System and methods of generating a computer model of a composite component

• US 10,062,202 B2
• Filed: 12/22/2014
• Issued: 08/28/2018
• Est. Priority Date: 12/22/2014
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Chen-Keat, Teresa Tianshu, Zheng, Li, Kray, Nicholas Joseph, Yang, Pinghai, Fairman, Ruben Egberto, Hartle, Michael Scott
• Primary Examiner(s): Gebresilassie, Kibrom K
• Application Number:
  US14/579,200
• Publication Number:
  US 20160179984A1
• Time in Patent Office: 1,345 Days
• Field of Search: None
• CPC Class Codes: B29C 70/30 Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• CPC Class Codes: G06F 2113/26 Composites
• CPC Class Codes: G06F 30/23 using finite element methods [FEM] or finite difference methods [FDM]
• CPC Class Codes: G06T 17/00 Three dimensional [3D] modelling, e.g. data description of 3D objects

Abstract

A method for generating a computer model of a composite component includes generating a surface mesh based on a ply drop region and a ply curved surface and generating node data including a plurality of node points relative to the ply drop region. The method also includes receiving composite data relating to a plurality of composite plies and generating a three dimensional model based on the composite data. The method further includes receiving layup table information and applying the node data, based on the layup table information, to generate a curve through a center of the surface mesh to define a plurality of element sets. The method also includes receiving composite draping data and determining, based on the draping data, where each element set intersects the three dimensional model. The method also includes analyzing an angle deviation of the plies based on the intersection of the element sets.

Claims

1. A method for generating a composite component using a computing device including at least one processor coupled to a memory device, the computing device being coupled to a layup device including a mandrel, the composite component having a base surface and a predefined ply curved surface formed by a ply of a plurality of composite plies, each ply of the plurality of composite plies having a ply thickness, said method comprising:

defining a ply drop region of the base surface;

generating a surface mesh based on the ply drop region and the ply curved surface;

generating node data including a plurality of node points relative to the ply drop region;

receiving composite data relating to the plurality of composite plies;

generating a three dimensional model based on the composite data;

receiving layup table information;

applying the node data, based on the layup table information, to generate a curve through a center of the surface mesh to define a plurality of element sets;

generating a manufacturing layup sequence for the plurality of composite plies

receiving composite draping data, wherein the composite draping data includes the manufacturing layup sequence;

determining, based on the draping data, where each element set of the plurality of element sets intersects the three dimensional model;

analyzing an angle deviation of a ply of the plurality of plies based on the intersection of the element sets;

and

coupling the plurality of composite plies to the mandrel according to the manufacturing layup sequence.

2. The method of claim 1, wherein receiving composite data comprises receiving registration data relative to a lifting model.

3. The method of claim 1, wherein receiving composite data comprises receiving registration data relative to a bird strike model.

4. The method of claim 1, wherein generating the three dimensional model comprises using composite data which represents a two dimensional model of the ply curved surface.

5. The method of claim 1, wherein receiving layup table information comprises receiving information relating to at least one of layup sequence, a ply orientation, a ply angle, a ply thickness, and a ply geometry.

6. The method of claim 1, wherein receiving composite draping data comprises receiving a hand layup draping angle.

7. The method of claim 1, wherein receiving composite draping data comprises receiving an automated fiber placement draping angle.

8. The method of claim 1, wherein analyzing the angle deviation comprises determining a centroid location of each element set of the plurality of element sets.

9. A device for generating a composite component, the composite component including a base surface, a ply curved surface, and a plurality of composite plies, said device comprising:

a computing device comprising

a memory device configured to store a characteristic of the composite component;

an interface coupled to said memory device and configured to receive said characteristic of the composite component;

a processor coupled to said memory device and said interface device, said processor configured to;

define a ply drop region of the base surface;

generate a surface mesh based on the ply drop region and the ply curved surface;

generate node data including a plurality of node points relative to the ply drop region;

receive composite data relating to the plurality of composite plies;

generate a three dimensional model based on the composite data;

receive layup table information;

apply the node data, based on the layup table information, to generate a curve through a center of the surface mesh to define a plurality of element sets;

generating a manufacturing layup sequence for the plurality of composite plies

receive composite drape data, wherein the composite draping data includes the manufacturing layup sequence;

determine, based on the drape data, where each element set of the plurality of element sets intersects the three dimensional model; and

analyze an angle deviation of a ply of the plurality of plies based on the intersection of the element sets; and

a layup device coupled to the computing device, the layup device comprising a mandrel and a tool configured to apply manufacturing processes to the plurality of composite plies coupled to the mandrel of the layup according to the manufacturing layup sequence.

10. The device of claim 9, wherein the composite data includes registration data relative to a lifting model.

11. The device of claim 9, wherein the composite data includes registration data relative to a bird strike model.

12. The device of claim 9, wherein the layup table information includes information relating to at least one of layup sequence, a ply orientation, a ply angle, a ply thickness, and a ply geometry.

13. The device of claim 9, wherein the composite draping data includes a hand layup draping angle.

14. The device of claim 9, wherein the composite draping data includes an automated fiber placement draping angle.

15. The device of claim 10, wherein said processor is further configured to analyze the angle deviation through determining a centroid location of each element set of the plurality of element sets.