Abstract: A manufacturing system includes a cutting machine, an adhesion machine, and a pick-and-place system. The cutting machine sequentially cuts a continuous length of a unidirectional prepreg into prepreg segments. Each prepreg segment has an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The adhesion machine has a conveyor belt and an adhesion station. The pick-and-place system sequentially picks up the prepreg segments from the cutting machine, and places the prepreg segments in end-to-end relation on the conveyor belt, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The conveyor belt feeds the prepreg segments to the adhesion station. The adhesion station adheres the prepreg segments to a continuous length of a backing material, thereby resulting in a continuous length of a backed cross-ply prepreg.

Abstract: A manufacturing system includes a cutting machine, an adhesion machine, and a pick-and-place system. The cutting machine sequentially cuts a continuous length of a unidirectional prepreg into prepreg segments. Each prepreg segment has an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The adhesion machine has a conveyor belt and an adhesion station. The pick-and-place system sequentially picks up the prepreg segments from the cutting machine, and places the prepreg segments in end-to-end relation on the conveyor belt, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The conveyor belt feeds the prepreg segments to the adhesion station. The adhesion station adheres the prepreg segments to a continuous length of a backing material, thereby resulting in a continuous length of a backed cross-ply prepreg.

Abstract: There is provided a mechanical avatar assembly for use in a confined space in a structure. The mechanical avatar assembly includes a rail assembly for attachment to an access opening to the confined space. The rail assembly includes two or more rail segments coupled together to form an elongated base having a rail and a gear rack extending along a length of the elongated base. The rail assembly further includes a carriage portion coupled to the rail, and movable relative to the rail, and a drive assembly coupled to the carriage portion and to the gear rack, to move the carriage portion along the rail. The mechanical avatar assembly further includes an articulating avatar arm coupled to, and movable via, the carriage portion. The mechanical avatar assembly further includes an image capturing device.

Abstract: An end effector, coupleable to a robot, for delivering a material to a surface, comprises a material applicator assembly, comprising a central shaft and an applicator co-rotatably coupled to the central shaft and configured to apply the material to the surface. The end effector also comprises a material supply carrier, comprising a base and a supply of the material coupled to the base. The material from the supply is feedable to the applicator. The end effector further comprises an actuator that rotatably couples the material supply carrier with the material applicator assembly. The actuator is operable to rotate the material supply carrier relative to the material applicator assembly.

Abstract: Systems and methods are provided for controlling robots and their end effectors. One embodiment is a method for controlling a robot. The method includes: maneuvering a robot via a robot controller that is dedicated to operating the robot, thereby altering a position of an end effector mounted to the robot, communicating from the robot controller to an end effector controller that is disposed at the end effector and is dedicated to operating the end effector, determining a position of the end effector via the end effector controller, and operating the end effector via the end effector controller based on the position of the end effector.

Abstract: Systems and methods are provided for robot control. One embodiment is a method for coordinating operations of robots performing work on a part. The method includes assigning a group of robots to a part, initiating work on the part via the group of robots, determining that a robot within the group is unable to continue performing work at a first location of the part, removing the robot from the group while other robots of the group continue performing the work, adding a functioning robot to the group at a second location that the robot is scheduled to occupy, and continuing work on the part via the group of robots.

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: Disclosed herein is an end effector, coupleable to a robot, for delivering a material to a surface. The end effector comprises a material applicator assembly, comprising a central shaft and an applicator co-rotatably coupled to the central shaft and configured to apply the material to the surface. The end effector also comprises a material supply carrier, comprising a base and a supply of the material coupled to the base. The material from the supply is feedable to the applicator. The end effector further comprises an actuator that rotatably couples the material supply carrier with the material applicator assembly. The actuator is operable to rotate the material supply carrier relative to the material applicator assembly.

Abstract: Systems and methods are provided for robot control. One embodiment is a method for coordinating operations of robots performing work on a part. The method includes assigning a group of robots to a part, initiating work on the part via the group of robots, determining that a robot within the group is unable to continue performing work at a first location of the part, removing the robot from the group while other robots of the group continue performing the work, adding a functioning robot to the group at a second location that the robot is scheduled to occupy, and continuing work on the part via the group of robots.

Abstract: Systems and methods are provided for controlling robots and their end effectors. One embodiment is a method for controlling a robot. The method includes: maneuvering a robot via a robot controller that is dedicated to operating the robot, thereby altering a position of an end effector mounted to the robot, communicating from the robot controller to an end effector controller that is disposed at the end effector and is dedicated to operating the end effector, determining a position of the end effector via the end effector controller, and operating the end effector via the end effector controller based on the position of the end effector.

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: 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: 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: 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 automated ply layup system uses a robot and an end effector for selecting plies from a kit and placing the plies at predetermined locations on a tool by further employing cameras for ply location detection, a laser scanner for detection and ply placement within a location on the tool, and compact sensors for compacting plies onto the tool.

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: Systems and methods for the dynamic control of task assignments in a fabrication process that employs a plurality of machines to fabricate a manufactured component. These systems and methods may include executing a plurality of task assignments with an available portion of the plurality of machines, monitoring a process variable that defines the available portion of the plurality of machines, and adjusting the plurality of task assignments to create a plurality of adjusted task assignments based upon the monitoring. The plurality of task assignments may include a plurality of tasks that are to be completed during fabrication of the manufactured component, and the executing may include initiating a respective task assignment of the plurality of task assignments with each machine in the available portion of the plurality of machines, thereby fabricating at least a portion of the manufactured component.

Abstract: An automated ply layup system uses a robot and an end effector for selecting plies from a kit and placing the plies at predetermined locations on a tool.