Each end effector <NUM> is supported on and mechanically coupled to a mover <NUM>. <FIG> and <FIG> illustrate each mover <NUM> having a telescopic post <NUM> coupling an end effector <NUM> to the mover <NUM>. The telescopic post <NUM> is configured to extend and retract the end effector <NUM> in a direction perpendicular to the stator surface <NUM>, along the mover z-axis <NUM> (<FIG>).

Alternatively or additionally, each mover <NUM> may include a joint assembly to facilitate rotation of the end effector <NUM> in any number of directions. For example, <FIG> illustrates a wrist joint <NUM> coupling the end effector <NUM> to the telescopic post <NUM>. The wrist joint <NUM> is configured to rotate an end effector <NUM> about at least two axes. In some examples, the wrist joint <NUM> can be configured as a universal joint, a ball-and-socket joint, or other joint configurations. In another example of a joint assembly, <FIG> shows a multi-axis robot arm <NUM> coupling the end effector <NUM> to the mover <NUM>. The multi-axis robot arm <NUM> can include any number of arm segments <NUM> and arm joints <NUM> to facilitate orientation of the end effector <NUM> about any number of axes.

Referring to <FIG> and <FIG>, each end effector <NUM> is configured to perform one or more functions in relation to a material sheet <NUM>, such as a composite ply of a composite laminate being laid up by the manufacturing system <NUM>. <FIG> shows an example of an end effector <NUM> configured as a gripper <NUM> configured to engage with (i.e., grip) the material sheet <NUM>, to allow for pickup of the material sheet <NUM>, such as from a material pickup station <NUM> (<FIG>). The gripper is <NUM> also configured to disengage from (i.e., release) the material sheet <NUM>, after being applied to a tooling surface <NUM> of a layup tool <NUM> at a material placement station <NUM>. In the example of <FIG> and <FIG>, the gripper <NUM> has a plurality of needles or hooks <NUM> protruding from a gripper plate <NUM> for mechanically engaging the material sheet <NUM>. However, in other examples not shown, the gripper <NUM> may comprise a plurality of suction cups for vacuum engagement of a material sheet <NUM>, or the gripper <NUM> may comprise an electrostatic device (not shown) for electrostatic engagement of a material sheet <NUM>.

<FIG> shows an example of an end effector <NUM> configured as a compaction device <NUM>. The compaction device <NUM> is configured to compact the material sheet <NUM> (<FIG>) against a tooling surface <NUM> (<FIG>) or against a previously applied material sheet <NUM>. In example shown, the compaction device <NUM> is a roller <NUM> configured to apply compaction pressure on a material sheet <NUM> during rolling application over a tooling surface <NUM>. In other examples not shown, the compaction device <NUM> may be a compaction shoe configured to slide over a material sheet <NUM> while applying compaction pressure.

<FIG> shows an example of an end effector <NUM> configured as a tacking device <NUM>. The tacking device <NUM> is configured to spot fix a material sheet <NUM> to a tooling surface <NUM> or to a previously applied material sheet <NUM>. The spot fixing of the material sheet <NUM> prevents movement of the material sheet <NUM> during subsequent layup, compacting, and/or trimming. In the example shown, the tacking device <NUM> is a soldering iron <NUM> configured to tack a material sheet <NUM> in position via spot heating. However, the tacking device <NUM> may be provided in any one of a variety of other configurations for spot fixing a material sheet <NUM> in position.

<FIG> shows an example of an end effector <NUM> configured as an inspection device <NUM>. The manufacturing system <NUM> can include one or more inspection devices <NUM> configured to actively monitor the pickup, placement, and/or forming of a material sheet <NUM> on a tooling surface <NUM>. For example, the inspection devices <NUM> can facilitate the accurate positioning of the material sheet <NUM> on the tooling surface <NUM> such that the sheet edges <NUM> (<FIG>) of the material sheet <NUM> align with edge locations <NUM> (<FIG>) projected onto the tooling surface <NUM> using one or more laser projection devices (not shown) included with the manufacturing system <NUM>. Feedback from the inspection devices <NUM> can facilitate adjustment of the controller software in a manner to improve the accuracy of the laydown of subsequently applied material sheets <NUM>. The inspection device <NUM> can be a visible light camera, an infrared sensor, an eddy current sensor, a temperature sensor, and/or any one of a variety of other sensor configurations having the capability to actively measure, observe, and/or sense the pick up, placement, forming, trimming, and other operations that can be performed on a material sheet <NUM>.

<FIG> shows an example of an end effector <NUM> configured as a cutting device <NUM>. In the example shown, the cutting device <NUM> is a knife blade <NUM> configured to cut a material sheet <NUM>, such as a composite ply. In this regard, in addition to grippers <NUM> for engaging a composite ply on a material cutting table <NUM>, a planar motor system <NUM> can include one or more mover-mounted cutting devices <NUM> for cutting any uncut material (e.g., uncut fibers) detected by a mover-mounted inspection device <NUM> (e.g., a force sensor, a camera - not shown) during pickup of the composite ply off the material cutting table <NUM>.

Referring still to <FIG> and <FIG>, the size (e.g., length and width) of each mover <NUM> may be dictated, at least in part, by the mass of the end effector <NUM>, and/or by the function performed by the end effector <NUM>. A mover <NUM> that supports an end effector <NUM> that is relatively heavy and/or which applies significant force to a material sheet <NUM> and/or to a layup tool <NUM> may be larger in size than a mover <NUM> that supports a lighter weight end effector <NUM>, and/or an end effector <NUM> that applies a limited amount of force to a material sheet <NUM> or a layup tool <NUM>. For example, a mover <NUM> supporting a gripper <NUM> (e.g., <FIG>) may be larger in size than a mover <NUM> supporting an inspection device <NUM>, a tacking device <NUM>, or a cutting device <NUM>, due to the requirement of the gripper <NUM> to support a portion of the mass of a material sheet <NUM> during pickup and placement, and the optional requirement of the gripper <NUM> to apply tensile force <NUM> to the material sheet <NUM> during forming over the tooling surface <NUM>, as shown in <FIG> and <FIG> and described below. Similarly, a mover <NUM> supporting a compaction device <NUM> may be relatively large in size due to the need for the compaction device <NUM> to apply compaction pressure on the material sheet <NUM> against the tooling surface <NUM> during the forming process. In contrast, a mover <NUM> supporting an inspection device <NUM> (e.g., <FIG>), a tacking device <NUM>, or a cutting device <NUM> may be relatively small in size, as neither the inspection device <NUM>, the tacking device <NUM>, or the cutting device <NUM> is required to apply a significant amount of force to the material sheet <NUM> or the layup tool <NUM>.

As mentioned above, the manufacturing system <NUM> includes a controller <NUM> (e.g.,. <FIG> and <FIG>). The controller <NUM> is communicatively coupled to the stator base <NUM> and the end effectors <NUM>. The controller <NUM> is configured to selectively activate the electrical coils <NUM> (<FIG>) in a manner causing electromagnetic fields that levitate the movers <NUM> relative to the stator surface <NUM>. In addition to levitating the moves, the electromagnetic fields prevent the movers <NUM> from moving perpendicularly away from the stator surface <NUM> beyond the above-mentioned mover-stator gap <NUM> (<FIG>). Furthermore, the electromagnetic fields are manipulated in a manner to propel the movers <NUM> parallel to the stator surface <NUM> along any one of an infinite variety of preprogrammed mover paths (not shown). As mentioned above, the controller <NUM> is configured to generate electromagnetic fields that cause independent, coordinated movement of the movers <NUM> over the stator surface <NUM>. In addition, the controller <NUM> commands the end effectors <NUM> to engage with and operate on the material sheet <NUM>. The movement of the stator base <NUM> (via the base transport system <NUM>), the movement of the movers <NUM>, and/or the movement of the end effectors <NUM> can occur sequentially and/or simultaneously.

The planar motor system <NUM> is configured such that the movers <NUM> are levitated at the above-mentioned mover-stator gap <NUM> (<FIG>) from the stator surface <NUM>, regardless of the orientation of the stator surface <NUM>. The movers <NUM> may be maintained at the mover-stator gap <NUM>, regardless of whether the stator surface <NUM> is horizontally oriented (i.e., facing downward or upward), or the stator surface <NUM> is non-horizontally oriented. In the example of <FIG>, the stator base <NUM> is fixedly coupled to the gantry <NUM>, and is maintained in a horizontal orientation with the stator surface <NUM> facing down. The electromagnetic fields are such that the movers <NUM> are maintained at a fixed mover-stator gap <NUM> below the stator surface <NUM>.

Additionally, although not shown, the base transport system <NUM> can orient the stator base <NUM> such that the stator surface <NUM> faces up, and the electromagnetic fields are such that the movers <NUM> are maintained at the mover-stator gap <NUM> relative to the stator surface <NUM>. In still other examples, the base transport system <NUM> can orient a stator base <NUM> non-horizontally (e.g., facing sideways), and the electromagnetic fields are such that the movers <NUM> are maintained at a fixed mover-stator gap <NUM> relative to the stator surface <NUM>. The base transport system <NUM> can reorient the stator base <NUM> such that the stator surface <NUM> faces in different directions (e.g., upward, downward, sideways) at different times during operation of the manufacturing system <NUM>, as shown in the example of <FIG>.

Referring to <FIG>, shown is an example of the base transport system <NUM> configured as a gantry <NUM>, supporting a planar motor system <NUM> having a stator base <NUM> and a plurality of movers <NUM>. The stator base <NUM> has a stator surface <NUM> that faces down. Each mover <NUM> supports a gripper <NUM> on a telescopic post <NUM>. Although not shown, the planar motor system <NUM> may also include one or more inspection devices <NUM> (<FIG>) and one or more cutting devices <NUM> (e.g., <FIG>), each supported on a mover <NUM>.

In <FIG>, the controller <NUM> commands the gantry <NUM> to lower the stator base <NUM> to a height above the material cutting table <NUM>. The material cutting table <NUM> is configured to support raw material <NUM>, such as composite fabric in planar form. The material sheet <NUM> (e.g., a composite ply) has been cut out of the raw material <NUM> along cut lines <NUM>, using a conventional cutting machine, such as a two-dimensional ply cutter (not shown).

As shown in <FIG>, the controller <NUM> commands the plurality of grippers <NUM> to engage the material sheet <NUM> at a corresponding plurality of engagement points <NUM> (<FIG>) distributed throughout the material sheet <NUM>. The material sheet <NUM> may also include a plurality of control points <NUM> (<FIG>) distributed throughout the material sheet <NUM>. The control points <NUM> enable tracking of the pickup, placement, and forming of the material sheet <NUM> via the inspection devices <NUM>. The grippers <NUM> may be engaged to the engagement locations in a planned sequence during pickup of the material sheet <NUM>,.

Referring to <FIG>, under command of the controller <NUM>, the gantry <NUM> raises the planar motor system <NUM> to thereby pick the material sheet <NUM> up off the material cutting table <NUM>, leaving only scrap material <NUM>. In some examples, the telescopic posts <NUM> may be partially retracted to facilitate extraction of the material sheet <NUM> from the raw material <NUM> on the material cutting table <NUM>. Alternatively or additionally, the controller <NUM> may be configured to adjust the positions of the movers <NUM> relative to each other on the stator surface <NUM>, and/or adjust the orientations of the grippers <NUM>, to facilitate extraction of the material sheet <NUM>.

During the initial stage of lifting the material sheet <NUM> off the material cutting table <NUM>, the inspection devices <NUM> (<FIG>) can inspect the cut lines <NUM> for any uncut material (e.g., uncut fibers of a composite ply) that may inhibit extraction of the material sheet <NUM> from the raw material <NUM>. Toward this end, the inspection devices <NUM> may be configured as visual cameras, or the grippers <NUM> may have force sensors, or any one of a variety of other devices may be included with the manufacturing system <NUM> for detecting uncut material along the cut lines <NUM>. The planar motor system <NUM> may include one or more cutting devices <NUM> (<FIG>), each mounted to a mover <NUM>, for cutting any uncut material detected by the inspection devices <NUM>. Alternatively, any uncut material can be manually cut by a technician.

<FIG> shows the material sheet <NUM> vertically raised by the gantry <NUM> above the material cutting table <NUM>. <FIG> shows the material sheet <NUM> engaged to the grippers <NUM> at the engagement points <NUM>. <FIG> shows the gantry <NUM> transporting the planar motor system <NUM> and material sheet <NUM> from the material cutting station to the material placement station <NUM>. At the material placement station <NUM>, the material sheet <NUM> is suspended above the tooling surface <NUM> of the layup tool <NUM>. The manufacturing system <NUM> may include one or more laser projectors (not shown) configured to project edge locations <NUM> onto the tooling surface <NUM>. The edge locations <NUM> define the intended location of the sheet edges <NUM> of the material sheet <NUM> when accurately positioned and formed over the tooling surface <NUM>.

Referring to <FIG>, the controller <NUM> is configured to command the gantry <NUM>, the movers <NUM>, and the end effectors <NUM> (e.g., the grippers <NUM>, the compaction devices <NUM>, the tacking devices <NUM>, and/or the inspection devices <NUM>) to operate in a coordinated manner for placing the material sheet <NUM> on the tooling surface <NUM> which, in the example shown, is non-planar. The controller <NUM> is configured to command the adjustment of the positions and/or orientations of the movers <NUM> and/or the grippers <NUM> as required during placement and forming of the material sheet <NUM> on the tooling surface <NUM>. After successful placement of the material sheet <NUM>, the controller <NUM> commands the plurality of grippers <NUM> to disengage from the engagement points <NUM>. The controller <NUM> commands the gantry <NUM> to raise the planar motor system <NUM> as shown in <FIG>, and return to the material pickup station <NUM> (<FIG>) to repeat the process of picking up a material sheet <NUM> for placement on the previously applied material sheet <NUM> on the layup tool <NUM>.

Referring to <FIG>, in some examples, the controller <NUM> commands the inspection devices <NUM> to monitor and record the movement of the control points <NUM> during forming of the material sheet <NUM> over the tooling surface <NUM>. As described below, the recordings of the control point movements can be analyzed to determine the accuracy of the positioning of the material sheet <NUM> on the tooling surface <NUM> during and after forming. <FIG> illustrates an initial stage of forming in which the material sheet <NUM> is in a planar configuration. As shown in <FIG>, a localized portion <NUM> (indicated as a cross-hatched region) of the planar material sheet <NUM> is initially in contact with the layup tool <NUM>, while remaining portions of the material sheet <NUM> are initially separated from the tooling surface <NUM>. Also shown in <FIG> is the optional application of tensile force <NUM> to the material sheet <NUM> via the grippers <NUM> (<FIG>) at the engagement points <NUM>. The tensile forces <NUM> can be applied in a manner that reduces or minimizes the occurrence of wrinkles in the material sheet <NUM> during forming over the tooling surface <NUM>.

<FIG> shows the material sheet <NUM> in an intermediate stage of forming. The controller <NUM> commands the movement of the movers <NUM> and/or the grippers <NUM> in a manner to incrementally form the material sheet <NUM> over the tooling surface <NUM>. For example, the controller <NUM> can command the movers <NUM> on opposite sides of the tooling surface <NUM> to move slightly toward each other (e.g., toward the centerline of the layup tool <NUM>) as the material sheet <NUM> conforms to the convex curvature of the tooling surface <NUM>. Simultaneously, the controller <NUM> can command the telescopic posts <NUM> to gradually extend as the grippers <NUM> gradually move the material sheet <NUM> toward contact with the tooling surface <NUM>.

<FIG> shows the completion of the forming process, illustrating the additional reorientation and/or repositioning of the movers <NUM> and/or grippers <NUM> to conform the material sheet <NUM> to the curvature of the tooling surface <NUM>. In <FIG>, the inspection devices <NUM> closely monitor and record movement of the control points <NUM> on the material sheet <NUM>. In addition, the inspection devices <NUM> may monitor and record any tensile forces <NUM> applied by the grippers <NUM> at their respective engagement points <NUM>. Toward this end, each gripper <NUM> may include a force sensor (not shown) configured to measure the magnitude and direction of the tensile force <NUM> applied at its engagement point <NUM>. The inspection devices <NUM> are also configured to record the formation of any wrinkles (not shown) occurring in each material sheet <NUM> during and/or at completion of the forming process.

As described in greater detail below, the above-noted information recorded by the inspection devices <NUM> during the forming process is continuously fed to the controller <NUM> as each material sheet <NUM> (e.g., composite ply) is applied to the layup tool <NUM>. The controller <NUM> contains a processor (not shown) configured to use artificial intelligence (e.g., machine learning) to analyze the tensile force <NUM> at each engagement point <NUM> and the movement of each control point <NUM> during the forming process, and the resulting wrinkles (e.g., wrinkle quantity, location, size, and direction) occurring in each material sheet <NUM>. Based on the analysis, the processor is configured to make adjustments to the controller software that controls the movements of the base transport system <NUM>, the movers <NUM>, and/or the end effectors <NUM>, in a manner to reduce wrinkle formation in subsequently applied material sheets <NUM>. For example, the controller software may be adjusted in a manner that slightly alters the direction and/or magnitude and/or sequence of tensile forces <NUM> applied at one or more the engagement points <NUM>.

Referring briefly <FIG>, shown in <FIG> and <FIG> are side views of an example of a manufacturing system <NUM> containing a large quantity of grippers <NUM>, which are engaged to a corresponding number of engagement points <NUM> on the material sheet <NUM> (<FIG> and <FIG>). <FIG> to show an initial stage of applying the planar material sheet <NUM> onto the layup tool <NUM>, resulting in the localized portion <NUM> (shown in crosshatch) in contact with the tooling surface <NUM>. <FIG> show an intermediate stage of forming the material sheet <NUM> over the tooling surface <NUM>. As mentioned above, the controller software may also be revised in a manner to adjust the sequence with which tensile forces <NUM> are applied to the engagement points <NUM>. For example, during the initial application of the material sheet <NUM>, the grippers <NUM> that are nearest the localized portion <NUM> (e.g., the inboard grippers) can apply tensile forces <NUM> at their corresponding engagement points <NUM>, while the grippers <NUM> nearest the sheet edges <NUM> (e.g., the outboard grippers) apply minimal or no tensile force at their engagement points <NUM>. At the intermediate stage of forming shown in <FIG>, the grippers <NUM> nearest the sheet edges <NUM> can apply tensile forces <NUM> at their corresponding engagement points <NUM>, while the inboard grippers <NUM> stop applying tensile force to their engagement points <NUM>, as such engagement points <NUM> are in contact with the layup tool <NUM> at that point during the forming process. The manufacturing system <NUM> of <FIG> can include inspection devices <NUM> (mounted to the movers <NUM>) and configured to monitor the movement of the control points <NUM> for feedback to the controller <NUM>, to facilitate adjustment of the movements of the movers <NUM> and grippers <NUM>, for improving the accuracy with which the material sheet <NUM> is positioned and formed over the tooling surface <NUM>.

Referring to <FIG>, shown is an example of the manufacturing system <NUM> wherein the controller <NUM> (<FIG>) is configured to cause the movers <NUM> and end effectors <NUM> to form the material sheet <NUM> into a shape complementary to the tooling surface <NUM>, prior to applying the material sheet <NUM> onto the tooling surface <NUM>. For example, in <FIG> and <FIG>, the material sheet <NUM> is supported in a planar configuration prior to being applied to the layup tool <NUM>. <FIG> shows the material sheet <NUM> supported in three-dimensional space above the layup tool <NUM>. The movers <NUM> and the grippers <NUM> in <FIG> have been repositioned and/or reoriented to form the material sheet <NUM> into a contour that approximately matches the contour of the tooling surface <NUM>, after which the material sheet <NUM> can be lowered onto the tooling surface, as shown in <FIG>. The manufacturing system <NUM> of <FIG> can include inspection devices <NUM> as mentioned above, for monitoring monitor the movement of the control points <NUM> for feedback to the controller <NUM>, for improving the accuracy with which the material sheet <NUM> is positioned and formed over the tooling surface <NUM>.

Referring to <FIG>, shown is an example of a manufacturing system <NUM> in which the base transport system <NUM> comprises a plurality of robotic devices <NUM>. Each robotic device <NUM> has a robot base <NUM>, and one or more arm segments <NUM> connected by arm joints <NUM>. In the example shown, each robot base <NUM> is mounted to a robot track <NUM> that extends between a material pickup station <NUM> containing a material cutting table <NUM>, and a material placement station <NUM> containing a layup tool <NUM>. In alternative examples not shown, each robotic device <NUM> can be fixedly mounted to a shop floor, wall, roof, or other fixed structure.

The manufacturing system <NUM> of <FIG> includes a plurality of stator bases <NUM>, each movably supported by a robotic device <NUM> (i.e., the base transport system <NUM>). As described above, the stator bases <NUM> each have a planar stator surface <NUM> covering an array of electrical coils <NUM> (<FIG>) configured to generate an electromagnetic field. Although <FIG> show each robotic device <NUM> supporting a single stator base <NUM>, in other examples not shown, a single robotic device <NUM> may be configured to support two or more stator bases <NUM>. Although each stator base <NUM> in <FIG> is shown as a unitary structure as illustrated in <FIG>, each stator base <NUM> can alternatively be comprised of a plurality of tiles <NUM> assembled in side-by-side relation, as shown in <FIG>.

The manufacturing system <NUM> includes a plurality of movers <NUM> associated with the stator bases <NUM>. Although <FIG> show each stator base <NUM> having two movers <NUM>, each with its own end effector <NUM>. Each stator base <NUM> can include any number of movers <NUM>, including a single mover <NUM>, or two or more movers <NUM>. As described above, each mover <NUM> contains multiple permanent magnets <NUM> (<FIG>) configured to cause levitated movement of the mover <NUM> relative to the stator surface <NUM> in response to electromagnetic fields generated by the electrical coils <NUM>. As mentioned above, the electromagnetic fields are such that the movers <NUM> are maintained at a fixed mover-stator gap <NUM> (<FIG>), regardless of the orientation of the stator surface <NUM>. For example, the movers <NUM> are maintained at a fixed mover-stator gap <NUM> regardless of whether the stator surface <NUM> is upward facing or downward facing as shown in <FIG>, or non-horizontally oriented as shown in <FIG>.

As mentioned above, the manufacturing system <NUM> further includes a plurality of end effectors <NUM> coupled to the movers <NUM>, and configured to perform one or more functions in relation to a material sheet <NUM>. The end effectors <NUM> can be any one of the above-described configurations shown in <FIG> and <FIG>, or the end effectors <NUM> can be provided in other configurations not shown.

In <FIG>, the manufacturing system <NUM> includes a controller <NUM> (<FIG>) communicatively coupled to the robotic devices <NUM>, the stator base <NUM>, and the end effectors <NUM>. The controller <NUM> is configured to cause the movers <NUM> to move in a coordinated manner to position the plurality of end effectors <NUM> respectively adjacent to a material sheet <NUM> located at the material pickup station <NUM>. In the example of <FIG>, the material sheet <NUM> is located on the material cutting table <NUM>, similar to the above-described arrangement shown in <FIG>. The end effectors <NUM> are shown as grippers <NUM> (<FIG>), as described above and shown in <FIG>.

The controller <NUM> is configured to cause the plurality of end effectors <NUM> (e.g., the grippers <NUM>) to engage the material sheet <NUM> for pickup off of the material staging location, and cause the robotic devices <NUM> to move the stator bases <NUM> through an envelope of motion to thereby transport the material sheet <NUM> from the material pickup station <NUM> to the material placement station <NUM>. Furthermore, the controller <NUM> is configured to cause the movers <NUM> and the end effectors <NUM> to form the material sheet <NUM> over the tooling surface <NUM>. As described above, the movers <NUM> and the grippers <NUM> can also be manipulated in a manner to locally apply tensile force <NUM> to the material sheet <NUM>, as shown in <FIG> and <FIG>, described above. Tensile forces <NUM> can be applied by the grippers <NUM> in a sequence that reduces or minimizes the occurrence of wrinkles in the material sheet <NUM>. In addition, the direction and magnitude of the tensile force <NUM> applied at each engagement limitation can be controlled in a manner to minimize the occurrence of wrinkles in the material sheet <NUM>, as described above.

<FIG> illustrate the process of forming a planar material sheet <NUM> over a layup tool <NUM> using the robotic devices <NUM>. <FIG> show the stator bases <NUM> positioned by the robotic devices <NUM> over the material cutting table <NUM>. The grippers <NUM> are in position for engaging (i.e., gripping) the material sheet <NUM>. <FIG> shows the robotic devices <NUM> being operated in a coordinate a manner to simultaneously raise their respective stator bases <NUM>, thereby lifting the material sheet <NUM> off of the material cutting table <NUM>. <FIG> shows the robotic devices <NUM> moving along the robot tracks <NUM> to thereby transport the material sheet <NUM> from the material cutting table <NUM> to the layup tool <NUM>.

<FIG> shows the stator bases <NUM> positioning the material sheet <NUM> over the layup tool <NUM> in preparation for forming over the tooling surface <NUM>. <FIG> show the reorientation and repositioning of the stator bases <NUM> and grippers <NUM> at the completion of the process of forming the material sheet <NUM> over the tooling surface <NUM>. After the forming process is complete, the grippers <NUM> disengage from the material sheet <NUM>, allowing the robotic devices <NUM> to return to the material pickup station <NUM> to repeat the process with another material sheet <NUM>. In some examples, the grippers <NUM> may disengage from the material sheet <NUM> in a predetermined sequence, which may help to minimize the occurrence of wrinkles in the material sheet <NUM>.

Any one or more of the components, configurations, and/or functionalities of the manufacturing system <NUM> described with regard to <FIG> are applicable to any one or more of the components, configurations, and/or functionalities of the manufacturing system <NUM> of <FIG>. Likewise, any one or more of the components, configurations, and/or functionalities of the manufacturing system <NUM> described herein with regard to <FIG> are applicable to any one or more of the components, configurations, and/or functionalities of the manufacturing system <NUM> of <FIG>.

Referring now to <FIG>, shown are operations included in a method <NUM> of processing a material sheet <NUM> using the manufacturing systems <NUM> as presently disclosed. The method <NUM> includes supporting the stator base <NUM> on a base transport system <NUM>. In the example manufacturing system <NUM> of <FIG>, the method <NUM> includes supporting the stator base <NUM> via a gantry <NUM>. In the example manufacturing system <NUM> of <FIG>, the method <NUM> includes supporting the stator base <NUM> via one or more robotic devices <NUM>. Regardless of the configuration of the base transport system <NUM>, the method <NUM> includes moving the stator base <NUM> through an envelope of motion that enables the end effectors <NUM> to pick up the material sheet <NUM> from a material pickup station <NUM>, and move the material sheet <NUM> over to a material placement station <NUM>.

Referring still to <FIG>, step <NUM> of the method <NUM> includes activating an array of electrical coils <NUM> (<FIG>) in a stator base <NUM> having a planar stator surface <NUM>, and thereby generating an electromagnetic field. The activation of the electromagnetic coils is performed under command of a controller <NUM>, as described above. For the stator base <NUM> configuration of <FIG>, step <NUM> comprises activating an array of electrical coils <NUM> in a single stator base <NUM>. For the stator base <NUM> configuration of <FIG>, step <NUM> comprises activating an array of electrical coils <NUM> in each of a plurality of tiles <NUM> positioned in side-by-side relation to each other and collectively defining the stator base <NUM>.

Step <NUM> of the method <NUM> includes levitating and independently moving a plurality of movers <NUM> in a coordinated manner over the stator surface <NUM> in response to the electromagnetic field. As described above, each mover <NUM> contains multiple permanent magnets <NUM>, as shown in <FIG>.

Step <NUM> of levitating and moving the plurality of movers <NUM> comprises moving at least one mover <NUM> with at least two degrees-of-freedom. Levitating and moving the movers <NUM> comprises translating each mover <NUM> in a direction parallel to the stator surface <NUM> along a mover x-axis <NUM> and/or along a mover y-axis <NUM>, as shown in <FIG> and described above. For example, each mover <NUM> can move in a direction parallel to the mover x-axis <NUM>, in a direction parallel to the mover y-axis <NUM>, or in any direction angle between the mover x-axis <NUM> and mover y-axis <NUM>. Levitating and moving the mover <NUM> can also include rotating the mover <NUM> about a mover z-axis <NUM>. In still further examples, each mover <NUM> can be rotated in either direction about the mover z-axis <NUM>, and/or each mover <NUM> can be slightly tilted (e.g., up to <NUM> degrees) about the mover x-axis <NUM> and/or about the mover y-axis <NUM>, as shown in <FIG>.

Step <NUM> of the method <NUM> includes performing one or more functions on a material sheet <NUM> using one or more end effectors <NUM> coupled to the movers <NUM>. To facilitate performance of the functions on the material sheet <NUM>, the method <NUM> can include extending and retracting the end effectors <NUM> in a direction perpendicular to the stator surface <NUM> using a telescopic post <NUM> coupling the end effector <NUM> to a mover <NUM>, as shown in <FIG> and <FIG>. Alternatively or additionally, the method <NUM> can include orienting the end effector <NUM> using a wrist joint <NUM> coupling the end effector <NUM> to one of the movers <NUM> (e.g., via telescopic post <NUM>) as shown in <FIG>, and/or using a multi-axis robot as shown in <FIG>.

In step <NUM>, the functions performed by the end effectors <NUM> can include engaging and/or operating on an object, such as a material sheet <NUM>. For example, step <NUM> can include cutting the material sheet <NUM> using a cutting device <NUM>, such as the knife blade <NUM> shown in <FIG>. The cutting device <NUM> may be required to sever uncut material along a cut line <NUM> separating a composite ply (i.e., the material sheet <NUM>) from scrap material <NUM>, as shown in <FIG>.

In another example, step <NUM> can include engaging with and disengaging from the material sheet <NUM> using a plurality of grippers <NUM>, each coupled to one of the movers <NUM>. As described above, <FIG> show an example of a gripper <NUM> having a plurality of hooks <NUM> protruding from a gripper plate <NUM>. However, in other examples, the gripper <NUM> can include an array of suction cups (not shown) for suction engagement of a material sheet <NUM>, or an electrostatic device (not shown) for electrostatic engagement of a material sheet <NUM>.

Step <NUM> can also include compacting the material sheet <NUM> against the tooling surface <NUM> or against a previously applied material sheet <NUM> using a compaction device <NUM>. <FIG> shows the compaction device <NUM> as a roller <NUM> configured to apply compaction pressure on a material sheet <NUM> against the tooling surface <NUM>. The compaction devices <NUM> can be applied to the material sheet <NUM> in a planned sequence to facilitate the forming process as the material sheet <NUM> is forced down onto the tooling surface <NUM>.

In still further examples, step <NUM> can include spot fixing the material sheet <NUM> in position on a layup tool <NUM> using a tacking device <NUM>. <FIG> shows an example of a tacking device <NUM> configured as a soldering iron <NUM>. However, the tacking device <NUM> may be provided as any mechanism or device capable of applying localized heat, such as to locally melt the material sheet <NUM> (e.g., locally melt the resin of a composite ply). The tacking devices <NUM> can be applied in a planned sequence and/or at planned locations on the material sheet <NUM> to fix the location and shape of the material sheet <NUM> during forming.

Step <NUM> can additionally include monitoring the pickup, placement, and forming of the material sheet <NUM> on the tooling surface <NUM> using one or more inspection devices <NUM>. As described above, an inspection device <NUM> can be a camera, an infrared sensor, a temperature sensor, or any other sensor configuration capable of measuring, observing, and/or sensing the pickup, placement, and forming, or for performing other operations on a material sheet <NUM>. Upon completion of the forming process, all end effectors <NUM> that can manipulate the shape of the material sheet <NUM> can be disengaged, and the inspection devices <NUM> can measure and confirm the shape and location on the material sheet <NUM> on the tooling surface <NUM>.

The process of engaging with and disengaging from a material sheet <NUM> using the grippers <NUM> can be described with reference to <FIG>. For example, <FIG> illustrates a plurality of grippers <NUM> engaging a gripping a corresponding plurality of engagement points <NUM> distributed throughout the material sheet <NUM>. As shown in <FIG>, the material sheet <NUM> has a planar configuration when supported on the material cutting table <NUM>. The process includes picking up the material sheet <NUM> by adjusting the positions and/or orientations of the base transport system <NUM>, the movers <NUM> and/or the grippers <NUM>. For example, <FIG> shows the gantry <NUM> lowering the stator base for pickup of the material sheet <NUM>, followed by raising the stator base <NUM> to lift material sheet <NUM> lifting off the material cutting table <NUM>. <FIG> shows the underside of the planar motor system <NUM> illustrating the material sheet <NUM> supported at the engagement points <NUM> by the grippers <NUM>, each of which is engaged to a mover <NUM> that is levitated (i.e., suspended) in relation to the stator surface <NUM> of the stator base <NUM>.

<FIG> illustrates the stator base <NUM> being moved by the gantry <NUM> through an envelope of motion to thereby transport the material sheet <NUM> from the material pickup station <NUM> to the material placement station <NUM>. <FIG> illustrates the placing of the material sheet <NUM> on the tooling surface <NUM>, which is non-planar. As described above, the process of forming the material sheet <NUM> to the tooling surface <NUM> involves re-adjusting the positions and/or orientations of the movers <NUM> and/or the grippers <NUM>, as shown in <FIG>. After the material sheet <NUM> is formed to the tooling surface <NUM>, the process includes disengaging the grippers <NUM> from the engagement points <NUM>, and moving the stator base <NUM> away from the tooling surface <NUM>, as shown in <FIG>.

Referring to <FIG>, as mentioned above, the process of placing the material sheet <NUM> on the tooling surface <NUM> comprises moving the stator base <NUM>, the movers <NUM>, and/or the grippers <NUM>. For example, the stator base <NUM> can be vertically translated via a gantry <NUM>, via robotic devices <NUM>, or by other means, to initially place a localized portion <NUM> (see <FIG> - cross-hatched region) of the material sheet <NUM> in contact with the tooling surface <NUM>, while remaining portions of the material sheet <NUM> are separated from the tooling surface <NUM>. The placement of the material sheet <NUM> on the tooling surface <NUM> can also include translating the movers <NUM> in a direction parallel to the stator surface <NUM>, and re-orienting and/or repositioning the z-location of the grippers <NUM> in a manner that facilitates the forming of the material sheet <NUM> over a tooling surface <NUM>.

As shown in <FIG>, the processor can additionally command the movement of the movers <NUM> and grippers <NUM> to apply tensile force <NUM> to the material sheet <NUM>, while incrementally forming the remaining portions of the material sheet <NUM> onto the tooling surface <NUM>. As mentioned above, each tensile force <NUM> is independently applied by one of the grippers <NUM> at its engagement point <NUM> with the material sheet <NUM>. The tensile forces <NUM> are applied as a result of translation of the movers <NUM> in a plane parallel to the stator surface <NUM>. The tensile forces <NUM> can be applied at the same or different magnitudes and/or in different directions, as commanded by the controller <NUM>.

The method <NUM> can include recording one or more parameters of the forming process using one or more inspection devices <NUM> while forming the material sheet <NUM> over the tooling surface <NUM>. For example, the inspection devices <NUM> can record the location on the tooling surface <NUM> where the localized portion <NUM> of the material sheet <NUM> is initially placed in contact with the tooling surface <NUM>. As mentioned above, the manufacturing system <NUM> may include one or more laser projection devices configured to project edge locations <NUM> on the tooling surface <NUM>. The inspection devices <NUM> can record images of the locations of the sheet edges <NUM> relative to the edge locations <NUM> projected by the laser projectors, and thereby determine the accuracy with which the material sheet <NUM> is applied to the tooling surface <NUM>.

Referring to <FIG>, as mentioned above, the inspection devices <NUM> can record the sequence with which tensile forces <NUM> are applied to the material sheet <NUM> at the engagement points <NUM>, and the magnitude and direction of each tensile force <NUM>. The application of tensile forces <NUM> at the engagement points <NUM> may reduce the quantity or size of wrinkles that can occur in the material sheet <NUM> at the completion of the forming process. The inspection devices <NUM> can also record the movement of control points <NUM> on the material sheet <NUM>, as a means to record the various shapes assumed by the material sheet <NUM> as it is formed over the tooling surface <NUM>. At the completion of the forming process, the inspection devices <NUM> can record the quantity, location, size (e.g., height and width), and lengthwise direction of each wrinkle in each material sheet <NUM>.

As mentioned above, the controller <NUM> (i.e., processor) can use artificial intelligence (i.e., machine learning, or deep learning) to analyze the parameters recorded by the inspection devices <NUM>, as a means to assess the accuracy and quality with which the material sheet <NUM> is formed over the tooling surface <NUM>. For example, the processor can analyze the sequence, magnitude, and direction of the tensile forces <NUM>, and the movement of the control points <NUM> during the forming process, and the quantity, location, size, and direction of wrinkles occurring in the formed material sheet <NUM>. The processor can make adjustments to the software program that the controller <NUM> operates on for controlling the movements of the movers <NUM> and the end effectors <NUM> during the application of subsequently applied material sheets <NUM>. In this regard, the adjustments are made with the intent of reducing the quantity and/or size of wrinkles in the material sheets <NUM>. In one example, the processor can adjust the sequence with which the tensile forces <NUM> are applied to the material sheet <NUM> at the different engagement points <NUM>, as described above with regard to <FIG>. Alternatively or additionally, the processor can adjust the magnitude and/or direction of the tensile forces <NUM>. The above-described process of recording the forming of each material sheet <NUM>, analyzing the recorded data, and adjusting the software, can be repeated for each material sheet <NUM>, until all of the material sheets <NUM> (e.g., all composite plies of a composite laminate) have been applied to the layup tool <NUM>.

Referring briefly to <FIG>, in some examples, the method can include forming the material sheet <NUM> in three-dimensional space prior to applying the material sheet <NUM> to a tooling surface <NUM>. For example, as described above, the method <NUM> can include positioning the movers <NUM>, extending or retracting the telescopic posts <NUM>, and reorienting the end effectors <NUM> in a manner to form a planar material sheet <NUM> (e.g., <FIG>) into a shape complementary to the tooling surface <NUM> (e.g., <FIG>), prior to placing the material sheet <NUM> on the tooling surface <NUM>.

Claim 1:
A manufacturing system (<NUM>), comprising:
a stator base (<NUM>) having a planar stator surface (<NUM>) covering an array of electrical coils (<NUM>) configured to generate an electromagnetic field;
a plurality of movers (<NUM>), each containing multiple permanent magnets (<NUM>) configured to cause the movers (<NUM>) to levitate and move relative to the stator surface (<NUM>) in response to the electromagnetic field;
one or more end effectors (<NUM>) coupled to the movers (<NUM>), each end effector (<NUM>) configured to perform one or more functions in relation to a material sheet (<NUM>); and
a controller (<NUM>) configured to selectively activate the electrical coils (<NUM>) in a manner causing independent, coordinated movement of the movers (<NUM>) over the stator surface (<NUM>), and causing the end effectors (<NUM>) to engage with and operate on the material sheet (<NUM>).