Abstract: A method that prepares data for analysis includes displaying a user interface that includes a data a data flow pane that displays a flow diagram having a plurality of nodes, each node specifying a respective primary operation, a change list pane corresponding to a user-selected node in the data flow pane, and a data pane that displays a plurality of rows for an intermediate dataset of the user-selected node. The method also includes, in response to receiving a user input to perform a secondary operation at the user-selected node: (i) displaying, in the change list pane, an ordered list of secondary operations performed at the user-selected node, including displaying the secondary operation, and (ii) updating the data pane in accordance with the secondary operation, including updating the plurality of rows for the intermediate dataset.

Abstract: An illustrative example of the present disclosure provides a method. A first set of composite plies including a first outer ply of a first composite structure is laid up. A first intermediate surface of the first outer ply is measured to form a first set of measurements. A laydown surface for a tool path of a composite placement machine is modified to form a modified tool path, wherein modifying the laydown surface comprises modifying the laydown surface such that a laydown surface of the modified tool path matches the first set of measurements. A composite ply is laid down using the composite placement machine and the modified tool path.

Abstract: An apparatus is provided for peeling a liner away from a substrate. The apparatus comprises a first member rotatable about an axis. The apparatus also comprises a second member disposed on the first member and for generating a suction force to be applied to the liner to peel a portion of the liner away from the substrate when the suction force of the second member is applied to the liner and the first member is rotating about its axis. The apparatus further comprises a third member synchronized to rotation of the first member about its axis such that the third member clamps the peeled portion of the liner against the first member while the second member is applying suction force to the liner and the first member is rotating about its axis.

Abstract: A method prepares data for analysis. The method displays a user interface including a data flow pane. The data flow pane includes a flow diagram having a plurality of nodes, each node having an intermediate set and specifying a primary operation. When a user selects a node, the user interface displays a change list pane with an ordered list of secondary operations performed at the node and a data pane with rows from an intermediate dataset of the node. When the user provides input to perform an additional secondary operation at the node, the user interface (i) performs the additional secondary operation, (ii) determines a logical ordering for the additional secondary operation based on the primary operation of the node, (iii) adds the additional secondary operation to the change list pane according to the logical ordering, and (iv) updates the data pane in accordance with the additional secondary operation.

Abstract: A process and system for improving surface quality of composite structures, including laying up a first set of composite plies including a first outer ply of a first composite structure. A first intermediate surface of the first outer ply is measured to form a first set of measurements. A laydown surface for a tool path of a composite placement machine is modified to form a modified tool path, wherein modifying the laydown surface comprises modifying the laydown surface such that a laydown surface of the modified tool path matches the first set of measurements. A composite ply is laid down using the composite placement machine and the modified tool path.

Abstract: A method compares data sets in a data preparation application. The method displays a user interface including a flow diagram having a plurality of nodes. Each of the nodes corresponds to a data set having a plurality of data fields. A user selects two nodes from the flow diagram. In response to the user selection, the method forms a composite data set comprising a union of two data sets corresponding to the two nodes and groups data values for each of a plurality of data fields in the composite data set to form a respective set of bins. The method then displays distributions of data values for the plurality of data fields in the composite data set. Each distribution comprises the respective set of bins for a respective data field. Each displayed bin depicts counts of data values in the respective bin originating from each of the two data sets.

Abstract: Systems and methods are provided for dynamically managing heater position for an Automated Fiber Placement (AFP) machine. One embodiment is a method that includes retrieving distance data indicating predicted distances of a heating surface of a heater of the AFP machine to a surface of a laminate being laid-up by the AFP machine, for each of multiple locations along a path. The method also includes directing the AFP machine to lay up the laminate in accordance with a Numerical Control (NC) program, identifying a current location of the heater in the path, determining a speed at which the heater of the AFP machine is moving, correlating the current location of the heater with a predicted distance, and adjusting an amount of power for the heater at the current location based on the predicted distance that was correlated with the current location, and the speed at the current location.

Abstract: Closed-loop systems and methods for controlling the temperature at the compaction point as an automated fiber placement (AFP) machine is placing material over complex surface features at varying speeds. The closed-loop system starts with multiple infrared temperature sensors directed at the layup surface in front of the compaction roller and also at the new layup surface behind the compaction roller. These sensors supply direct temperature readings to a control computer, which also receives speed data and a listing of active tows from the AFP machine and is also programmed with the number of plies in the current layup. In accordance with one embodiment, the heater control system uses a proportional-integral-derivative loop to control the temperature at the compaction point (e.g., at the interface of the compaction roller and a newly laid tow) and regulate the heater power to achieve the desired temperature.

Abstract: An infrared camera is directed aft of a compaction roller of a composite laying head. Heat is applied to a substrate by a heater mounted forward of the compaction roller. Infrared images are captured of composite tows laid down on a substrate by the compaction roller. Whether the composite tows have sufficient contact is determined using the infrared images.

Abstract: A method compares data sets in a data preparation application. The method displays a user interface including a data flow pane and a profile pane. The data flow pane displays a flow diagram with nodes, each node corresponding to a data set. When a user selects a first node, the method displays distributions of data values for data fields from a first data set for the first node. When a user selects a second node, the method: (1) forms a composite data set comprising a union of (i) the first data set and (ii) a second data set for the second node; (2) groups data values for each data field to form sets of bins; and (3) displays data value distributions for each data field using the bins. Each bin depicts counts of data values in the bin originating from the first data set and the second data set.

Abstract: An end effector transports, places and forms a composite ply on a tool having complex tool surfaces. The end effector includes a combination of vacuum and Bernoulli grippers for holding the composite ply while it is being transported and formed, and a set of mechanical actuators that form the composite ply down over the tool surfaces. The Bernoulli grippers allow the composite ply to slip while being held and formed.

Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.

Abstract: An article of manufacture comprises a strip that extends along and is centered on a virtual curvilinear path, comprising an arc, having an arc length and a radius. A ratio of the strip-width to the radius is greater than or equal to 0.003. The arc length is equal to or greater than a product of the radius and ?/64. Within each of discrete strip-regions of the strip, one of the unidirectional reinforcement fibers that is closest to the first longitudinal strip-edge is more buckled than another one of the unidirectional reinforcement fibers that is closest to the second longitudinal strip-edge. Ones of the unidirectional reinforcement fibers that are buckled are parallel to a smallest one of virtual surfaces, joining the first longitudinal strip-edge and the second longitudinal strip-edge.

Abstract: An automated fiber-placement method comprises delivering a first quantity of pulsed energy to first portions of at least one fiber-reinforced tape strip, and delivering a second quantity of pulsed energy to second portions of at least the one fiber-reinforced tape strip, alternating with the first portions. Each one of the second portions at least partially overlaps two adjacent ones of the first portions such that overlapping regions of the first portions and the second portions have a higher temperature than non-overlapping regions of the first portions and the second portions. The automated fiber-placement method further comprises laying down at least the one fiber-reinforced tape strip against a substrate along a virtual curvilinear path, such that (i) at least the one fiber-reinforced tape strip is centered on the virtual curvilinear path, and (ii) the overlapping regions are transformed into discrete tape-regions, geometrically different from the overlapping regions.

Abstract: A method prepares data for analysis. The method displays a user interface including a data flow pane. The data flow pane includes a flow diagram having a plurality of nodes, each node having an intermediate set and specifying a primary operation. When a user selects a node, the user interface displays a change list pane with an ordered list of secondary operations performed at the node and a data pane with rows from an intermediate dataset of the node. When the user provides input to perform an additional secondary operation at the node, the user interface (i) performs the additional secondary operation, (ii) determines a logical ordering for the additional secondary operation based on the primary operation of the node, (iii) adds the additional secondary operation to the change list pane according to the logical ordering, and (iv) updates the data pane in accordance with the additional secondary operation.

Abstract: An article of manufacture (200) comprises a strip (202) that extends along and is centered on a virtual curvilinear path (128), comprising an arc (156), having an arc length (154) and a radius (134). A ratio of the strip-width (208) to the radius (134) is greater than or equal to 0.003. The arc length (154) is equal to or greater than a product of the radius (134) and ?/64. Within each of discrete strip-regions (222) of the strip (202), one of the unidirectional reinforcement fibers (132) that is closest to the first longitudinal strip-edge (204) is more buckled than another one of the unidirectional reinforcement fibers (132) that is closest to the second longitudinal strip-edge (206). Ones of the unidirectional reinforcement fibers (132) that are buckled are parallel to a smallest one of virtual surfaces, joining the first longitudinal strip-edge (204) and the second longitudinal strip-edge (206).

Abstract: An automated fiber-placement method comprises delivering a first quantity of pulsed energy to first portions of at least one fiber-reinforced tape strip, and delivering a second quantity of pulsed energy to second portions of at least the one fiber-reinforced tape strip, alternating with the first portions. Each one of the second portions at least partially overlaps two adjacent ones of the first portions such that overlapping regions of the first portions and the second portions have a higher temperature than non-overlapping regions of the first portions and the second portions. The automated fiber-placement method further comprises laying down at least the one fiber-reinforced tape strip against a substrate along a virtual curvilinear path, such that (i) at least the one fiber-reinforced tape strip is centered on the virtual curvilinear path, and (ii) the overlapping regions are transformed into discrete tape-regions, geometrically different from the overlapping regions.

Abstract: An automated fiber-placement method (300) comprises delivering a first quantity of pulsed energy (122) to first discrete portions (124) of at least one fiber-reinforced tape strip (104), and delivering a second quantity of pulsed energy (123) to second discrete portions (125) of at least the one fiber-reinforced tape strip (104), alternating with the first discrete portions (124). The first quantity of pulsed energy (122) heats the first discrete portions (124) to a first temperature. The second quantity of pulsed energy (123) heats the second discrete portions (125) to a second temperature.

Abstract: A composite manufacturing system is provided. The composite manufacturing system comprises a fiber placement head, a compaction roller associated with the fiber placement head, and a temperature regulation system associated with the compaction roller. The temperature regulation system is configured to actively control a temperature of the compaction roller. The temperature regulation system comprises a number of temperature sensors, a cooling system, and a controller. The number of temperature sensors are configured to detect the temperature of the compaction roller. The cooling system is associated with the compaction roller and is configured to cool the compaction roller. The controller is in communication with the number of temperature sensors and the cooling system. The controller is configured to cool the compaction roller such that the temperature is below a threshold temperature.

Abstract: A method prepares data for analysis. The method displays a user interface, which includes multiple panes, including a data flow pane. The data flow pane includes a flow diagram having multiple nodes, each specifying a primary operation and/or multiple secondary operations. Each primary operation retrieves data from a data source, transforms data, or builds an output data set. When a user selects a node, the user interface displays a change list pane, which is an ordered list of secondary operations performed at the node. When the user provides input to perform a secondary operation at the selected node, the user interface (i) performs the secondary operation, (ii) updates the selected node with an indicator that the node includes secondary operations, (iii) determines a logical ordering for the secondary operation based on the primary operation, and (iv) adds the secondary operation to the change list pane according to the logical ordering.