Patent Application
20220221845
Composite structures and components (e.g., composite laminates) may comprise multiple layer of fibrous material, each layer in turn including multiple sub-layers or plies installed above the preceding plies or sub-layers atop one or more molds or core materials (e.g., honeycomb cores, pre-preg materials) to form a lightweight yet durable structure. Such composite structures may include aircraft and vehicular interior panels (e.g., seating panels, footrests, doors, aprons, and other interior surfaces) but may also include exterior control surfaces depending upon the selection of materials. As such structural components may involve complex geometries and variances in thickness and/or reinforcement, great care must be taken to ensure accuracy and precision in ply placement. Conventional approaches have evolved from painstaking manual measurement and/or cumbersome manufacturing templates to the use of laser projection. However, laser systems remain expensive and may not be optimally suited for complex geometries or layouts (e.g., scanning multiple molds). Nor are laser projection systems equipped to display ply seating positions or orientations, splice/dart locations, or dress/drape methods for structural components incorporating fabric layers or coverings. Further, if multiple operators are using a laser projection system, the overall pace of assembly will be determined by the slowest operator or task.
Similarly, some composite structures may incorporate bonded assemblies (e.g., thermoforming, co-curing, co-bonding of components), hook-and-loop fasteners, clips, and other like elements by which secondary components may be added to primary components. Currently, incorporating bonded assemblies and fasteners into component assembly requires prototype fixtures which incorporate both a lengthy design and manufacturing process (4 weeks on average) and are vulnerable to subsequent design changes based on assembly revisions. Further, even with extended life cycles these fixtures may be subjected to normal wear and tear as well as adhesive buildup; in addition, they require extensive storage space.
A method for augmented reality (AR) assisted manufactured assembly of composite components is disclosed. In embodiments, the method includes providing an augmented reality (AR; e.g., virtual reality (VR), mixed reality (MR)) viewing device to operators (e.g., participants, observers) involved in a composite structure assembly. The method includes identifying, via the AR viewing devices, the composite structure to be assembled or manufactured, each composite structure having an associated dataset including all sequences of ordered assembly steps for assembling that composite structure. The method includes loading the associated dataset for display and operator interaction via the AR viewing device. For each assembly step of each assembly sequence, the method includes: displaying AR objects via the viewing device, each AR object indicating a placement or orientation of a layer, ply, fastener, or other component to be added relative to any previously assembled components (e.g., based on the current step or sequence and any prior sequences or steps already executed); displaying any operator alerts associated with the current assembly step; accepting control input from the operator via the AR viewing device; and generating a recording verifying the completion of the assembly step. The method includes producing, based on the set of verified assembly steps, a recording verifying the completion of all associated or necessary assembly sequences.
In some embodiments, the composite structure includes a set of composite layers (e.g., a single assembly step may incorporate multiple layers) assembled in sequence over a mold. The method includes displaying, via the AR viewing device, AR objects indicating the placement or orientation of a particular layer or layers.
In some embodiments, each layer may incorporate one or more composite plies, and the method include displaying, via the AR viewing device, AR objects indicating the placement or orientation of a particular ply or plies.
In some embodiments, the method includes displaying, via the AR viewing device, assembly locations associated with the current assembly step, e.g., a splice or dart location.
In some embodiments, the method includes displaying, via the AR viewing device, dress and drape methods associated with the current assembly step.
In some embodiments, the method includes displaying, via the AR viewing device, additional dataset information relevant to the current composite structure, e.g., bills of materials, instructional video clips, and technical drawings and illustrations.
In some embodiments, the method includes identifying, via the AR viewing device, a bonded assembly incorporating multiple sets of fastener components (e.g., hook and loop fasteners, clips) attached to a backing layer. The method includes displaying, via the AR viewing device, AR objects indicative of a placement or orientation of a component or set of components (e.g., fasteners of a certain type added via the current assembly step).
In some embodiments, the method includes identifying the particular composite structure (e.g., or type thereof) via the AR viewing device by scanning the field of view for image targets indicative of the composite structure. For example, image targets may include QR codes or other encoded information attached to a mold or backing layer, a component or part of the composite structure, or a work order for the composite structure. In some embodiments, the method includes identifying the composite structure by scanning or identifying the mold, backing layer, component or part, or work order itself.
In some embodiments, the method includes displaying, via the AR viewing device, instructions for the operator.
In some embodiments, the method includes displaying, via the AR viewing device, operator alerts associated with a curing oven (e.g., for curing layers or plies for subsequent assembly or attachment).
In some embodiments, the method includes displaying, via the AR viewing device, operator alerts associated with a ply cutter (e.g., for cutting of layers or plies for subsequent assembly or attachment).
In some embodiments, the method includes: accepting, via the AR viewing device, control input in the form of spoken instructions from the operator; and determining a current assembly step or sequence based on the spoken instructions.
In some embodiments, the method includes displaying, via the AR viewing device, an interactive menu and accepting control input from the operator via the interactive menu.
In some embodiments, the method includes initiating, via the AR viewing device, the next assembly step of a current assembly sequence based on the received control input, e.g., upon completion of a current or prior assembly step.
This Summary is provided solely as an introduction to subject matter that is fully described in the Detailed Description and Drawings. The Summary should not be considered to describe essential features nor be used to determine the scope of the Claims. Moreover, it is to be understood that both the foregoing Summary and the following Detailed Description are example and explanatory only and are not necessarily restrictive of the subject matter claimed.
The detailed description is described with reference to the accompanying figures. The use of the same reference numbers in different instances in the description and the figures may indicate similar or identical items. Various embodiments or examples (“examples”) of the present disclosure are disclosed in the following detailed description and the accompanying drawings. The drawings are not necessarily to scale. In general, operations of disclosed processes may be performed in an arbitrary order, unless otherwise provided in the claims. In the drawings:
and
Before explaining one or more embodiments of the disclosure in detail, it is to be understood that the embodiments are not limited in their application to the details of construction and the arrangement of the components or steps or methodologies set forth in the following description or illustrated in the drawings. In the following detailed description of embodiments, numerous specific details may be set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art having the benefit of the instant disclosure that the embodiments disclosed herein may be practiced without some of these specific details. In other instances, well-known features may not be described in detail to avoid unnecessarily complicating the instant disclosure.
As used herein a letter following a reference numeral is intended to reference an embodiment of the feature or element that may be similar, but not necessarily identical, to a previously described element or feature bearing the same reference numeral (e.g., 1, 1a, 1b). Such shorthand notations are used for purposes of convenience only and should not be construed to limit the disclosure in any way unless expressly stated to the contrary.
Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
In addition, use of “a” or “an” may be employed to describe elements and components of embodiments disclosed herein. This is done merely for convenience and “a” and “an” are intended to include “one” or “at least one,” and the singular also includes the plural unless it is obvious that it is meant otherwise.
Finally, as used herein any reference to “one embodiment” or “some embodiments” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment disclosed herein. The appearances of the phrase “in some embodiments” in various places in the specification are not necessarily all referring to the same embodiment, and embodiments may include one or more of the features expressly described or inherently present herein, or any combination or sub-combination of two or more such features, along with any other features which may not necessarily be expressly described or inherently present in the instant disclosure.
Broadly speaking, embodiments of the inventive concepts disclosed herein are directed to the use of augmented reality (AR; e.g., virtual reality (VR), mixed reality (MR)) to facilitate component placement during the assembly and bonding of composite structures. Wearable AR devices provide assemblers with holographic overlays of each successive layer of plies or components detailed to indicate and ensure proper alignment, placement, and bonding of each component. Assemblers may interact via the AR devices with the holographic overlays as well as monitor the cutting and curing of plies and components. Further, the AR devices provide quality verification, remote support, and standardized training by capturing each step of the assembly and bonding processes.
Referring to
Referring also to
Due to the variable structure of the aisle panel 102 and footwell panel 104, the ply assembly process (e.g., lay-up process) may be staggered. For example, referring also to
Referring now to
In embodiments, the AR viewing devices 402 may incorporate onboard control processors and data storage (e.g., memory) and/or may be wirelessly linked to a central processing unit 408 incorporating control processors and data storage configured for generating and/or storing assembly sequences 410 for the structural composite panel 100. For example, each assembly sequence 410 may include three-dimensional AR/holographic ply representations of each ply or layer component of the structural composite panel 100 and any associated sequences of assembly steps for optimal assembly of the structural composite panel.
In embodiments, the assembly process may commence with the loading of the appropriate assembly sequence 410 for display and interaction via the AR viewing devices 402. For example, the operator may scan the structural composite panel 100 for image targets identifying a specific structural composite or component and loading its associated assembly sequences 410. The image targets may include, but are not limited to, QR codes or other encoded information (412) attached to, or incorporated into, a component of the structural composite panel 100 or a work order for the structural composite panel. If, for example, the structural composite panel 100 is to be assembled via the sequential lay-up of individual plies or layers over a mold or backing layer, the encoded information may be attached to or incorporated into the mold or backing layer. In some embodiments, a structural composite panel 100 may be identified via visual recognition of the mold, backing layer, component, or part via the AR viewing devices 402 (e.g., the mold, backing layer, component, or part, may itself serve as a data point identifiable by the AR viewing devices).
In embodiments, each ply representation may graphically incorporate any associated splice or dart locations, dress or drape methods, fastener elements, and alignment indicators associated with assembling or bonding the corresponding ply or layer to any adjacent plies or layers. In some embodiments, assembly sequences 410 may additionally incorporate detailed illustrations of each ply and its associated indicators as well as any bills of materials or specifications associated with the corresponding ply materials.
In embodiments the AR viewing devices 402 may be worn by operators directly involved in the assembly of the structural composite panel 100 or other individuals, e.g., quality control personnel, supervisors, or other observers viewing the assembly process for training purposes. For example, the operator or operators may load any necessary assembly sequences 410 to the AR viewing devices 402 and/or central processing unit 408 prior to the assembly process or at its outset. The AR viewing devices 402 may guide the operators through each step or layer of the assembly process by displaying, at each assembly step, holographic ply representations superimposed over the actual plies to be attached or added at that assembly step, positioned and oriented to indicate the proper alignment of the ply and any additional assembly details (e.g., splice/dart locations, dress/drape methods, fastener elements). In some embodiments, AR viewing devices 402 may include both wearable viewers worn by individuals directly involved in the assembly process as well as tablets or other portable computing and display devices used by observers or trainees.
In embodiments, the assembling operators may indicate completion of an assembly step, or view other portions of the assembly sequences 410, via control input submitted via the AR viewing devices 402. For example, the AR viewing devices 402 may display interactive menus within the field of view of the operators, allowing the operators to select (e.g., via gesture-based interaction with the menu) a particular layer or ply to be displayed, to select additional details (e.g., bills of materials, specification drawings, technical illustrations) associated with a displayed layer or ply, or to indicate completion of a layer, ply, or assembly step and advance to the subsequent layer, ply, or assembly step. In some embodiments, the AR viewing devices 402 may include microphones configured to capture spoken instructions from operators. For example, the AR viewing devices 402 may advance to the next assembly step, or manipulate or select AR objects to be displayed within the field of view of the AR viewing devices, based on the spoken instructions received. Spoken instructions may include, for example, preprogrammed sequences executable when particular words or phrases (e.g., “next”, “next step”) are heard and recognized by the AR viewing devices 402.
In embodiments, other individuals not directly involved in the assembly process may likewise be able to follow and observe via AR viewing devices 402 of their own. In addition, an AR recording 414 may be generated of the assembly process, showing each assembly step as it appears to the operators and including any audio commentary provided by the operators and/or observers. For example, AR recordings 414 of the assembly process may be used to verify assembly procedures for quality assurance purposes, or to provide standardized training to assembly personnel anywhere in the world.
Referring also to
In embodiments, referring in particular to
Referring also to
Referring now to
In embodiments, the use of AR viewing devices 402 may eliminate the need to design and manufacture (and occasionally redesign and remanufacture in response to design revisions), store, and replace prototype fixtures for fastener elements. For example, while bonded assemblies 602 may require a less precise assembly process than structural composite panels 100, prototype fixtures for these bonded assemblies (as noted above) may be subject to adhesive buildup and/or wear and tear which may shorten their lifecycle. For example, referring in particular to
In embodiments, referring also to
In embodiments, the AR viewing devices 402 similarly receive operator input (e.g., via interactive menus 518 or via spoken instructions by the operator) to verify the completion of assembly steps and of the assembly sequence (410,
Referring now to
At a step 702, AR viewing devices are provided to operators participating in the assembly of a composite structure (e.g., composite panel, combination of one or more such composite panels, bonded assembly). In some embodiments, AR viewing devices may include wearable AR viewing devices as well as tablets or other portable devices configured to present an AR display, and may additionally be provided to observers, trainees, or other individuals not directly participating in the assembly process.
At a step 704, the AR viewing device identifies within its field of view the composite structure to be assembled. For example, the composite structure may be a structure panel comprising multiple layers or plies assembled in sequence over a mold. In some embodiments, the composite structure may be a bonded assembly incorporating multiple sets of fastener elements and components bonded to a backing layer. In some embodiments, the AR viewing device identifies the composite structure by scanning encoded information (e.g., a QR code) attached to a component, backing layer, mold, or work order; in some embodiments the composite structure may be identified by scanning the component, backing layer, mold, or work order itself.
At a step 706, the AR viewing device loads the dataset associated with the identified composite structure for display and interaction. For example, each dataset includes any associated sequences of assembly steps for assembling or manufacturing the identified composite structure.
Steps 708-714 may apply to each assembly step of the assembly sequence. At the step 708, for each assembly step of the assembly sequence, the AR viewing device displays AR objects corresponding to the current assembly step, e.g., indicating the proper placement and orientation of any layer or ply over any previously applied layers or plies. In some embodiments, the displayed AR objects may include any appropriate splice and dart locations. In some embodiments, the displayed AR objects may include any appropriate dress and drape methods. In some embodiments, the displayed AR objects may include bills of materials, video clips, or technical drawings and illustrations. In some embodiments (e.g., when the composite structure is a bonded assembly), the displayed AR objects may include hook and loop fastener placements, clip placements, and other placement or orientation indicators for bonded assembly components.
At a step 710, the AR viewing device displays operator alerts associated with a particular assembly step. In some embodiments, the displayed operator alerts include instructions to the operator. In some embodiments, the displayed operator alerts include an interactive menu capable of displaying and/or traversing the full assembly sequence. In some embodiments, the displayed operator alerts include monitoring information or control sequences for a curing oven (e.g., monitoring oven temperature). In some embodiments, the displayed operator alerts are associated with a ply cutter (e.g., monitoring the cutting of subsequent or future plies).
At a step 712, the AR viewing device accepts operator input indicating a completion of an assembly step. In some embodiments, operator input may be submitted via the displayed interactive menu or as spoken instructions captured by a microphone of the AR viewing device. For example, operator input may be able to cause the AR viewing device to display other steps of the assembly sequence or additional information relevant to the current assembly step, e.g., technical illustrations, instructive video clips, bills of materials. In some embodiments, operator input indicative of the completion of an assembly step may signal the AR viewing device to initiate the next or subsequent assembly step in the assembly sequence.
At the step 714, the AR viewing device generates a verification of each completed assembly step. For example, the AR viewing device may record or capture the operator input indicating the completion of each assembly step.
At a step 716, the AR viewing devices generate a record documenting or capturing the completion of the full assembly sequence based on the captured verifications of each completed assembly step. For example, the AR viewing device may record the interactive display presented to the operators and any explanatory audio commentary offered by the operators, e.g., for quality assurance or standardized training in best practices.
It is to be understood that embodiments of the methods disclosed herein may include one or more of the steps described herein. Further, such steps may be carried out in any desired order and two or more of the steps may be carried out simultaneously with one another. Two or more of the steps disclosed herein may be combined in a single step, and in some embodiments, one or more of the steps may be carried out as two or more sub-steps. Further, other steps or sub-steps may be carried in addition to, or as substitutes to one or more of the steps disclosed herein.
Although inventive concepts have been described with reference to the embodiments illustrated in the attached drawing figures, equivalents may be employed and substitutions made herein without departing from the scope of the claims. Components illustrated and described herein are merely examples of a system/device and components that may be used to implement embodiments of the inventive concepts and may be replaced with other devices and components without departing from the scope of the claims. Furthermore, any dimensions, degrees, and/or numerical ranges provided herein are to be understood as non-limiting examples unless otherwise specified in the claims.
