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    Test system and method for creating controlled and repeatable out-of-plane fiber distortion in composite laminates
    1.
    发明授权
    Test system and method for creating controlled and repeatable out-of-plane fiber distortion in composite laminates 有权

    公开(公告)号：US11090882B2

    公开(公告)日：2021-08-17

    申请号：US16142093

    申请日：2018-09-26

    Applicant: The Boeing Company

    Inventor： Gagandeep Saini ,  Karl M. Nelson ,  William H. Ingram

    IPC: B32B41/00 ,  B29C70/54 ,  B29C70/36 ,  B29K105/08 ,  B29K307/04

    Abstract: In one version there is provided a test system including a layup tool having a layup surface, and two fairing bars attached to the layup surface. The test system includes the composite laminate having a plurality of stacked plies, and positioned between the two fairing bars. The test system includes fiber distortion initiator(s) positioned at one or more locations under, and adjacent to, one or more plies of the plurality of stacked plies. The test system includes two caul plates with a gap in between, and positioned over the composite laminate. When the test system undergoes a pressurized cure process with a vacuum compaction, a restricted outward expansion of the plurality of stacked plies by the fairing bars, and a pressure differential region formed by the one or more fiber distortion initiators at the one or more locations, create the controlled and repeatable out-of-plane fiber distortion in the composite laminate.

    Device for emulating temperature of a composite structure through a thermal cure cycle
    3.
    发明授权
    Device for emulating temperature of a composite structure through a thermal cure cycle 有权

    公开(公告)号：US09835500B2

    公开(公告)日：2017-12-05

    申请号：US14718688

    申请日：2015-05-21

    Applicant: The Boeing Company

    Inventor： Karl M. Nelson

    IPC: G01K7/02 ,  B29C35/02

    CPC classification number: G01K7/02 ,  B29C35/0288 ,  Y10T29/49004 ,  Y10T29/4935 ,  Y10T29/49366

    Abstract: A temperature emulator may include a stack assembly having a pair of end plates positioned at an uppermost and lowermost location of the stack assembly, a plurality of heat sink plates disposed between the pair of end plates, each of the heat sink plates having a plurality of heat sink cutouts, a plurality of shim plates separating adjacent pairs of the end plates and the heat sink plates, each of the shim plates having a shim cutout, an open cavity formed by a plurality of adjacent heat sink cutouts and shim cutouts, thermal insulation disposed within the cavity, and at least one temperature sensor coupled to at least one of the plurality of heat sink plates.

    SYSTEMS AND METHODS FOR FIBER PLACEMENT INSPECTION DURING FABRICATION OF FIBER-REINFORCED COMPOSITE COMPONENTS
    4.
    发明申请
    SYSTEMS AND METHODS FOR FIBER PLACEMENT INSPECTION DURING FABRICATION OF FIBER-REINFORCED COMPOSITE COMPONENTS 有权
    纤维增强复合材料制造过程中纤维布置检验的系统与方法

    公开(公告)号：US20160102966A1

    公开(公告)日：2016-04-14

    申请号：US14463433

    申请日：2014-08-19

    Applicant: The Boeing Company

    Inventor： James A. Grossnickle ,  Kevin Earl McCrary ,  Karl M. Nelson ,  Craig Allen Cramer

    IPC: G01B11/06

    CPC classification number: G01B11/06 ,  B29C70/382 ,  B29C2037/906 ,  B32B5/026 ,  B32B5/26 ,  B32B2260/021 ,  B32B2260/046 ,  B32B2262/0261 ,  B32B2262/101 ,  B32B2262/106 ,  G06T7/001 ,  G06T7/521 ,  G06T2207/10028

    Abstract: The disclosed systems and methods relate to inspecting uncured fiber-reinforced composite components by non-contact 3D measurements of the component using 3D digital image correlation with patterned illumination. Systems comprise a light projector configured to project a light pattern onto a form, a digital camera configured to image the light pattern, and may comprise and/or be associated with an AFP machine that is configured to lay uncured composite on the form. Methods comprise projecting a light pattern onto a form, acquiring a baseline 3D profile of the form by imaging the light pattern on the form, laying an uncured fiber piece onto the form, projecting the light pattern onto the uncured fiber piece, acquiring a test 3D profile of the fiber piece by imaging the light pattern on the uncured fiber piece, and computing a thickness difference between the test 3D profile and the baseline 3D profile.

    Abstract translation: 所公开的系统和方法涉及通过使用与图案化照明的3D数字图像相关性的部件的非接触3D测量来检查未固化的纤维增强复合材料部件。 系统包括被配置为将光图案投影到表格上的光投影仪，被配置为对光图案进行成像的数字照相机，并且可以包括和/或与被配置为将未固化复合材料放置在所述表格上的AFP机器相关联。 方法包括将光图案投影到表格上，通过将图案上的光图案成像，将未固化的纤维片放置在形式上，将光图案投影到未固化的纤维片上，获得形状的基线3D轮廓，获得测试3D 通过对未固化的纤维片上的光图案进行成像，并计算测试3D轮廓和基线3D轮廓之间的厚度差，来测量纤维片的轮廓。

    HEATING OPERATION PROCESS CONTROL
    5.
    发明申请
    HEATING OPERATION PROCESS CONTROL 有权

    公开(公告)号：US20220219411A1

    公开(公告)日：2022-07-14

    申请号：US17505875

    申请日：2021-10-20

    Applicant: THE BOEING COMPANY

    Inventor： Keith D. Humfeld ,  Geoffrey A. Butler ,  Karl M. Nelson

    IPC: B29C70/44 ,  B29C70/54 ,  G06N3/08

    Abstract: Heating operation control includes obtaining sensor data indicating measured temperatures within a heating vessel during a heating operation; determining sets of thermal stack parameters. Each set of candidate thermal stack parameters is descriptive of a respective configuration of a thermal stack modeled by a first machine learning model to generate one or more estimated tool temperature values. The thermal stack includes the tool and a part coupled to the tool. Heating operation control also includes determining a temperature profile for the heating operation. The temperature profile is determined, via a second machine learning model, based on the plurality of sets of thermal stack parameters and one or more process specifications of the thermal stack.

    Systems and methods of curing a thermoset composite to a desired state of cure
    6.
    发明授权
    Systems and methods of curing a thermoset composite to a desired state of cure 有权

    公开(公告)号：US11331833B2

    公开(公告)日：2022-05-17

    申请号：US16484771

    申请日：2018-03-15

    Applicant: The Boeing Company ,  Toray Industries, Inc.

    Inventor： Hardik Dalal ,  Karl M. Nelson ,  Travis James Sherwood ,  Felix N. Nguyen

    IPC: B29C35/02 ,  B29C37/00 ,  B29K101/10 ,  B29L31/30

    Abstract: Systems and methods of curing a thermoset composite (TSC) to a target state of cure (SOC) are disclosed herein. The methods include heating the thermoset composite to greater than a threshold temperature. During the heating, the methods further include monitoring an actual temperature of the thermoset composite, determining a maximum temperature achieved by the thermoset composite, and determining an elapsed time that the actual temperature of the thermoset composite is greater than the threshold temperature. The methods further include ceasing the heating based, at least in part, on the maximum temperature of the TSC and the elapsed time. The systems include a heating assembly, a support mandrel, a thermoset composite, a temperature detector, and a controller programmed to perform the methods.

    Device for emulating temperature of an exothermic composite structure through a thermal cure cycle
    8.
    发明授权
    Device for emulating temperature of an exothermic composite structure through a thermal cure cycle 有权
    用于通过热固化循环模拟放热复合结构的温度的装置

    公开(公告)号：US09304048B2

    公开(公告)日：2016-04-05

    申请号：US13904363

    申请日：2013-05-29

    Applicant: The Boeing Company

    Inventor： Karl M. Nelson ,  Scott R. Campbell

    IPC: G01K7/02 ,  B29C35/02

    CPC classification number: G01K7/02 ,  B29C35/0288 ,  Y10T29/49004 ,  Y10T29/49366

    Abstract: A temperature emulator may include a stacked assembly including a pair of end plates positioned at an uppermost and lowermost location of the stacked assembly, a plurality of heat sink plates positioned between the pair of end plates, a plurality of shim plates positioned between adjacent pairs of heat sink plates, and an exothermic charge assembly positioned between at least one pair of heat sink plates, the exothermic charge assembly including an exotherm charge configured to react exothermally in response to a thermal cure cycle.

    Abstract translation: 温度仿真器可以包括堆叠的组件，其包括位于堆叠组件的最上部和最下部位置处的一对端板，定位在该对端板之间的多个散热板，多个垫片， 散热板和位于至少一对散热板之间的放热电荷组件，放热电荷组件包括构造为响应于热固化循环而放热反应的放热电荷。

    System and method for a heating operation process control
    10.
    发明授权
    System and method for a heating operation process control 有权

    公开(公告)号：US12138867B2

    公开(公告)日：2024-11-12

    申请号：US17505875

    申请日：2021-10-20

    Applicant: THE BOEING COMPANY

    Inventor： Keith D. Humfeld ,  Geoffrey A. Butler ,  Karl M. Nelson

    IPC: G05B13/02 ,  B29C70/44 ,  B29C70/54 ,  G06N3/08

    Abstract: Heating operation control includes obtaining sensor data indicating measured temperatures within a heating vessel during a heating operation; determining sets of thermal stack parameters. Each set of candidate thermal stack parameters is descriptive of a respective configuration of a thermal stack modeled by a first machine learning model to generate one or more estimated tool temperature values. The thermal stack includes the tool and a part coupled to the tool. Heating operation control also includes determining a temperature profile for the heating operation. The temperature profile is determined, via a second machine learning model, based on the plurality of sets of thermal stack parameters and one or more process specifications of the thermal stack.

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