Patent Description:
Composite materials comprised of carbon fiber can be dry or in a prepreg form in which a resonant is infused in the carbon fiber material. These composite materials can take the form of plies. These plies can be cut into desired shapes and laid up the tool. The plies in the tool can be cured to form a composite part.

This process of forming a composite part involves numerous steps in which a ply is handled. A human operator can lay up a ply in a work area such as a cutter flatbed where a cutter can be applied to a shape with desired dimensions. When the size of the cut is large, a human operator or multiple human operators remove the ply from the scrap material and transport the ply to another location for further processing or storage. This process may involve rolling and folding the ply when acceptable. One further processing is used, the ply may be placed on a tool in which the boundaries of the ply are aligned to laser projections.

This type of processing using human operators can be slower and more tedious than desired. Further, this process is labor-intensive and plies can be easily damaged during handling.

Automated systems can be used to handle the plies. For example, an end effector on a robotic system can perform pick and place operations in which an end effector with adhesion surface, such as a vacuum, can move the plies to different locations and positions the plies for processing. These automated systems can have errors in accurately positioning composite plies during different operations. These errors can result in the final composite part then out of tolerance.

Document <CIT>, according to its abstract, states an iterative method for draping fiber plies to produce a preform for a composite wall with an organic matrix. The method comprises the sequential stacking of woven fiber plies on a template. The plies are covered with reference markings, particularly with tracer threads forming a grid pattern, the positions of the threads being indicated by means of illuminated marks projected by a laser. The reference markings of the plies are moved in turn until they coincide with their corresponding marks, thereby ensuring the correct positioning of the corresponding ply. The stack contains plies with threads orientated at -<NUM>°/+<NUM>° and at <NUM>°/<NUM>°. The illuminated marks change with each type of ply so as to project dedicated indications onto the plies. The present disclosure also provides a draping installation and a composite wall of a casing of an axial turbine engine, or of a motor vehicle structure.

Document <CIT>, according to its abstract, states a method and apparatus for managing a rework of a composite structure. Boundary geometries are identified for the layer boundaries in an image of a rework area. The image includes layer boundaries for exposed layers in the rework area. Layer orientations are identified for the exposed layers. A description of a patch for installation in the rework area is generated using the boundary geometries and layer orientations. The patch has plies having ply boundaries with the boundary geometries corresponding to the layer boundaries and ply orientations corresponding to the layer orientations. An operation of a ply cutting system is controlled using the group of files describing the patch, enabling fabricating the patch for the rework area using the group of files describing the patch.

Document <CIT>, according to its abstract, states a method of producing fiber semi-finished products for the manufacture of fiber composite components, wherein the individual fiber semi-finished products are formed from a plurality of fiber strips, the method including the steps of: a) providing a fiber laying apparatus with a laying head for laying fiber strips in a fiber laying region for producing a plurality of fiber semi-finished products, b) determining a nesting arrangement of the fiber semi-finished products to be produced in the fiber laying region for positioning the individual fiber strips of the fiber semi-finished products in dependence on the outer contour of the fiber semi-finished products to be produced and the available laying space in the fiber laying region by means of a nesting program running on a computing machine, wherein an optimized arrangement of at least two fiber semi-finished products is determined in dependence on their outer contour and a fiber orientation architecture by means of the nesting program in such a way that one or more fiber strips are deposited together without cut interruption for the at least two fiber semi-finished products, and c) depositing the fiber strips in the fiber laying region by means of the at least one depositing head of the fiber laying device for forming the fiber semi-finished products according to the determined nesting arrangement.

For example, it would be desirable to have a method and apparatus that overcome a technical problem with placing composite plies within the desired tolerances for manufacturing composite parts.

According to the present disclosure, a method and a system as defined in the independent claims are provided. Further embodiments of the claimed invention are defined in the dependent claims. Although the claimed invention is only defined by the claims, the below embodiments, examples, and aspects are present for aiding in understanding the background and advantages of the claimed invention.

An embodiment of the present disclosure provides a method for manufacturing a composite part. A set of reference locations is identified for a set of fiducial markers on a composite ply from a ply shape model for the composite part. The set of fiducial markers is created at the set of reference locations on the composite ply. The composite ply is cut to have a shape defined by the ply shape model.

Another embodiment of the present disclosure provides a method for manufacturing a composite part. A composite ply is cut to have a shape defined by a ply shape model for the composite part using automated manufacturing equipment. A set of fiducial markers is created at a set of reference locations on the composite ply using the automated manufacturing equipment.

Yet another embodiment of the present disclosure provides a composite manufacturing system comprising fabrication equipment and a fabrication controller in a computer system. The fabrication controller controls fabrication equipment to identify a set of reference locations for a set of fiducial markers on a composite ply from a ply shape model for a composite part; created the set of fiducial markers at the set of reference locations on the composite ply; and cut the composite ply to have a shape defined by the ply shape model.

Still another embodiment of the present disclosure provides a composite manufacturing system comprising fabrication equipment and a fabrication controller in a computer system. The fabrication controller controls fabrication equipment to cut a composite ply to have a shape defined by a ply shape model for a composite part and create a set of fiducial markers at a set of reference locations on the composite ply.

According to an aspect of the present disclosure a method for manufacturing a composite part, the method comprises identifying a set of reference locations for a set of fiducial markers on a composite ply from a ply shape model for the composite part; creating the set of fiducial markers at the set of reference locations on the composite ply; and cutting the composite ply to have a shape defined by the ply shape model.

Advantageously, the method further comprises identifying a current position of the composite ply having the shape using the set of fiducial markers using a sensor system; and generating instructions for a placement device to move the composite ply having the shape from the current position to a desired position.

Preferably, the method is one wherein generating instructions for the placement device to move the composite ply having the shape from the current position to the desired position comprises generating the instructions for the placement device to perform a pick operation that picks up the composite ply from the current position and places the composite ply in the desired position.

Preferably, the method is one wherein generating instructions for the placement device to move the composite ply having the shape from the current position to the desired position comprises generating the instructions for the placement device to place the composite ply in the desired position on another composite ply as part of forming a composite charge.

Preferably, the method is one wherein generating instructions for the placement device to move the composite ply having the shape from the current position to the desired position comprises generating the instructions for the placement device to place the composite ply on a layup tool.

Preferably, the method further comprises identifying a current position for the set of fiducial markers on composite ply using a sensor system; generating instructions for a placement device to move an end effector on the placement device from current position to a desired position with respect the set of fiducial markers.

Preferably, the method is one wherein cutting the composite ply to have the shape defined by the ply shape model comprises cutting the composite ply to have the shape defined by the ply shape model with a tool; and wherein forming the set of fiducial markers at the set of reference locations on the composite ply comprises creating the set of fiducial markers at the set of reference locations on the composite ply with the tool.

Preferably, the method is one wherein creating the set of fiducial markers at the set of reference locations on the composite ply comprises creating the set of fiducial markers at the set of reference locations on the composite ply after cutting the composite ply to have the shape defined by the ply shape model.

Preferably, the method is one wherein creating the set of fiducial markers at the set of reference locations on the composite ply comprises creating the set of fiducial markers at the set of reference locations on the composite ply prior to cutting the composite ply to have the shape defined by the ply shape model.

Preferably, the method is one wherein creating the set of fiducial markers at the set of reference locations on the composite ply comprises creating the set of fiducial markers directly on the composite ply at the set of reference locations.

Preferably, the method is one wherein creating the set of fiducial markers at the set of reference locations on the composite ply comprises creating the set of fiducial markers directly on a backing for the composite ply at the set of reference locations.

Preferably, the method is one wherein the set of fiducial markers is comprised of at least one of an ink, a reflective ink, a magnetic ink, a sticker, a paint, or a liquid chalk.

Preferably, the method is one wherein the composite ply is processed to form the composite part for a platform selected from a group comprising a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, a space-based structure, an aircraft, a commercial aircraft, a rotorcraft, a tilt-rotor aircraft, a tilt wing aircraft, a vertical takeoff and landing aircraft, an electrical vertical takeoff and landing vehicle, a personal air vehicle, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, and a building.

According to another aspect of the present disclosure, a method for manufacturing a composite part, the method comprises cutting a composite ply to have a shape defined by a ply shape model for the composite part using automated manufacturing equipment; and creating a set of fiducial markers at a set of reference locations on the composite ply using the automated manufacturing equipment.

Advantageously, the method further comprises identifying the set of reference locations for the set of fiducial markers on the composite ply from the ply shape model.

Preferably, the method is one wherein further comprises identifying a current position of the composite ply having the shape using the set of fiducial markers using a sensor system; and generating instructions for a placement device to move the composite ply having the shape from the current position to a desired position.

Preferably, the method is one wherein creating the set of fiducial markers at the set of reference locations on the composite ply using the automated manufacturing equipment comprises creating the set of fiducial markers at the set of reference locations on the composite ply using the automated manufacturing equipment after cutting the composite ply to have the shape defined by the ply shape model using the automated manufacturing equipment.

Preferably, the method is one wherein creating the set of fiducial markers at the set of reference locations on the composite ply using the automated manufacturing equipment comprises creating the set of fiducial markers at the set of reference locations on the composite ply using the automated manufacturing equipment prior to cutting the composite ply to have the shape defined by the ply shape model using the automated manufacturing equipment.

Preferably, the method is one wherein creating the set of fiducial markers at the set of reference locations on the composite ply using the automated manufacturing equipment comprises creating the set of fiducial markers directly on the composite ply at the set of reference locations using the automated manufacturing equipment.

Preferably, the method is one wherein creating the set of fiducial markers at the set of reference locations on the composite ply using the automated manufacturing equipment comprises creating the set of fiducial markers directly on a backing for the composite ply at the set of reference locations using the automated manufacturing equipment.

According to yet another aspect of the present disclosure, a composite manufacturing system comprises fabrication equipment; and a fabrication controller in a computer system that controls fabrication equipment to identify a set of reference locations for a set of fiducial markers on a composite ply from a ply shape model for a composite part; create the set of fiducial markers at the set of reference locations on the composite ply; and cut the composite ply to have a shape defined by the ply shape model.

Advantageously, the composite manufacturing system is one wherein the fabrication controller controls the fabrication equipment to identify a current position of the composite ply having the shape using the set of fiducial markers using a sensor system; and generate instructions for a placement device to move the composite ply having the shape from the current position to a desired position.

Preferably, the composite manufacturing system is one wherein in generating instructions for the placement device to move the composite ply having the shape from the current position to the desired position, the fabrication controller controls the fabrication equipment to generating the instructions for the placement device to perform a pick operation that picks up the composite ply from the current position and places the composite ply in the desired position.

Preferably, the composite manufacturing system is one wherein in generating instructions for the placement device to move the composite ply having the shape from the current position to the desired position, the fabrication controller controls the fabrication equipment to generate the instructions for the placement device to place the composite ply in the desired position on another composite ply as part of forming a composite charge.

Preferably, the composite manufacturing system is one wherein in generating instructions for the placement device to move having the shape from the current position to the desired position, the fabrication controller controls the fabrication equipment to generate the instructions for the placement device to place the composite ply on a layup tool.

Preferably, the composite manufacturing system is one wherein in cutting the composite ply to have the shape defined by the ply shape model, the fabrication controller controls the fabrication equipment to cut the composite ply to have the shape defined by the ply shape model with a tool; and wherein in creating the set of fiducial markers at the set of reference locations on the composite ply, the fabrication controller controls the fabrication equipment to create the set of fiducial markers at the set of reference locations on the composite ply with the tool.

Preferably, the composite manufacturing system is one wherein in creating the set of fiducial markers at the set of reference locations on the composite ply, the fabrication controller controls the fabrication equipment to create the set of fiducial markers at the set of reference locations on the composite ply after cutting the composite ply to have the shape defined by the ply shape model.

Preferably, the composite manufacturing system is one wherein in creating the set of fiducial markers at the set of reference locations on the composite ply, the fabrication controller controls the fabrication equipment to create the set of fiducial markers at the set of reference locations on the composite ply prior to cutting the composite ply to have the shape defined by the ply shape model.

Preferably, the composite manufacturing system is one wherein in creating the set of fiducial markers at the set of reference locations on the composite ply, the fabrication controller controls the fabrication equipment to create the set of fiducial markers directly on the composite ply at the set of reference locations.

Preferably, the composite manufacturing system is one wherein in creating the set of fiducial markers at the set of reference locations on the composite ply, the fabrication controller controls the fabrication equipment to create the set of fiducial markers directly on a backing for the composite ply at the set of reference locations.

Preferably, the composite manufacturing system is one wherein the set of fiducial markers is comprised of at least one of an ink, a reflective ink, a magnetic ink, a sticker, a paint, or a liquid chalk.

Preferably, the composite manufacturing system is one wherein the composite ply is processed to form the composite part for a platform selected from a group comprising a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, a space-based structure, an aircraft, a commercial aircraft, a rotorcraft, a tilt-rotor aircraft, a tilt wing aircraft, a vertical takeoff and landing aircraft, an electrical vertical take off and landing vehicle, a personal air vehicle, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, and a building.

According to still another aspect of the present disclosure, a composite manufacturing system comprises fabrication equipment; and a fabrication controller in a computer system that controls fabrication equipment to cut a composite ply to have a shape defined by a ply shape model for a composite part; and create a set of fiducial markers at a set of reference locations on the composite ply.

Advantageously, the composite manufacturing system is one wherein the fabrication controller controls the fabrication equipment to identify the set of reference locations for the set of fiducial markers on the composite ply from the ply shape model.

Preferably, the composite manufacturing system is one wherein the fabrication controller controls the fabrication equipment to identify a current position of the composite ply having the shape using the set of fiducial markers using a sensor system; and generate instructions for a placement device to move the composite ply having the shape from the current position to a desired position.

The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that currently used automation systems or handling composite plies can have errors that are cumulative at different steps such that the final positioning can be out of tolerance. The illustrative embodiments recognize and take into account that these errors can be errors in ply cutter positioning, errors in cutting of the composite material, robot calibration errors, errors in robot alignment to pick areas, and positioning errors in other operations that involve moving or handling composite plies. For example, the illustrative embodiments recognize and take account that positioning errors can also occur during storage unit movement, movement of the ply to a pick zone on a belt, and other types of operations that move or position the composite ply.

The illustrative embodiments recognize and take into account that errors, even small errors, occurring during different operations in which a ply or layup of plies are moved can accumulate resulting in the final positioning being out of tolerance.

The illustrative embodiments recognize and take into account that automated processing of plies involve cutting sheets of composite material to create plies shapes, moving the plies to storage using a robot, placing the plies in storage, picking stored plies, placing the plies on a tool, and other operations. The illustrative embodiments recognize and take into account that these and other operations performed to manufacture composite parts result in the accumulated errors that make maintaining required positional tolerance very difficult.

Illustrative embodiments recognize and take into account that one manner in which errors can be reduced include scanning or identifying a ply boundary for a composite ply while the composite ply is secured to a robot and the factor after a pick operation. Those embodiments recognize and take into account that the scanning of the boundary of the composite ply can be used to determine an as picked position for the composite ply.

The illustrative embodiments recognize and take into account that boundary scanning of plies can remove positional errors from previous operations, but cut quality, cutter calibration, and errors from calculations of the new position often do not provide a level of accuracy that meets tolerances for manufacturing a composite part.

Thus, illustrative embodiments recognize and take into account that creating one or more fiducial markers on a composite ply prior to the composite ply being indexed to a pick area can increase the accuracy in positioning the composite ply during operations performed to manufacture a composite part. The illustrative embodiments recognize and take account that the set of additional markers can have a design that can include a shape or pattern that enables a camera to resolve the position and orientation of a set of fiducial markers. Those embodiments recognize and take account that automated movement of the ply can occur with an inspection using a camera prior to the movement operation to measure the set of fiducial markers with respect to an end effector or other tool that may move or position the composite ply.

The illustrative embodiments recognize and take into account that with the use of the set of fiducial markers, additional error can be avoided as a relative position of the composite ply is recalculated before each operation that moves the composite ply, such as a pick operation.

Illustrative embodiments also recognize and take into account that creating the set of fiducial markers as early as possible can reduce the amount of error. For example, the illustrative embodiments recognize and take account that creating the set of fiducial markers just prior to or subsequent to cutting the composite ply to have a shape for use in forming a composite part. The illustrative embodiments recognize and take into account that forming the set of fiducial markers just before or after cutting the composite ply can also remove air from indexing the cutter belt to move the to a pick position.

Thus, the illustrative embodiments recognize and take into account that the final position of the composite ply is a combination of the accuracy in marking fiducial markers on the composite ply, final robot accuracy, and tolerances of the boundaries of the composite ply formed from cutting the composite ply.

With reference now to the figures and in particular with reference to <FIG>, an illustration of a composite manufacturing system is depicted in accordance with an illustrative embodiment. Composite manufacturing system <NUM> in composite can operate cells <NUM> to manufacture composite parts <NUM>. In this illustrative example, composite parts <NUM> can take a number of different forms. For example, composite parts <NUM> can be selected from at least one of a skin panel, a stringer, a door, a nacelle, or other suitable type of composite part.

As used herein, the phrase "at least one of," when used with a list of items, means different combinations of one or more of the listed items can be used, and only one of each item in the list may be needed. In other words, "at least one of" means any combination of items and number of items may be used from the list, but not all of the items in the list are required. The item can be a particular object, a thing, or a category.

As depicted, composite manufacturing system <NUM> comprises a number of different cells that operate to fabricate composite parts <NUM>. As depicted, cells <NUM> in composite manufacturing system <NUM> can comprise, for example, cutting and knitting cell <NUM>, automated charge layup cell <NUM>, charge to tool transfer and forming cell <NUM>, curing cell <NUM>, and cleaning cell <NUM>.

As depicted, cutting and knitting cell <NUM> is a cell in composite manufacturing system <NUM> that operates to create composite plies <NUM> for use in manufacturing composite parts <NUM>. In this illustrative example, cutting and knitting cell <NUM> automatically performs cutting operations using automated cutting and marking machine <NUM> and automated cutting and marking machine <NUM>. As depicted, automated cutting and marking machine <NUM> and automated cutting and marking machine <NUM> can be cutting beds, automated flatbed cutting systems, conveyor cutting beds, or other suitable types of automated cutting and marking machines. In the illustrative example, a marking functionality combined with a cutting function by using multifunction tools in these cutting machines can modify the cutting machines to function as cutting and marking machines. The cutting and marking machines can be, for example, computer numerical control (CNC) machines.

In this illustrative example, automated cutting and marking machine <NUM> has multifunction tool <NUM>, and automated cutting and marking machine <NUM> has multifunction tool <NUM>. In this illustrative example, multifunction tool <NUM> and multifunction tool <NUM> are integrated tools in which each of these tools has a cutter (not shown) and a marker (not shown). The cutter can take a number of different forms. For example, the cutter can be an electric oscillating knife, a drag knife, ultrasonic knife, a laser cutter, or some other suitable type of device that can cut composite materials to form composite plies <NUM> with a shape for manufacturing composite parts <NUM>. The marker can be an inkjet printer, a pen, a sticker applicator, or some other device that can mark on composite plies <NUM>.

As depicted, multifunction tool <NUM> can move in the direction of arrow <NUM> along gantry <NUM>. Multifunction tool <NUM> can also move in the direction of arrow <NUM> on gantry <NUM>. Additionally, gantry <NUM> can move in the direction of arrow <NUM> on flatbed <NUM> of automated cutting and marking machine <NUM>. In similar fashion, gantry <NUM> can move in the direction of arrow <NUM> on flatbed <NUM> of automated cutting and marking machine <NUM>. In this illustrative example, flatbed <NUM> and flatbed <NUM> can be beds with moving conveyor belts.

In addition to cutting composite plies <NUM>, multifunction tool <NUM> and multifunction tool <NUM> can also mark composite plies <NUM> to create fiducial markers <NUM> on composite plies <NUM>.

As depicted, pick and place robot <NUM> can move composite plies <NUM> with fiducial markers <NUM> from automated cutting and marking machine <NUM> and automated cutting and marking machine <NUM> to storage <NUM> to form kit <NUM>. In this illustrative example, pick and place robot <NUM> can detect fiducial markers <NUM> on composite plies <NUM> when picking up composite plies <NUM> from flatbed <NUM> and flatbed <NUM> and placing composite plies <NUM> onto storage <NUM>. Pick and place robot <NUM> can include the camera system (not shown) to detect fiducial markers <NUM> on composite plies <NUM>.

As depicted, kit <NUM> contains the composite plies <NUM> with shapes needed to form a composite part in composite parts <NUM>. In this illustrative example, storage <NUM> can be a cart or other mobile platform that can be moved automatically or by a human operator. Storage <NUM> enables moving composite plies <NUM> to other cells for additional processing to manufacture composite parts <NUM>.

As depicted, storage <NUM> can move composite plies <NUM> to charge layup cell <NUM> for further processing. In this illustrative example, pick and place robot <NUM> picks up composite ply <NUM> from storage <NUM> and places composite ply <NUM> onto preform table <NUM>. In this illustrative example, pick and place robot <NUM> can include camera <NUM> that detects fiducial marker <NUM> on composite ply <NUM> for use in picking up composite ply <NUM> from storage <NUM> and placing composite ply <NUM> onto preform table <NUM>.

With the use of fiducial marker <NUM>, composite ply <NUM> can be placed on preform table <NUM> with a desired level of tolerance. In this illustrative example, preform table <NUM> is a carrier for composite plies and can take the form of a grid that is composed of metallic strips bonded in a grid fashion.

Although pick and place robot <NUM> can also move composite plies <NUM> with a desired level tolerance using fiducial markers <NUM>, that type of placement can be optional with the use of pick and place robot <NUM> in charge layup cell <NUM>. In other words, the use of fiducial marker <NUM> to place composite ply <NUM> onto preform table <NUM> can be used to reduce or eliminate the effect of other positional errors occurring from other movement of composite ply <NUM> on flatbed <NUM>, on storage <NUM> by pick and place robot <NUM>, and other movement of these composite plies.

In this illustrative example, charge layup cell <NUM> is an example of a cell in which errors from prior movement can be reduced or eliminated. In this depicted example, errors can be reduced or eliminated when placing composite ply <NUM> onto preform table <NUM> using fiducial marker <NUM>.

The layup of composite plies can be performed to form a charge, such as charge <NUM> on preform table <NUM>. Preform table <NUM> can be moved to charge to tool transfer and forming cell <NUM>.

As depicted, charge <NUM> has been moved onto tool <NUM> from preform table <NUM>. In this illustrative example, a resin can be infused into charge <NUM> from resin reservoir <NUM>. The addition of resin can be optional when a prepreg is used.

Tool <NUM> with charge <NUM> infused with resin can be moved into autoclave <NUM> in curing cell <NUM>. Thereafter, composite parts <NUM> can be removed from tool <NUM> by robotic arm <NUM> in cleaning cell <NUM>. In this cell, operations such as the bagging and tool cleaning of tool <NUM> can be performed such that tool <NUM> can be cleaned for further use.

In this illustrative example, computer <NUM> can run program <NUM> to control the different cells in composite manufacturing system <NUM> to automatically perform operations to manufacture composite parts <NUM>. As depicted, computer <NUM> can communicate with computers or other control devices for (not shown) the manufacturing equipment in cells <NUM> using communications link <NUM>. Communications link <NUM> can be at least one of a physical connection or a wireless connection.

Thus, the illustrative examples can create fiducial markers <NUM> directly on composite plies <NUM> prior to composite plies <NUM> being indexed in cutting and knitting cell <NUM> for movement by a pick and place robot, such as pick and place robot <NUM> and pick and place robot <NUM>. From the time that fiducial markers <NUM> are created on composite plies <NUM>, subsequent movement of composite plies <NUM> can be performed using a camera on the pick and place robot to resolve the position of composite plies <NUM> with respect to an end effector on the pick and place robot. In this manner, the positioning of the end effector with respect to fiducial markers <NUM> can be determined with a desired level of accuracy using fiducial markers <NUM>.

Subsequent operations moving composite plies <NUM> do not introduce additional error as the relative position of composite plies <NUM> can be determined before each operation moving composite plies <NUM>.

Turning next to <FIG>, an illustration of an automated cutting and marking machine is depicted in accordance with an illustrative embodiment. As depicted, automated cutting and marking machine <NUM> is an example of one implementation for automated cutting and marking machine <NUM> and automated cutting and marking machine <NUM> in <FIG>.

In this illustrative example, automated cutting and marking machine <NUM> comprises flatbed <NUM>, gantry <NUM>, multifunction tool <NUM>. As depicted, multifunction tool <NUM> is movably attached to gantry <NUM>. Gantry <NUM> is movably attached to flatbed <NUM>.

In this illustrative example, gantry <NUM> is a bridge like overhead structure that supports multifunction tool <NUM>. As depicted, gantry <NUM> can move along flatbed <NUM> in the direction of arrow <NUM>. In this example, multifunction tool <NUM> can move along gantry <NUM> in the direction of arrow <NUM>. As result, multifunction tool <NUM> can be moved in two dimensions represented by arrow <NUM> and arrow <NUM> over surface <NUM> of flatbed <NUM>.

In this illustrative example, multifunction tool <NUM> can comprise two components. These components can be a cutter <NUM> and marker <NUM>. As depicted, cutter <NUM> and marker <NUM> are mounted within housing <NUM> of multifunction tool <NUM>. Housing <NUM> of multifunction tool <NUM> is movably connected to gantry <NUM>.

As depicted, automated cutting and marking machine <NUM> can be programmed to cut composite ply <NUM> into shape <NUM> and generate fiducial markers, such as fiducial marker <NUM>, fiducial marker <NUM>, and fiducial marker <NUM>, on surface <NUM> of composite ply <NUM>. These fiducial markers on example of an implementation for fiducial markers <NUM> and fiducial marker <NUM> in <FIG>.

In this illustrative example, cutter <NUM> has cut composite ply <NUM> to have shape <NUM>. As depicted, composite ply <NUM> has been cut to have shape <NUM> prior to the creation of fiducial markers. In this illustrative example, fiducial marker <NUM> and fiducial marker <NUM> have been created on surface <NUM> by marker <NUM>. In this example, marker <NUM> has not yet completed creation of fiducial marker <NUM> on surface <NUM> of composite ply <NUM>.

Turning to <FIG>, an illustration of a cutter in the multifunction tool in <FIG> is depicted in accordance with an illustrative embodiment. In this illustrative example, cutter <NUM> takes the form of drag blade <NUM>. The illustration of cutter <NUM> as drag blade <NUM> is provided as one example of an implementation for cutter <NUM>. This illustrative example is not meant to limit the types of cutters that may be used in other illustrative examples. For example, cutter <NUM> can also be implemented using an electric oscillating knife, an ultrasonic knife, a laser cutter, a kit cutting machine, a driven rotary blade, or other suitable type of cutter.

With reference to <FIG>, an illustration of a marker in the multifunction tool in <FIG> is depicted in accordance with an illustrative embodiment. As depicted, marker <NUM> takes the form of ink pen <NUM>.

The illustration of marker <NUM> as ink pen <NUM> is provided as one example of an implementation for marker <NUM>. This illustrative example is not meant to limit the types of markers that may be used in other illustrative examples. For example, marker <NUM> can also be implemented using inkjet printer, a sticker applicator, or some other device that can mark on surface <NUM> of composite ply <NUM>.

Turning now to <FIG>, an illustration of an automated cutting and marking machine is depicted in accordance with an illustrative embodiment. As depicted, automated cutting and marking machine <NUM> is an example of another type of automated cutting and marking machine that can be used in place of the automated cutting and marking machine <NUM> and automated cutting and marking machine <NUM> depicted in <FIG>.

In this illustrative example, automated cutting and marking machine <NUM> comprises platform <NUM>, robotic arm <NUM>, and end effector <NUM>. In this example, robotic arm <NUM> can move end effector <NUM> in three dimensions, including a plane defined by x axis <NUM> and y axis <NUM>.

Composite ply <NUM> is located on surface <NUM> of platform <NUM>. In this example, end effector <NUM> is a multifunction tool including cutter <NUM> and marker <NUM> as shown in this exposed view of housing <NUM> for end effector <NUM>.

As depicted, robotic arm <NUM> can move end effector <NUM> to create fiducial marker <NUM>, fiducial marker <NUM>, and fiducial marker <NUM> on surface <NUM> of composite ply <NUM> using marker <NUM>. These fiducial markers is an example of an implementation for fiducial markers <NUM> and fiducial marker <NUM> in <FIG>.

As depicted, composite ply <NUM> has not been cut by cutter <NUM> in end effector <NUM>. As can be seen in this example, fiducial markers are created prior to cutting composite ply <NUM>.

With reference next to <FIG>, an illustration of a composite ply with fiducial markers is depicted in accordance with an illustrative embodiment. As depicted, composite ply <NUM> is comprised of carbon fibers and can be cut into shape <NUM>.

In this illustrative example, fiducial marker <NUM>, fiducial marker <NUM>, and fiducial marker <NUM> have been created on surface <NUM> of composite ply <NUM>.

In this example, fiducial marker <NUM> has been created at reference location <NUM>, fiducial marker <NUM> has been created at reference location <NUM>, and fiducial marker <NUM> has been created at reference location <NUM>.

These reference locations can be identified from computer-aided design (CAD) model <NUM> of composite ply <NUM>. In this illustrative example, computer-aided design model <NUM> specifies geometry <NUM> for shape <NUM> for composite ply <NUM>. Geometry <NUM> can be used to cut composite ply <NUM> to have shape <NUM> with desired dimensions.

Computer-aided design model <NUM> also includes reference locations <NUM> with respect to geometry <NUM>. Reference locations <NUM> can be used to create fiducial marker <NUM> at reference location <NUM>, fiducial marker <NUM> at reference location <NUM>, and fiducial marker <NUM> at reference location <NUM> on composite ply <NUM>.

Turning to <FIG>, an illustration of a fiducial marker is depicted in accordance with an illustrative embodiment. Fiducial marker <NUM> is an example of one implementation for fiducial marker <NUM> and fiducial marker <NUM> in <FIG>, and fiducial marker <NUM>, fiducial marker <NUM>, and fiducial marker <NUM> in <FIG>. As depicted, fiducial marker <NUM> has a symmetric shape.

With reference to <FIG>, another illustration of a fiducial marker is depicted in accordance with an illustrative embodiment. Fiducial marker <NUM> is an example of one implementation for fiducial marker <NUM> and fiducial marker <NUM> in <FIG>, and fiducial marker <NUM>, fiducial marker <NUM>, and fiducial marker <NUM> in <FIG>. As depicted, fiducial marker <NUM> has an asymmetric shape.

The illustration of fiducial marker <NUM> in <FIG>, fiducial marker <NUM> in <FIG>, and fiducial marker <NUM> in <FIG> are presented as nonlimiting examples of fiducial markers that may be used in the different illustrative examples. The presentation of these fiducial markers is not meant to limit the manner in which other fiducial markers may be implemented in other illustrative examples. For example, in some illustrative examples a fiducial marker may have multiple colors. In yet other illustrative examples, fiducial marker may have other shapes or sizes in addition to or in place of the ones depicted in these examples. The particular shape and size of fiducial markers can be selected to increase the ability of a sensor to detect fiducial marker and its orientation.

Turning next to <FIG>, an illustration of a flowchart of a process for manufacturing a composite part is depicted in accordance with an illustrative embodiment. The process in <FIG> can be implemented in hardware, software, or both. When implemented in software, the process can take the form of program code that is run by one of more processor units located in one or more hardware devices in one or more computer systems. For example, the process can be implemented in computer <NUM> running program <NUM> in <FIG>.

The process begins by identifying a set of reference locations for a set of fiducial markers on a composite ply from a ply shape model for the composite part (operation <NUM>). The process forms the set of fiducial markers at the set of reference locations on the composite ply (operation <NUM>).

The process cuts the composite ply to have a shape defined by the ply shape model (operation <NUM>). The process terminates thereafter.

In this illustrative example, operation <NUM> and operation <NUM> can be performed using the same tool. In other words, cutting the composite ply and the creating of the set of fiducial markers at the set of reference locations on the composite ply can be formed using a single tool. For example, an end effector for a robotic arm having both a cutter and a marker can be present. In another example, the tool can be a multifunction tool head that moves along one axis on a gantry with a gantry moving on another axis.

With reference to <FIG>, an illustration of a flowchart of a process for performing manufacturing operation is depicted in accordance with an illustrative embodiment. The process illustrated in <FIG> is an example of an additional operation that can be performed with the operations depicted in the flowchart in <FIG>.

The process performs identifies a current position of the composite ply having the shape using the set of fiducial markers using a sensor system (operation <NUM>). The process generates instructions for a placement device to move the composite ply having the shape from the current position to a desired position (operation <NUM>). The process terminates thereafter.

Turning now to <FIG>, an illustration of a flowchart of a process for creating a set of fiducial markers is depicted in accordance with an illustrative embodiment. The operation illustrated in <FIG> is an example one implementation for operation <NUM> in <FIG>.

The process creates the set of fiducial markers at the set of reference locations on the composite ply after cutting the composite ply to have the shape defined by the ply shape model (operation <NUM>). The process terminates thereafter.

Turning now to <FIG>, another illustration of a flowchart of a process for creating a set of fiducial markers is depicted in accordance with an illustrative embodiment. The operation illustrated in <FIG> is an example one implementation for operation <NUM> in <FIG>.

The process creates the set of fiducial markers at the set of reference locations on the composite ply prior to cutting the composite ply to have the shape defined by the ply shape model (operation <NUM>). The process terminates thereafter.

With reference next to <FIG>, an illustration of a flowchart of a process for creating a set of fiducial markers is depicted in accordance with an illustrative embodiment. The operation illustrated in <FIG> is an example one implementation for operation <NUM> in <FIG>.

The process creates the set of fiducial markers directly on the composite ply at the set of reference locations (operation <NUM>). The process terminates thereafter.

Turning to <FIG>, an illustration of a flowchart of a process for creating a set of fiducial markers is depicted in accordance with an illustrative embodiment. The operation illustrated in <FIG> is an example one implementation for operation <NUM> in <FIG>.

The process creates the set of fiducial markers directly on a backing for the composite ply at the set of reference locations (operation <NUM>). The process terminates thereafter.

With reference next to <FIG>, an illustration of a flowchart of a process for performing a set of manufacturing operations is depicted in accordance with an illustrative embodiment. The operations illustrated in <FIG> are examples of implementations for operation <NUM> in <FIG>.

The process generates instructions for the placement device to perform a pick operation that picks up the composite ply from the current position and places the composite ply in the desired position (operation <NUM>). The process generates the instructions for the placement device to place the composite ply in the desired position on another composite ply as part of forming a composite charge (operation <NUM>).

The process generates the instructions for the placement device to place the composite ply on a layup tool (operation <NUM>). The process terminates thereafter.

Turning to <FIG>, an illustration of a flowchart of a process for performing a set of manufacturing operations is depicted in accordance with an illustrative embodiment. The process illustrated in <FIG> is an example of an additional operations that can be performed with the operations depicted in the flowchart in <FIG>.

The process begins by selecting a composite ply having a set of fiducial markers (operation <NUM>). The process picks up the composite ply (operation <NUM>). The process places the composite ply on another composite ply using the set of fiducial markers to form a layup composite ply (operation <NUM>). In operation <NUM>, the set of fiducial markers can be used to place the composite ply on another composite ply with a desired position for the layup of composite plies being formed.

A determination is made as to whether another composite ply is needed (operation <NUM>). If another composite poly is needed, the process returns to operation <NUM> to select another composite ply for the layup of composite plies. Otherwise, the process terminates.

Thus, the manufacturing operation performed in <FIG>, can be used to lay up a composite ply, a stack of composite plies, a charge, a composite preform, or other structure using composite plies or other composite materials. By using composite plies with a set of fiducial markers, the placement of each composite ply relative to a previously placed composite ply can be performed with the desired level of accuracy. This accuracy can reduce the need to rework or discarding of composite parts made from the composite plies laid up using fiducial markers.

The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of apparatuses and methods in an illustrative embodiment. In this regard, each block in the flowcharts or block diagrams can represent at least one of a module, a segment, a function, or a portion of an operation or step. For example, one or more of the blocks can be implemented as program code, hardware, or a combination of the program code and hardware. When implemented in hardware, the hardware can, for example, take the form of integrated circuits that are manufactured or configured to perform one or more operations in the flowcharts or block diagrams. When implemented as a combination of program code and hardware, the implementation may take the form of firmware. Each block in the flowcharts or the block diagrams can be implemented using special purpose hardware systems that perform the different operations or combinations of special purpose hardware and program code run by the special purpose hardware.

In some alternative implementations of an illustrative embodiment, the function or functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be performed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved. Also, other blocks may be added in addition to the illustrated blocks in a flowchart or block diagram. For example, although forming the set of additional markers in operation <NUM> is shown as being performed before cutting the composite ply in operation <NUM> in <FIG>, these operations can be performed in reverse order. As another example, the different operations illustrated in <FIG> can be performed in different orders from the one depicted in the flowchart in <FIG>. Additionally, two or more of these operations can be performed in parallel.

With reference now to <FIG>, an illustration of a block diagram of a composite part manufacturing environment is depicted in accordance with an illustrative embodiment. The different components and operations shown and described in <FIG> can be implemented in composite part manufacturing environment <NUM>.

In this illustrative example, composite manufacturing system <NUM> can operate to manufacture composite part <NUM> for platform <NUM>. As depicted, composite manufacturing system <NUM> in <FIG> is one implementation of fabrication equipment <NUM> in composite manufacturing system <NUM>.

In this illustrative example, platform <NUM> can take a number. For example, platform <NUM> can be selected from a group comprising a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, a space-based structure, an aircraft, a commercial aircraft, a rotorcraft, a tilt-rotor aircraft, a tilt wing aircraft, a vertical takeoff and landing aircraft, an electrical vertical takeoff and landing vehicle, a personal air vehicle, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, a building, and other suitable types of platforms.

Composite part <NUM> for platform <NUM> can also take a number of different forms. For example, composite part <NUM> can be selected from at least one of a skin panel, a stringer, a wing, a wing box, a nacelle, a fuselage section, a door, a panel, a control surface, a vertical stabilizer, a horizontal stabilizer, a rudder, and elevator, aileron, a vehicle hood, a wall panel, a pipe, a composite sandwich panel, and other suitable types of composite parts for use in platform <NUM>.

In this illustrative example, composite manufacturing system <NUM> comprises a number of different components. As depicted, composite manufacturing system <NUM> includes fabrication equipment <NUM>, computer system <NUM>, and fabrication controller <NUM>.

Fabrication equipment <NUM> is physical equipment and can include physical machines or devices that can be used to perform operations in manufacturing composite part <NUM>. In this illustrative example, fabrication equipment <NUM> can include automated manufacturing equipment <NUM>. Automated manufacturing equipment <NUM> is a hardware system and can include software. Automated manufacturing equipment can perform tasks without needing input or instructions from a human operator. Automated manufacturing equipment <NUM> can include circuits such as a processor unit, an application specific integrated circuit (ASIC), or other hardware that is configured or designed to enable performance of the tasks. This hardware can be programmable and can be, for example, a computer numeric control (CNC) machine.

For example, automated manufacturing equipment <NUM> can be a machine that cuts composite ply <NUM>. For example, automated manufacturing equipment <NUM> can be a cutting machine that employs a cutter such as an electric oscillating knife, an ultrasonic knife, a laser cutter, a kit cutting machine, a drag knife, a driven rotary blade, or other suitable type of machine that can be automated to cut composite ply <NUM>.

As another example, automated manufacturing equipment <NUM> can still be an automated fiber placement (AFP) machine such as a pick and place robot that operates to move or position composite ply <NUM>. In another illustrative example, automated manufacturing equipment <NUM> can be an inkjet printer or ink jet robot that can print on composite ply <NUM>.

In yet another example, automated manufacturing equipment <NUM> can be a multifunction machine. For example, automated manufacturing equipment <NUM> can perform cutting and marking operations. For example, automated manufacturing equipment <NUM> can comprise a flatbed with a gantry having a multifunction tool having a cutter and a marker.

In this illustrative example, composite ply <NUM> can be comprised of fibers in which resin can be infused and cured to form composite part <NUM>. In the illustrative examples, composite ply <NUM> can already have resin infused such that composite ply <NUM> can be a layer of prepreg.

These fibers can be, for example, a carbon fiber. The fibers can also be used in addition to or in place of the carbon fiber, such as fiberglass fibers, para-aramid fibers, aramid fibers, or other suitable fibers that can be used to form composite ply <NUM>. In an illustrative example, many layers of composite by <NUM> can be laid out in different orientations and cured different shapes to form composite part <NUM>. Composite ply <NUM> can be laid up by itself or with other plies to form a face sheet with a core material between the two face sheets to form a composite sandwich for composite part <NUM>.

In the illustration of example, fabrication equipment <NUM> can also include a charge layup system, a conveyor, an autoclave, an oven, a lathe, a paint application system, or other suitable pieces of equipment that can be operated to manufacture composite part <NUM>. These other types of fabrication equipment <NUM> may or may not be automated.

As depicted, fabrication controller <NUM> is located in computer system <NUM>. Fabrication controller <NUM> can be implemented in software, hardware, firmware, or a combination thereof. When software is used, the operations performed by fabrication controller <NUM> can be implemented in program code configured to run on hardware, such as a processor unit. When firmware is used, the operations performed by fabrication controller <NUM> can be implemented in program code and data and stored in persistent memory to run on a processor unit. When hardware is employed, the hardware can include circuits that operate to perform the operations in fabrication controller <NUM>.

In the illustrative examples, the hardware can take a form selected from at least one of a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware configured to perform a number of operations. With a programmable logic device, the device can be configured to perform the number of operations. The device can be reconfigured at a later time or can be permanently configured to perform the number of operations. Programmable logic devices include, for example, a programmable logic array, a programmable array logic, a field programmable logic array, a field programmable gate array, and other suitable hardware devices. Additionally, the processes can be implemented in organic components integrated with inorganic components and can be comprised entirely of organic components excluding a human being. For example, the processes can be implemented as circuits in organic semiconductors.

As used herein, a "number of" when used with reference items means one or more items. For example, a number of operations is one or more operations.

Computer system <NUM> is a physical hardware system and includes one or more data processing systems. When more than one data processing system is present in computer system <NUM>, those data processing systems are in communication with each other using a communications medium. The communications medium can be a network. The data processing systems can be selected from at least one of a computer, a server computer, a tablet computer, or some other suitable data processing system. Computer system <NUM> can be configured to perform at least one of the steps, operations, or actions described in the different illustrative examples using software, hardware, firmware, or a combination thereof.

In this illustrative example, program <NUM> can be example of an implementation for fabrication controller <NUM> when fabrication controller <NUM> takes the form of software.

In this illustrative example, fabrication controller <NUM> can perform one or more of the different operations illustrated in the flowcharts in <FIG>.

As depicted, fabrication controller <NUM> can control fabrication equipment <NUM> to cut composite ply <NUM> to have shape <NUM> defined by ply shape model <NUM> for composite part <NUM> using automated manufacturing equipment <NUM>. In this illustrative example, ply shape model <NUM> is information readable by fabrication controller <NUM>. Ply shape model <NUM> can be, for example, a computer-aided design (CAD) model that defines shape <NUM> for composite ply <NUM>.

Additionally, ply shape model <NUM> can also identify a set of reference locations <NUM> on composite ply <NUM>. As used herein, a "set of" when used with reference to items means one or more items. For example, a set of reference locations is one or more reference locations.

Thus, with this information, ply shape model <NUM> contains information that can be used to cut composite ply <NUM>, create a set of fiducial markers <NUM> on composite ply <NUM>, or both cut composite ply <NUM> and create a set of fiducial markers on composite ply <NUM>.

Fabrication controller <NUM> can control fabrication equipment <NUM> to create a set of fiducial markers <NUM> at the set of reference locations <NUM> on composite ply <NUM> using automated manufacturing equipment <NUM>. In this illustrative example, fabrication controller <NUM> can identify the set of reference locations <NUM> for the set of fiducial markers <NUM> on composite ply <NUM> from ply shape model <NUM> for composite part <NUM>.

In illustrative example, composite ply <NUM> can be cut to add shape <NUM> defined by ply shape model <NUM> using tool <NUM> in automated manufacturing equipment <NUM> and the set of fiducial markers <NUM> can be created at the set of reference locations <NUM> with tool <NUM>. For example, tool <NUM> can be cutter <NUM> controlled by fabrication controller <NUM> can be a laser cutter and an inkjet printhead in a multifunction tool in automated manufacturing equipment <NUM> in which the tool can move along an x axis on a bridge or gantry with the bridge or gantry being movable along a y-axis.

In another illustrative example, tool <NUM> can marker <NUM> controlled by fabrication controller <NUM> to create the set of fiducial markers <NUM>. Tool <NUM> can be, for example, an ink pen, inkjet printer, a sticker applicator, or some other device capable of creating a set of fiducial markers <NUM>. In one illustrative example, tool <NUM> can be a hybrid tool containing both a cutter and a marker.

In another example, cutting tool <NUM> can be end effector <NUM>. In one illustrative example, end effector <NUM> can comprise an ultrasonic knife and an ink pen on a robotic arm in automated manufacturing equipment <NUM>.

In illustrative example, the set of fiducial markers <NUM> can be created in a number of different ways. For example, creating the set of fiducial markers <NUM> at the set of reference locations <NUM> on composite ply <NUM> is performed by fabrication controller <NUM> controlling fabrication equipment <NUM> to create the set of fiducial markers <NUM> at the set of reference locations <NUM> on composite ply <NUM> after cutting composite ply <NUM> to have shape <NUM> defined by ply shape model <NUM>. In another illustrative example, fabrication controller <NUM> can control fabrication equipment <NUM> to create the set of fiducial markers <NUM> at the set of reference locations <NUM> on composite ply <NUM> prior to cutting composite ply <NUM> to have shape <NUM> defined by ply shape model <NUM>.

In creating the set of fiducial markers <NUM> at the set of reference locations <NUM> on composite ply <NUM>, fabrication controller <NUM> can control fabrication equipment <NUM> to create the set of fiducial markers <NUM> directly on composite ply <NUM> at the set of reference locations <NUM>. In another illustrative example, fabrication controller <NUM> can control fabrication equipment <NUM> to create the set of fiducial markers <NUM> directly on backing <NUM> for composite ply <NUM> at the set of reference locations <NUM>. In this case, the set of fiducial markers <NUM> is performed indirectly on composite ply <NUM>.

In this illustrative example, the set of fiducial markers <NUM> can take a number of different forms. For example, the set of fiducial markers <NUM> can be comprised from least one of an ink, a reflective ink, a magnetic ink, a sticker, a paint, a liquid chalk, or some other suitable marketing mechanism.

In illustrative example, after cutting composite ply <NUM> and creating a set of fiducial markers <NUM> at the set of reference locations <NUM>, fabrication controller <NUM> can control fabrication equipment <NUM> to perform a set of manufacturing operations <NUM> with composite ply <NUM> having shape <NUM> using the set of fiducial markers <NUM> at the set of reference locations <NUM> on composite ply <NUM>.

For example, fabrication controller <NUM> can control fabrication equipment <NUM> to perform a set of manufacturing operations <NUM>. In performing the set of manufacturing operations <NUM>, fabrication controller <NUM> can control placement tool <NUM> in fabrication equipment <NUM> to perform pick operation <NUM> that picks up composite ply <NUM> from current position <NUM> and places composite ply <NUM> in desired position <NUM> using the set of fiducial markers <NUM>. In this illustrative example, desired position <NUM> can be location in three-dimensional space. For example, desired position <NUM> can be described using the Cartesian coordinate system. Additionally, desired position <NUM> can also identify in orientation for composite ply <NUM>.

In another illustrative example, fabrication controller <NUM> can identify current position <NUM> for a set of fiducial markers <NUM> on composite ply <NUM> using sensor system <NUM>. Fabrication controller <NUM> can generate instructions <NUM> for placement device <NUM> to move an end effector on placement device <NUM> from current position <NUM> to a desired position <NUM> with respect to the set of fiducial markers <NUM>. This desired position can be a position such that the end effector can pickup composite ply <NUM> on which the set of fiducial markers <NUM> are located.

In the illustrative example, fabrication controller <NUM> can generate instructions <NUM> can be generated to perform a number of manufacturing operations <NUM>. Instructions <NUM> include at least one of code, commands, or data that can be used by automated manufacturing equipment <NUM> to perform manufacturing operations <NUM>.

For example, fabrication controller <NUM> can generate instructions <NUM> for placement device <NUM> to move the composite ply <NUM> having shape <NUM> from current position <NUM> to a desired position <NUM>. In another illustrative example, fabrication controller <NUM> can generate instructions <NUM> for placement device <NUM> to perform pick operation <NUM> that picks up composite ply <NUM> from current position <NUM> and places composite ply <NUM> in desired position <NUM>. In yet another illustrative example, fabrication controller <NUM> can generate instructions <NUM> for placement device <NUM> to place composite ply <NUM> in desired position <NUM> on another composite ply <NUM> as part of forming composite charge <NUM>.

In yet another illustrative example, fabrication controller <NUM> can generate instructions <NUM> for placement device <NUM> to place composite ply <NUM> on layup tool <NUM>. In this illustrative example, layup tool <NUM> can be a component in fabrication equipment <NUM> and can be, for example, a charge layup tool, a mandrel, a cure mandrel, or some other tool that can be used to process composite ply <NUM> to form composite part <NUM>.

In this illustrative example, fabrication controller <NUM> can control the operation of fabrication equipment <NUM> including automated manufacturing equipment <NUM> utilizing program <NUM>. Program <NUM> can be, for example, a computer numerical control (CNC) program or some other suitable program code that may be used to control the operation of fabrication equipment <NUM> including automated manufacturing equipment <NUM>.

As depicted, sensor system <NUM> is a physical hardware system that detects information about fabrication equipment <NUM> including automated manufacturing equipment <NUM>, the environment around fabrication equipment <NUM> including automated manufacturing equipment <NUM>, or both, to generate sensor data <NUM>. Sensor system <NUM> can be comprised of at least one of a camera system, a laser sensor, an ultrasonic sensor, a light detection and ranging scanner, an encoder, a rotary encoder, a temperature sensor, a pressure sensor, an accelerometer, or some other suitable type of sensor.

Sensor system <NUM> can generate sensor data <NUM> about the operation of fabrication equipment <NUM> including automated manufacturing equipment <NUM>. Sensor data <NUM> can be used by fabrication controller <NUM> to control the operation of fabrication equipment <NUM> including automated manufacturing equipment <NUM>. In this illustrative example, a portion or all of sensor system <NUM> can be associated or connected to automated manufacturing equipment <NUM>, such a as placement device <NUM>.

For example, sensor system <NUM> can comprise a camera located on in end effector <NUM> of placement device <NUM>. With this example implementation, end effector <NUM> be moved by fabrication controller <NUM> sending instructions <NUM> to placement device <NUM> until the set of fiducial markers <NUM> are in a selected position within the field of view of the camera in sensor system <NUM>.

For example, the set of fiducial markers <NUM> can be centered within the image in sensor data <NUM> generated by a camera on sensor system <NUM>. In this depicted, example, the set of fiducial markers <NUM> position can be identified within ply shape model <NUM>. When the set of fiducial markers <NUM> are in the correct location within the image, then the coordinates of the set of fiducial markers <NUM> can be determined with respect a camera coordinate system for the camera in sensor system <NUM>. A transform can be used to transform the coordinates in the camera coordinate system into coordinates for a base coordinate system of the base of the robotic arm. Another transform is present for transforming the ordinance from the base coordinate system into coordinates for the end effector coordinate system.

In yet another illustrative example, the camera in sensor system <NUM> may be located in another location other than on in end effector <NUM>. In this example, camera can be located such the camera can generate images of end effector <NUM>, the set of fiducial markers <NUM>, and desired position <NUM> such as on layup tool <NUM>. In this example, an image can be of composite ply <NUM> in a position in the camera coordinate system. A transform can made to transform the coordinates into the coordinate system for end effector <NUM>.

In this manner, a ply in the effector line in three dimensions can be determined. With this information, end effector <NUM> can be moved to pick up ply <NUM> from current position <NUM>. A similar process can be used to move composite ply <NUM> from current position <NUM> to a desired position <NUM>, such as on layup tool <NUM> or on another composite ply <NUM>.

The illustration of composite part manufacturing environment <NUM> in <FIG> is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the ones illustrated may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in an illustrative embodiment.

For example, the set of manufacturing operations <NUM> can take other forms in addition to the set of manufacturing operations <NUM> described in the different illustrative examples. For example, the set of manufacturing operations <NUM> can also include laying up composite ply <NUM> with other composite plies to form a charge or composite preform. As another example, the set of manufacturing operations <NUM> can include infusing a resin into composite ply <NUM>.

Turning now to <FIG>, an illustration of a block diagram of a data processing system is depicted in accordance with an illustrative embodiment. Data processing system <NUM> can be used to implement computer <NUM> in <FIG> and computer system <NUM> in <FIG>. In this illustrative example, data processing system <NUM> includes communications framework <NUM>, which provides communications between processor unit <NUM>, memory <NUM>, persistent storage <NUM>, communications unit <NUM>, input/output (I/O) unit <NUM>, and display <NUM>. In this example, communications framework <NUM> takes the form of a bus system.

Processor unit <NUM> serves to execute instructions for software that can be loaded into memory <NUM>. Processor unit <NUM> includes one or more processors. For example, processor unit <NUM> can be selected from at least one of a multicore processor, a central processing unit (CPU), a graphics processing unit (GPU), a physics processing unit (PPU), a digital signal processor (DSP), a network processor, or some other suitable type of processor. Further, processor unit <NUM> can may be implemented using one or more heterogeneous processor systems in which a main processor is present with secondary processors on a single chip. As another illustrative example, processor unit <NUM> can be a symmetric multi-processor system containing multiple processors of the same type on a single chip.

Memory <NUM> and persistent storage <NUM> are examples of storage devices <NUM>. A storage device is any piece of hardware that is capable of storing information, such as, for example, without limitation, at least one of data, program code in functional form, or other suitable information either on a temporary basis, a permanent basis, or both on a temporary basis and a permanent basis. Storage devices <NUM> may also be referred to as computer-readable storage devices in these illustrative examples. Memory <NUM>, in these examples, can be, for example, a random-access memory or any other suitable volatile or non-volatile storage device. Persistent storage <NUM> can take various forms, depending on the particular implementation.

For example, persistent storage <NUM> may contain one or more components or devices. For example, persistent storage <NUM> can be a hard drive, a solid-state drive (SSD), a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by persistent storage <NUM> also can be removable. For example, a removable hard drive can be used for persistent storage <NUM>.

Communications unit <NUM>, in these illustrative examples, provides for communications with other data processing systems or devices. In these illustrative examples, communications unit <NUM> is a network interface card.

Input/output unit <NUM> allows for input and output of data with other devices that can be connected to data processing system <NUM>. For example, input/output unit <NUM> can provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, input/output unit <NUM> can send output to a printer. Display <NUM> provides a mechanism to display information to a user.

Instructions for at least one of the operating systems, applications, or programs can be located in storage devices <NUM>, which are in communication with processor unit <NUM> through communications framework <NUM>. The processes of the different embodiments can be performed by processor unit <NUM> using computer-implemented instructions, which can be located in a memory, such as memory <NUM>.

These instructions are program instructions and are also referred to as program code, computer usable program code, or computer-readable program code that can be read and executed by a processor in processor unit <NUM>. The program code in the different embodiments can be embodied on different physical or computer-readable storage media, such as memory <NUM> or persistent storage <NUM>.

Program code <NUM> is located in a functional form on computer-readable media <NUM> that is selectively removable and can be loaded onto or transferred to data processing system <NUM> for execution by processor unit <NUM>. Program code <NUM> and computer-readable media <NUM> form computer program product <NUM> in these illustrative examples. In the illustrative example, computer-readable media <NUM> is computer-readable storage media <NUM>.

Computer-readable storage media <NUM> is a physical or tangible storage device used to store program code <NUM> rather than a media that propagates or transmits program code <NUM>. Computer readable storage media <NUM>, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.

Alternatively, program code <NUM> can be transferred to data processing system <NUM> using a computer-readable signal media. The computer-readable signal media are signals and can be, for example, a propagated data signal containing program code <NUM>. For example, the computer-readable signal media can be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals can be transmitted over connections, such as wireless connections, optical fiber cable, coaxial cable, a wire, or any other suitable type of connection.

Further, as used herein, "computer-readable media <NUM>" can be singular or plural. For example, program code <NUM> can be located in computer-readable media <NUM> in the form of a single storage device or system. In another example, program code <NUM> can be located in computer-readable media <NUM> that is distributed in multiple data processing systems. In other words, some instructions in program code <NUM> can be located in one data processing system while other instructions in program code <NUM> can be located in another data processing system. For example, a portion of program code <NUM> can be located in computer-readable media <NUM> in a server computer while another portion of program code <NUM> can be located in computer-readable media <NUM> located in a set of client computers.

The different components illustrated for data processing system <NUM> are not meant to provide architectural limitations to the manner in which different embodiments can be implemented. In some illustrative examples, one or more of the components may be incorporated in or otherwise form a portion of, another component. For example, memory <NUM>, or portions thereof, can be incorporated in processor unit <NUM> in some illustrative examples. The different illustrative embodiments can be implemented in a data processing system including components in addition to or in place of those illustrated for data processing system <NUM>. Other components shown in <FIG> can be varied from the illustrative examples shown. The different embodiments can be implemented using any hardware device or system capable of running program code <NUM>.

Illustrative embodiments of the disclosure may be described in the context of aircraft manufacturing and service method <NUM> as shown in <FIG> and aircraft <NUM> as shown in <FIG>. Turning first to <FIG>, an illustration of an aircraft manufacturing and service method is depicted in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method <NUM> may include specification and design <NUM> of aircraft <NUM> in <FIG> and material procurement <NUM>.

During production, component and subassembly manufacturing <NUM> and system integration <NUM> of aircraft <NUM> in <FIG> takes place. Thereafter, aircraft <NUM> in <FIG> can go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service <NUM> by a customer, aircraft <NUM> in <FIG> is scheduled for routine maintenance and service <NUM>, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method <NUM> may be performed or carried out by a system integrator, a third party, an operator, or some combination thereof.

With reference now to <FIG>, an illustration of a block diagram of an aircraft is depicted in which an illustrative embodiment may be implemented. In this example, aircraft <NUM> is produced by aircraft manufacturing and service method <NUM> in <FIG> and may include airframe <NUM> with plurality of systems <NUM> and interior <NUM>. Examples of systems <NUM> include one or more of propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, different illustrative embodiments may be applied to other industries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method <NUM> in <FIG>.

In one illustrative example, components or subassemblies produced in component and subassembly manufacturing <NUM> in <FIG> can be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft <NUM> is in service <NUM> in <FIG>. As yet another example, one or more apparatus embodiments, method embodiments, or a combination thereof can be utilized during production stages, such as component and subassembly manufacturing <NUM> and system integration <NUM> in <FIG>. One or more apparatus embodiments, method embodiments, or a combination thereof may be utilized while aircraft <NUM> is in service <NUM>, during maintenance and service <NUM> in <FIG>, or both. The use of a number of the different illustrative embodiments may substantially expedite the assembly of aircraft <NUM>, reduce the cost of aircraft <NUM>, or both expedite the assembly of aircraft <NUM> and reduce the cost of aircraft <NUM>.

For example, composite manufacturing system <NUM> in <FIG> and composite manufacturing system <NUM> in <FIG> can be used during component and subassembly manufacturing <NUM> to manufacture composite parts. The use of additional markers can reduce the amount of rework or discarding of composite parts or charges or preforms for composite parts. As another example, composite manufacturing system <NUM> in <FIG> and composite manufacturing system <NUM> in <FIG> can be used during maintenance and service <NUM> to manufacture composite parts for various maintenance and service operations that may include modification, reconfiguration, refurbishment, and other maintenance or service.

Turning now to <FIG>, an illustration of a block diagram of a product management system is depicted in accordance with an illustrative embodiment. Product management system <NUM> is a physical hardware system. In this illustrative example, product management system <NUM> includes at least one of manufacturing system <NUM> or maintenance system <NUM>.

Manufacturing system <NUM> is configured to manufacture products, such as aircraft <NUM> in <FIG>. As depicted, manufacturing system <NUM> includes manufacturing equipment <NUM>. Manufacturing equipment <NUM> includes at least one of fabrication equipment <NUM> or assembly equipment <NUM>.

Fabrication equipment <NUM> is equipment that is used to fabricate components for parts used to form aircraft <NUM> in <FIG>. For example, fabrication equipment <NUM> can include machines and tools. These machines and tools can be at least one of a drill, a hydraulic press, a furnace, a mold, a composite tape laying machine, a vacuum system, a lathe, or other suitable types of equipment. Fabrication equipment <NUM> can be used to fabricate at least one of metal parts, composite parts, semiconductors, circuits, fasteners, ribs, skin panels, spars, antennas, or other suitable types of parts.

Assembly equipment <NUM> is equipment used to assemble parts to form aircraft <NUM> in <FIG>. In particular, assembly equipment <NUM> is used to assemble components and parts to form aircraft <NUM> in <FIG>. Assembly equipment <NUM> also can include machines and tools. These machines and tools may be at least one of a robotic arm, a crawler, a faster installation system, a rail-based drilling system, or a robot. Assembly equipment <NUM> can be used to assemble parts such as seats, horizontal stabilizers, wings, engines, engine housings, landing gear systems, and other parts for aircraft <NUM> in <FIG>.

In this illustrative example, maintenance system <NUM> includes maintenance equipment <NUM>. Maintenance equipment <NUM> can include any equipment needed to perform maintenance on aircraft <NUM> in <FIG>. Maintenance equipment <NUM> may include tools for performing different operations on parts on aircraft <NUM> in <FIG>. These operations can include at least one of disassembling parts, refurbishing parts, inspecting parts, reworking parts, manufacturing replacement parts, or other operations for performing maintenance on aircraft <NUM> in <FIG>. These operations can be for routine maintenance, inspections, upgrades, refurbishment, or other types of maintenance operations.

In the illustrative example, maintenance equipment <NUM> may include ultrasonic inspection devices, x-ray imaging systems, vision systems, drills, crawlers, and other suitable devices. In some cases, maintenance equipment <NUM> can include fabrication equipment <NUM>, assembly equipment <NUM>, or both to produce and assemble parts that needed for maintenance.

Product management system <NUM> also includes control system <NUM>. Control system <NUM> is a hardware system and may also include software or other types of components. Control system <NUM> is configured to control the operation of at least one of manufacturing system <NUM> or maintenance system <NUM>. In particular, control system <NUM> can control the operation of at least one of fabrication equipment <NUM>, assembly equipment <NUM>, or maintenance equipment <NUM>.

The hardware in control system <NUM> can be implemented using hardware that may include computers, circuits, networks, and other types of equipment. The control may take the form of direct control of manufacturing equipment <NUM>. For example, robots, computer-controlled machines, and other equipment can be controlled by control system <NUM>. In other illustrative examples, control system <NUM> can manage operations performed by human operators <NUM> in manufacturing or performing maintenance on aircraft <NUM>. For example, control system <NUM> can assign tasks, provide instructions, display models, or perform other operations to manage operations performed by human operators <NUM>. In these illustrative examples, program <NUM> in <FIG> and fabrication controller <NUM> in <FIG> can be implemented in control system <NUM> to manage at least one of the manufacturing or maintenance of aircraft <NUM> in <FIG>. For example, at least one of program <NUM> in <FIG> or fabrication controller <NUM> in <FIG> can operate to control the manufacture composite parts using fabrication equipment <NUM> in manufacturing equipment <NUM>.

In the different illustrative examples, human operators <NUM> can operate or interact with at least one of manufacturing equipment <NUM>, maintenance equipment <NUM>, or control system <NUM>. This interaction can occur to manufacture aircraft <NUM> in <FIG>.

Of course, product management system <NUM> may be configured to manage other products other than aircraft <NUM> in <FIG>. Although product management system <NUM> has been described with respect to manufacturing in the aerospace industry, product management system <NUM> can be configured to manage products for other industries. For example, product management system <NUM> can be configured to manufacture products for the automotive industry as well as any other suitable industries.

Thus, in one or more illustrative examples, the final position of a composite ply can be a combination of the accuracy of the creating of fiducial markers onto the composite ply, final robot accuracy and the tolerances of the boundaries. Fiducial markers in the different illustrative examples are easier to implement and more accurate than other approaches such as those using boundaries for determining movement of each component. In the illustrative examples, the composite ply can be cut to a desired shape, and the fiducial maker on that composite ply with the desired shape can be created in the same location, such as in the same cell and on the same cutting machine. Further, determining locations using fiducial markers is simpler as compared to extracting boundaries because boundaries of the composite plies can be fluffy or have loose threads.

Additionally, with the use of additional markers, the field of view of the camera is much smaller when only the section of the composite ply with the fiducial makers needs to be inspected as compared to the entire composite ply boundaries being used. As a result, the use of fiducial markers can result in a better pixels/mm resolution as compared to current techniques using boundaries. In other words, a greater density of pixels can be present in an image with fiducial markers as compared to an image using ply boundaries.

The description of the different illustrative embodiments has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the embodiments in the form disclosed. The different illustrative examples describe components that perform actions or operations. In an illustrative embodiment, a component can be configured to perform the action or operation described. For example, the component can have a configuration or design for a structure that provides the component an ability to perform the action or operation that is described in the illustrative examples as being performed by the component. Further, to the extent that terms "includes", "including", "has", "contains", and variants thereof are used herein, such terms are intended to be inclusive in a manner similar to the term "comprises" as an open transition word without precluding any additional or other elements.

Claim 1:
A method for manufacturing a composite part (<NUM>), the method comprising:
identifying (<NUM>) a set of reference locations (<NUM>) for a set of fiducial markers (<NUM>) on a composite ply (<NUM>) from a ply shape model (<NUM>) for the composite part (<NUM>);
forming (<NUM>), with a marker of an end effector, the set of fiducial markers (<NUM>) at the set of reference locations (<NUM>) on the composite ply (<NUM>); and
cutting (<NUM>), with a cutter of the end effector, the composite ply (<NUM>) to have a shape (<NUM>) defined by the ply shape model (<NUM>).