Systems and methods for fiber placement inspection during fabrication of fiber-reinforced composite components

An inspection method and fiber technology, applied in image enhancement, instrumentation, image data processing, etc., can solve problems such as weakening of composite parts

Active Publication Date: 2016-03-02
THE BOEING CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Interlaminar voids are delamination defects that can lead to weakening of cured composite parts

Method used

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  • Systems and methods for fiber placement inspection during fabrication of fiber-reinforced composite components
  • Systems and methods for fiber placement inspection during fabrication of fiber-reinforced composite components

Examples

Experimental program
Comparison scheme
Effect test

Embodiment approach

[0146] Clause 1. An inspection method, said inspection method comprising:

[0147] projecting 102 a light pattern onto the inspection area on the form 30;

[0148] acquiring 104 a baseline 3D profile of the forming part by imaging the light pattern on the forming part;

[0149] laying 106 an uncured fiber sheet onto the form in the inspection area;

[0150] projecting 108 the light pattern onto the uncured fiber sheet on the form;

[0151] acquiring 110 a test 3D profile of the uncured fiber sheet on the form by imaging the light pattern on the uncured fiber sheet on the form; and

[0152] A thickness difference between the test 3D profile and the baseline 3D profile is calculated 112 .

[0153] Clause 2. The inspection method of clause 1, wherein the step of obtaining 104 said baseline 3D profile and obtaining 110 said test 3D profile comprises performing digital image correlation.

[0154] Clause 3. The inspection method according to any one of clauses 1-2, further compr...

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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.

Description

technical field [0001] The present disclosure relates to systems and methods for inspecting fiber placement during manufacture of fiber reinforced composite components. Background technique [0002] Automated fiber placement is a technology for manufacturing fiber-reinforced composite parts. The technology uses automated fiber placement (AFP) machines (also known as advanced fiber placement machines) that precisely place and layer uncured sliver fiber tapes onto molds and / or mandrels . AFP machines are commonly used to manufacture large complex shaped structures such as housings, air turbine blades, pressure vessels, and other industrial products. [0003] Uncured fiber tapes generally comprise carbon fibers pre-impregnated with thermosetting and / or thermoplastic materials (pre-impregnated carbon fiber tapes). The tape can take the form of a tow, which is an untwisted bundle of continuous filaments, and can be thin and narrow (common thicknesses range from about 0.005" (0...

Claims

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Application Information

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IPC IPC(8): B29C70/54B29C70/38
CPCB29C70/382B29C70/54G06T7/001B29C2037/906G06T2207/10028B32B5/026B32B5/26B32B2260/021B32B2260/046B32B2262/0261B32B2262/101B32B2262/106G06T7/521G01B11/06
Inventor J·A·葛罗尼柯K·E·麦卡瑞K·M·尼尔森C·A·克莱默
Owner THE BOEING CO
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