Method and system for in-process monitoring of compression rollers in a composite material layup machine.

Abstract

To provide a method and system for in-process monitoring of a compression roller in a composite lay-up machine.SOLUTION: A method includes orienting one or more thermal imaging cameras to a compression roller 14 of a composite laying head 36 of a composite lay-up machine. The thermal imaging cameras are mounted to a rear of the compression roller. The method includes applying heat to a substrate by means of a heater 38. The heater is mounted in front of the compression roller. The method includes using the thermal imaging camera to acquire a thermal image of the compression roller while one or more composite tows 32a of the composite lay-up are laid on the substrate by the compression roller. The method further includes identifying one or more temperature profiles of the compression rollers based on the one or more thermal images and analyzing the identified temperature profiles to determine one or more of a lay-up quality of the composite lay-up and a heating history of the composite lay-up.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates generally to composite manufacturing, and more specifically, to improvements in manufacturing composite structures. In particular, the present disclosure relates to methods and systems for in-process monitoring of compression rollers of composite layup machines.

Background Art

[0002] Composite structures may be used in a wide range of applications, including aircraft manufacturing, due to their high strength-to-weight ratio, corrosion resistance, and other favorable properties. Further, composite materials provide a long service life for various components of an aircraft. In particular, in aircraft manufacturing, composite structures may be used to form the fuselage, wings, tail and other portions of an aircraft.

[0003] However, monitoring the quality of composite materials and performing process control during the manufacturing process remains a challenge. Composite materials are laid up on a substrate or tool, and composite layup machines are typically used to automatically lay up such composite materials into a composite layup. During the manufacturing process, the composite layup may be monitored for any issues that affect overall layup quality, and issues such as the presence of layup defects, foreign object debris (FOD), and problems with tape tack quality may occur, for example.

[0004] There are known in-process monitoring methods and systems. One such known in-process monitoring method is visual inspection by an operator. Visual inspection by an operator is a qualitative rather than quantitative measurement, and visual inspection by an operator is not as sensitive as desired. Furthermore, when an operator manually performs visual inspection, operation of the composite layup machine is stopped during the inspection. This may cause delays in the manufacturing process, resulting in increased manufacturing costs.

[0005] Another known in-process monitoring method and system involves monitoring part surfaces or substrates using cameras (e.g., infrared (IR) cameras). However, monitoring part surfaces or substrates can be difficult due to variations in surface contours, and reflections and shifts within the IR camera's field of view, which can occur when viewing materials or objects, can prevent the camera from being set to view the tool while it is moving. Furthermore, angle and spatial limitations can make it difficult for the IR camera to view the optimal position when monitoring part surfaces or substrates. This can lead to inconsistent monitoring and inspection.

[0006] Another known in-process monitoring method and system involves monitoring and measuring the actual layup to provide data on the layup condition. However, such measurements are exposed to a large amount of noise and may require processing.

[0007] Therefore, it is desirable to have methods and systems that offer advantages over known methods and systems, taking into account at least some of the problems described above, as well as other potential problems. For example, it would be desirable to have at least one method or system that quantitatively evaluates the layup quality and layup state of composite layups during the layup process and automates the verification of layup quality. Another example would be to have at least one method or system that uses an infrared (IR) camera positioned to view at an optimal location in a way that is unobtrusive and easily visible, in order to determine the layup quality and / or heating history of composite layups. [Overview of the project]

[0008] Exemplary embodiments of this disclosure provide a method and system for in-process monitoring of compression rollers in a composite layup to determine the layup quality of the composite layup. As described in the detailed description below, versions of this method and system may offer significant advantages over known methods and systems.

[0009] A method is provided in this version of the disclosure. The method includes the step of oriented one or more infrared cameras onto the compression rollers of the composite laying head of a composite layup machine, the one or more infrared cameras being mounted on the rear of the compression rollers. The method further includes the step of applying heat to the substrate with a heater, the heater being mounted on the front of the compression rollers.

[0010] The method further includes using one or more infrared cameras to acquire infrared images of one or more compression rollers while laying one or more composite tows of a composite layup onto a substrate using compression rollers. The method further includes identifying one or more temperature profiles of the compression rollers based on one or more infrared images to acquire one or more identified temperature profiles. The method further includes analyzing one or more identified temperature profiles to determine one or more of the layup quality of the composite layup and the heating history of the composite layup.

[0011] Another version of this disclosure provides a method for in-process monitoring of compression rollers of a composite layup machine. The method includes the step of orienting one or more infrared cameras to the rear of the compression rollers of the composite laying head of the composite layup machine, the one or more infrared cameras being mounted on the rear of the compression rollers. The method further includes the step of applying heat to the substrate with a heater, the heater being mounted on the front of the compression rollers.

[0012] The method further includes the step of monitoring the back of a compression roller by using one or more infrared cameras to acquire one or more infrared images of the back of the compression roller while laying one or more composite tows of a composite layup onto a substrate with the compression roller. The method further includes the step of identifying one or more temperature profiles of the back portion of the compression roller based on one or more infrared images, and acquiring one or more identified temperature profiles, wherein one or more composite tows are in contact with the compression roller. The method further includes the step of analyzing one or more identified temperature profiles to determine one or more of the layup quality of the composite layup and the heating history of the composite layup.

[0013] Another version of this disclosure provides a system for in-process monitoring of compression rollers in a composite layup machine. The system includes a composite layup machine, which comprises (i) a composite layup head having compression rollers connected to a composite layup head, (ii) a heater mounted in front of the compression rollers and configured to heat the substrate, and (iii) one or more infrared cameras mounted behind the compression rollers for monitoring the compression rollers. The one or more infrared cameras are configured to each capture an infrared image of one or more of the compression rollers while laying one or more composite tows of a composite layup onto the substrate by the compression rollers.

[0014] The system further comprises a control system configured to control a composite layup machine. The system further comprises a computer system having a composite analyzer. The composite analyzer is configured to identify one or more temperature profiles of a compression roller based on one or more infrared images, acquire one or more identified temperature profiles, and analyze one or more identified temperature profiles in order to determine one or more of the layup quality of the composite layup and the heating history of the composite layup.

[0015] The features, functions, and advantages described herein can be achieved independently in various versions of this disclosure, or combined in other versions, as can be seen in the following description and drawings.

[0016] This disclosure will be better understood by referring to the following detailed description in conjunction with the accompanying drawings illustrating exemplary versions, which are not necessarily drawn to scale. The drawings are illustrative and not intended to be descriptive or limiting to the claims. [Brief explanation of the drawing]

[0017] [Figure 1] This shows the index of Figure 1, including Figures 1A and 1B. [Figure 1A] This is an illustration of a block diagram of part of a system for in-process monitoring of compression rollers of a composite material layup machine used in a manufacturing environment, in accordance with an exemplary version of this disclosure. [Figure 1B] This is a diagram illustrating the block diagram of the continuation of the system shown in Figure 1A of this disclosure. [Figure 2] This is a block diagram illustrating an exemplary version of the computer system shown in Figure 1B. [Figure 3] This is a side view illustration of a version of the system of this disclosure for in-process monitoring of compression rollers in a composite material layup machine. [Figure 4A] This is an illustration of a perspective side view of another version of a system for in-process monitoring of the compression rollers of a composite material layup machine. [Figure 4B] This is an illustration of the system's perspective rear view shown in Figure 4A. [Figure 5] This is an illustration of a perspective rear view of another version of a system for in-process monitoring of the compression rollers of a composite material layup machine. [Figure 6] This is a flowchart illustrating one version of the method of this disclosure. [Figure 7]It is an illustration of a flow diagram of one version of the method for in-process monitoring of a compression roller of a composite layup machine of the present disclosure. [Figure 8A] It is an illustration representing a tow twist infrared (IR) image of a region of interest on a back portion of a compression roller. [Figure 8B] It is an illustration of a graph showing the tow twist temperature profile of the region of interest in FIG. 8A. [Figure 9A] It is an illustration representing a tow end infrared (IR) image of a region of interest on a back portion of a compression roller. [Figure 9B] It is an illustration of a graph showing the tow end temperature profile of the region of interest in FIG. 9A. [Figure 10A] It is an illustration representing a missing tow infrared (IR) image of a region of interest on a back portion of a compression roller. [Figure 10B] It is an illustration of a graph showing the missing tow temperature profile of the region of interest in FIG. 10A. [Figure 11A] It is an illustration representing a tow fold infrared (IR) image of a region of interest on a back portion of a compression roller. [Figure 11B] It is an illustration of a graph showing the tow fold temperature profile of the region of interest in FIG. 11A. [Figure 12A] It is an illustration representing a fuzz ball infrared (IR) image of a region of interest on a back portion of a compression roller. [Figure 12B] It is an illustration of a graph showing the fuzz ball temperature profile of the region of interest in FIG. 12A. [Figure 13A] It is an illustration representing a gap infrared (IR) image of a region of interest on a back portion of a compression roller. [Figure 13B] It is an illustration of a graph showing the gap temperature profile of the region of interest in FIG. 13A. [Figure 14] It is an illustration representing good / bad tack quality infrared (IR) images of a region of interest on a back portion of a compression roller. [Figure 15] It is an illustration of a perspective view of an aircraft incorporating a composite part formed from a composite layup of tows that can be monitored using an exemplary version of the system and method of the present disclosure. [Figure 16] This is a diagram illustrating a flowchart of the manufacturing and maintenance methods for an exemplary aircraft. [Figure 17] This is an illustrative block diagram of an aircraft. [Modes for carrying out the invention]

[0018] The figures shown in this disclosure represent various aspects of the presented version, and only the differences are described in detail.

[0019] The versions disclosed hereafter will be described more comprehensively with reference to the attached drawings, but the attached drawings represent only some, not all, of the disclosed versions. In practice, several different versions may be provided, and these should not be interpreted as being limited to the versions specified herein. Rather, these versions are described in order to make this disclosure comprehensive and complete, and to ensure that the scope of this disclosure is fully conveyed to those skilled in the art.

[0020] This specification includes references to “one version” or “a version.” Examples of the expressions “one version” or “a version” do not necessarily refer to the same version. Certain features, structures, or characteristics may be combined in any appropriate manner consistent with this disclosure.

[0021] As used herein, “comprising” is an open-ended term, and as used in the claims, it does not preclude any additional structure or step.

[0022] As used herein, “configured to” means that various parts or components may be described or claimed to perform a task. In such contexts, “configured to” is used to suggest a structure by indicating that the part or component includes a structure that performs these tasks during operation. Thus, it can be said that a part or component is configured to perform the task even when the specified part or component is not currently available (e.g., not installed).

[0023] As used herein, expressions such as "first," "second," etc., are used as indicators for the nouns that follow them and do not suggest any kind of order (e.g., spatial, temporal, logical, etc.).

[0024] Where used herein, an element or step described in the singular and followed by the word “one (a or an)” should be understood not to necessarily exclude multiple elements or steps.

[0025] Where used herein, the expression "at least one of" used with a list of items means that any combination of one or more of the listed items may be used, and that only one of each item in the list may be required. In other words, "at least one of" means that any combination and any number of items from the list may be used, but not all of the listed items are required. An item can be a specific object, article, or category.

[0026] Referring here to the drawings, Figure 1 is an index illustration showing Figure 1, including Figures 1A and 1B. Figure 1A is an illustration of a block diagram of part of a system 10 for in-process monitoring 12 of the back surface 16 of a compression roller 14, in particular, of a composite layup machine 18 (e.g., an automated fiber placement (AFP) composite layup machine 18a (see Figure 3)) used in a manufacturing environment 20, according to an exemplary version of the present disclosure. Figure 1B is an illustration of a block diagram of a continuation portion of the system 10 of Figure 1A of the present disclosure.

[0027] The blocks in Figures 1A and 1B represent elements, and the lines connecting the various blocks do not suggest any particular dependency relationship between the elements. Furthermore, while the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and / or physical connections between various elements, it should be noted that other alternative or additional functional relationships or physical connections may be shown in the versions disclosed herein. When implemented in exemplary embodiments, one or more of these blocks may be combined, divided, or combined and divided into different blocks. Furthermore, the illustrations of system 10 and computer system 80 in Figures 1A and 1B are not intended to suggest any physical or structural limitations on the manner in which the exemplary embodiments may be implemented. Other components may be used in addition to or instead of the illustrated components. Some components may not be necessary.

[0028] The exemplary version recognizes and considers one or more different considerations. For example, the exemplary version recognizes and considers that automated fiber placement (AFP) is a composite manufacturing process. The exemplary version recognizes and considers that automated fiber placement (AFP) is a very delicate process. The exemplary version recognizes and considers that manufacturing outside the acceptable range can add undesirable costs and flow time to the manufacturing process. The exemplary version recognizes and considers that means of monitoring, controlling, and improving the automated fiber placement (AFP) process are desirable.

[0029] The exemplary version recognizes and takes into account that the adhesion between uncured composite layers affects the bond strength between the uncured composite layers, referred to as tack 22 (see Figure 1A). Furthermore, the exemplary version recognizes and takes into account that, in order to determine the layup quality 26 (see Figure 1B) and heating history 28 (see Figure 1B) of the composite layup 30 (see Figure 1A), in-process monitoring 12 on the back surface 16 of the compression roller 14 identifies one or more temperature profiles 24 (Figure 1B) of the compression roller 14 and obtains one or more identified temperature profiles 24a (see Figure 1B).

[0030] The composite layup 30 is made from layers of tow 32 (see Figures 1A-1B), such as composite tow 32a (see Figures 1A-1B). As used herein, “tow” means a continuous, untwisted bundle of individual fibers forming a narrow tape and made from a material such as carbon, acrylic, viscose rayon, or other preferred material. In one exemplary version, the tow is a bundle of carbon fibers 3mm-13mm wide and 0.13mm thick impregnated in epoxy resin and wound onto a spool. In one version, the tow 32 (such as composite tow 32a) includes a material 34 (see Figure 1B), such as composite material 34a (see Figure 1B). The tow 32 (such as composite tow 32a) may be in the form of a tape 35 (see Figure 1B) or other preferred form.

[0031] Composite material 34a includes thermoplastic and thermosetting materials known in the art of composite component manufacturing, such as carbon fiber reinforced polymer (CFRP) materials. Composite material 34a may include unidirectional or bidirectional fibers, i.e., prepregs, which are impregnated in or retained within a suitable resin matrix, such as thermoplastic or thermosetting, and reinforced. Exemplary thermoplastic resins include polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polyphenylene sulfide (PPS), polyetherimide (PEI), polyaryl ether ketone (PAEK), or other suitable thermoplastic resins. Exemplary thermosetting resins include epoxy, silicone, polyimide, bismaleimide, or other suitable thermosetting resins.

[0032] As shown in Figure 1A, the system 10 includes a composite layup machine 18. The composite layup machine 18 includes a composite layup head 36 (see Figure 1A) having compression rollers 14 connected to a composite layup head 36. As further shown in Figure 1A, the composite layup machine 18 includes a heater 38 mounted in front of the front 17 (see Figure 3) of the compression rollers 14. The heater 38 includes an infrared (IR) heater 38a (see Figure 1A), a laser heater 38b (see Figure 1A), or another preferred heater. The heater 38 is configured to apply heat 40 (see Figure 1A) to a substrate 42 (see Figure 1A). In one exemplary version, the substrate 42 is in the form of a test substrate 42a (see Figure 1A).

[0033] When a tow 32 (such as a composite tow 32a) is laid on a substrate 42 to form a composite material layup 30, the substrate 42 heats the tow 32 (such as a composite tow 32a) on the substrate 42. The heat 40 is conducted from the substrate 42 to the tow 32 (such as a composite tow 32) which is resting on the substrate 42. In the manufacturing environment 20, a composite material laying head 36 lays the tow 32, which is in the form of a composite tow 32a or the like, on the substrate 42, and a compression roller 14 compresses the tow 32 (such as a composite tow 32a) onto the substrate 42. The tow 32 (such as a composite tow 32a) is laid so as to have sufficient contact 44 (see Figure 1A) with the substrate 42 and a degree of adhesion 46 (see Figure 1A) between the tows 32 (such as a composite tow 32a).

[0034] The substrate 42 and the test substrate 42a can take any preferred form. In some exemplary embodiments, the substrate 42 and the test substrate 42a each have a pre-formed laminated surface of the tow 32 (such as a composite tow 32a). In some exemplary embodiments, the substrate 42 and the test substrate 42a each have a tool surface.

[0035] The composite layup 30 is used to form parts 48 (see Figure 15), such as composite part 48a (see Figure 15). In one exemplary version, part 48 (such as composite part 48a) is used in the manufacture of a vehicle 50 (see Figure 15), such as an aircraft 50a (see Figure 15). Part 48 (such as composite part 48a) may be made in the manufacture of a vehicle 50, including rotary-wing aircraft, spacecraft, ships, and other suitable vehicles, or in the manufacture of a suitable structure.

[0036] As further shown in Figure 1A, the parameters 52 of the composite material layup machine 18 include the compression speed 54 of the compression roller 14, the compression pressure 56 applied by the compression roller 14, the temperature output 58 of the heater 38, and the heat 40 of the heater 38.

[0037] As shown in Figure 1A, the composite material layup machine 18 further comprises one or more infrared (IR) cameras 60, also known as thermal cameras. One or more IR cameras 60 are mounted or attached to the composite material laying head 36 of the composite material layup machine 18 at a position behind or behind the back surface 16 of the compression rollers 14, in order to monitor the compression rollers 14, specifically the back surface 16 of the compression rollers 14. As shown in Figure 1A, each IR camera 60 may be a photographic infrared (IR) camera 60a, a video infrared (IR) camera 60b, a combo photographic / video infrared (IR) camera 60c, or another preferred IR camera.

[0038] One or more IR cameras 60 are configured to capture one or more infrared (IR) images 62 (see Figures 1A and 1B) of the compression roller 14, specifically the back portion 16a (see Figure 1A) of the back surface 16 of the compression roller 14, while one or more tows 32 (see Figures 1A and 1B), such as one or more composite tows 32a of the composite layup 30, are laid and compressed on the substrate 42 by the compression roller 14. Each of the one or more IR cameras 60 is positioned behind the back surface 16 of the compression roller 14 and is directed toward the rear of the back surface 16.

[0039] As shown in Figure 1A, one or more IR images 62 include one or more infrared (IR) photographic images 62a, one or more infrared (IR) video images 62b, or one of other preferred IR images. Each IR image 62 has pixels 64 (see Figure 1B) with intensity 66 (see Figure 1B). Intensity 66 represents the temperature 68 (see Figure 1B) of each tow 32 (e.g., composite tow 32a). Intensity 66 further indicates the amount of heat 40 conducted to the tow 32. Intensity 66 further indicates the level of contact between the tow 32 and the substrate 42. A greater amount of contact between the tow 32 and the substrate 42 results in the conduction of a greater amount of heat 40. The temperature 68 of the tow 32, such as the composite tow 32a, in each of the one or more IR images 62 is lower than the temperature at the compression point 164 (see Figure 3) below the compression roller 14.

[0040] In one version, as shown in Figures 3 and 4A-4B, one IR camera 60 is mounted or attached to the composite layup machine 18 at position 158 or position 158a, respectively, which is behind or at the rear of the back surface 16 of the compression roller 14. In another version, as shown in Figure 5, two IR cameras 60 are mounted or attached to the composite layup machine 18 at positions 158b and 158c, respectively, which are behind or at the rear of the back surface 16 of the compression roller 14. System 10 may also use two or more IR cameras 60 positioned behind or at the rear of the back surface 16 of the compression roller 14. When there are two or more IR cameras 60, they are synchronized together to acquire two or more IR images 62 configured to be merged together in the computer software 146 (see Figure 2) of the computer system 80 (see Figures 1B and 2).

[0041] As shown in Figure 1A, the system 10 further comprises a control system 70. The control system 70 is configured to control the composite material layup machine 18. The control system 70 comprises one or more controllers 72 (see Figure 1A). Each controller 72 is configured to adjust one or more of the compression speed 54 of the compression roller 14, the compression pressure 56 applied by the compression roller 14, and the temperature output 58 of the heater 38, based on one or more identified temperature profiles (TP(S)) 24a (see Figure 1B), one or more temperature profiles 24 (see Figure 1B), and at least one layup state 74 (see Figure 1B), such as one or more identified temperature profiles (TP(S)) 24a (see Figure 1B), and one or more layup states 74 (see Figure 1B). This is done to limit the material 34 (such as composite material 34a) of one or more tows 32 (such as composite tow 32a), and to prevent the material 34 (such as composite material 34a) from sticking to the surface 76 (see Figure 3) of the compression roller 14 and to prevent the material 34 (such as composite material 34a) from wrapping around all or part of the outer circumference 78 (see Figure 3) of the compression roller 14.

[0042] Therefore, one of the one or more controllers 72 is configured to adjust or modify at least one of the following when it is determined that one or more layup states 74 (see Figure 1B) exist: the compression speed 54 of the compression roller 14, the compression pressure 56 applied by the compression roller 14, and the temperature output 58 of the heater 38. In some exemplary embodiments, one of the one or more controllers 72 also controls the operation of the composite material laying head 36 within the manufacturing environment 20.

[0043] As shown in Figure 1B, the system 10 further comprises a computer system 80 having one or more computers 82. As shown in Figure 1B, the computer system 80 further comprises an analyzer 86 (such as a composite material analyzer 86a). The analyzer 86, such as the composite material analyzer 86a, is configured to identify one or more temperature profiles 24 or thermal artifacts of the compression roller 14 based on one or more IR images 62 in order to obtain one or more identified temperature profiles 24a. Identifying one or more temperature profiles 24 of the compression roller 14 based on one or more IR images 62 includes identifying one or more temperature profiles 24 of the back portion 16a of the back surface 16 of the compression roller 14 and obtaining one or more identified temperature profiles 24a, where one or more tows 32 (such as one or more composite material tows 32a) are in contact with the compression roller 14.

[0044] The analyzer 86 (such as the composite material analyzer 86a) is further configured to enable the analysis of one or more identified temperature profiles 24a to determine one or more of the layup quality 26 of the composite material layup 30 and the heating history 28 of the composite material layup 30. In some exemplary embodiments, the analyzer 86 (such as the composite material analyzer 86a) analyzes each of one or more IR images 62 to determine the layup quality 26 of the composite material layup 30 and / or the heating history 28 of the composite material layup 30. In some exemplary embodiments, the analyzer 86, such as the composite material analyzer 86a, analyzes only a portion of one or more IR images 62.

[0045] One or more identified temperature profiles 24a are used to determine at least one layup state 74 of the composite layup 30. As shown in Figure 1B, at least one layup state 74 includes one or more of the following: layup defects 88, foreign object debris (FOD) 90, tape tack quality 92, or other preferred layup states. As shown in Figure 1B, the layup defects 88 include toe twists 88a, misaligned toe ends 88b, missing toe 88c, toe folds 88d, fuzz balls 88e, gaps 88f, overlaps 88g, or other preferred layup defects.

[0046] A tow twist 88a is a tow 32 that has become deformed and twisted when laid on the substrate 42 by the composite material laying head 36. A misaligned tow end 88b is an end of a tow 32 that is cut or added by the composite material layup machine 18 when laid on the substrate 42 and is not aligned with or suitable for the end of the component, and occurs when the compression roller 14 continues to rotate over the end between the portion of the tow 32 laid on the substrate 42 and the surface 156 (see Figure 3) (metal surface, etc.) of the substrate 42. A missing tow 88c is a tow 32 that is not laid on the substrate 42 without being fed out from the composite material laying head 36 or without falling. Missing tows 88c are also called detached tows. A tow fold 88d is a tow 32 or an end of a tow 32 that has folded over itself when laid on the substrate 42 by the composite material laying head 36. The gap 88f is the empty area between the two tows 32, where the tows 32 are not properly laid by the composite material laying head 36 on the substrate 42, resulting in the formation of a gap 88f between the tow 32 and the adjacent tow.

[0047] As used herein, “fuzzball” refers to a mass of scattered fibers and resin that accumulates during the operation of the composite laying head and deposits or falls onto one of the substrates, components, or tows. If the compression roller 14 rides over a fuzzball 88e created within the composite laying head 36 and falls onto the substrate 42, component, or tow 32, the thermal signature 94 (see Figure 1B) of the fuzzball 88e may appear in the infrared image 62. The fuzzball 88e is a layup defect 88, but is also a type of foreign matter fragment 90. However, the fuzzball 88e has a temperature profile 24 and thermal signature 94 (see Figure 1B) that is very different from the temperature profile 24 and thermal signature 94 of other types of foreign matter fragments 90.

[0048] As shown in Figure 1B, tape tack quality 92 includes good tack quality 92a or poor tack quality 92b. Tape tack quality 92 may also include other types of tape tack quality. Tack 22 (see Figure 1A) is a description of the strength of the bond between the tow 32 (e.g., composite tow 32a) and the substrate 42. Tack 22 is affected by the temperature 68 of the tow 32 (e.g., composite tow 32a) and laid on the substrate 42. Tack 22 is also affected by the contact between the tow 32 (e.g., composite tow 32a) and the substrate 42. Tack 22 may be measured in Newtons. Tack 22 may vary depending on the type of material 34 (e.g., composite material 34a) of the tow 32 (e.g., composite tow 32a), the humidity 96 of the manufacturing environment 20 (see Figure 1A), and the temperature 98 of the manufacturing environment 20 (see Figure 1A). Tack 22 may also be affected by the storage conditions of the tow 32 (composite material tow 32a, etc.), the manufacturing conditions of the tow 32 (composite material tow 32a, etc.), and the laying time of the tow 32 (composite material tow 32a, etc.).

[0049] Determining at least one layup state 74 of a composite layup 30 based on one or more identified temperature profiles 24a includes identifying the size 100 (see Figure 1B) of the at least one layup state 74 based on one or more IR images 62, determining whether the size 100 of the at least one layup state 74 is greater than a threshold size 102 (see Figure 1B), and receiving an instruction 104 (see Figure 1B) to the user interface 106 (see Figure 1B) when the size 100 of the at least one layup state 74 is greater than the threshold size 102. The threshold size 102 is based on a known reference size 108 (see Figure 1B). Data for the known reference size 108 includes at least one of the following: specification requirements for the threshold size 102, infrared images 62 during layup, ultrasound data, or visual inspection data.

[0050] Instructions 104 for the user interface 106 may include warnings, notifications, alarms, or other suitable instructions that can actually be heard, seen, or felt by vibration. When the size 100 of the layup state 74 is below the threshold size 102, such information is removed and no instructions 104 are provided for the user interface 106.

[0051] As shown in Figure 1B, the machine vision 110 may identify at least one layup state 74 and be used to automatically warn or notify the user interface 106 of the computer system 80 of at least one layup state 74 by instruction 104, etc. As used herein, “machine vision” means the computer’s ability to see and includes techniques and methods used for automatically extracting information from an image, the extracted information may be a simple signal indicating good / bad parts, or a complex set of data such as the identification, position, and orientation of each object in the image.

[0052] Based on one or more IR images 62, one or more temperature profiles 24 of the compression roller 14 are identified and one or more identified temperature profiles 24a are obtained. Then, one of one or more computers 82 and computer program products 84 (see Figure 2) may be used to generate an aggregate depiction 112 (see Figure 1B) of two or more identified temperature profiles 24a of the compression roller 14, enabling a comparison 114 (see Figure 1B) of the two or more identified temperature profiles 24a.

[0053] As shown in Figure 1B, for example, the analyzer 86 (e.g., composite material analyzer 86a), the IR image 62, and the layup state 74 are all located on the computer system 80. In some exemplary embodiments, at least one of the analyzer 86 (e.g., composite material analyzer 86a), the IR image 62, or the layup state 74 may be located on different computer systems. In another example, the computer system 80 is depicted within the manufacturing environment 20, but the computer system 80 may be located in any preferred location. In some exemplary embodiments, the computer system 80 is located outside the manufacturing environment 20.

[0054] Referring here to Figure 2, which is a block diagram illustrating a more detailed exemplary version of the computer system 80 of Figure 1B. The computer system 80 is used in conjunction with one or more versions of system 10 (see Figure 1A), method 200 (see Figure 6), and method 220 of the present disclosure (see Figure 7). The computer system 80 may be used to implement an analyzer 86 (see Figure 1B), such as a composite material analyzer 86a (see Figure 1B).

[0055] In this exemplary embodiment, as shown in Figure 2, the computer system 80 includes a data bus 116 such as a communication framework that provides communication between one or more computers 82, a storage device 118 including computer memory 120 and fixed storage device 122, an associative memory 124, one or more computer communication devices 126, one or more input / output devices 128, and a display 130.

[0056] As shown in Figure 2, the computer system 80 comprises one or more computers 82, each including one or more processor devices 132 and an operating system 134. The computer system 80 is used to implement one or more computers 82. One or more computers 82, or one or more processor devices 132, may be configured to control one or more functions of one or more elements of the composite material analyzer 86a via a computer program product 84 stored on a storage device 118. One or more computers 82, or one or more processor devices 132, work to execute instructions for the computer program product 84, which can be loaded into computer memory 120. Depending on the specific execution mode, the processor device 132 may be several processors, one multiprocessor core, or some other type of processor.

[0057] As shown in Figure 2, the computer system 80 further comprises a storage device 118 including computer memory 120 and a fixed storage device 122. The storage device 118 is any hardware capable of temporarily, permanently, or temporarily and permanently storing information (but not limited to, data, program code in functional form, or at least one of other suitable information). The computer memory 120 may comprise one or more of random access memory (RAM) including dynamic RAM and / or static RAM, on-chip or off-chip cache memory, or any other suitable volatile or non-volatile computer memory storage device. The fixed storage device 122 may comprise one or more of flash memory, hard drives, solid-state hard drives, read-only memory (ROM), hard disks, floppy disk drives, and magnetic storage devices such as rewritable magnetic tape, rewritable optical disk drives and / or media, non-volatile random access memory (NVRAM), or other suitable fixed storage devices. The media used by the fixed storage device 122 may also be removable. For example, a removable hard drive may be used as the fixed storage device 122.

[0058] As shown in Figure 2, the computer system 80 further comprises one or more computer communication devices 126, such as a networking communication device 136 for linking system 10 (see Figure 1A) to, for example, one or more separate systems. The networking communication device 136 comprises network links between various computers and devices connected together within the network data processing system, for example, via wired connections, wireless communication links, fiber optic cables, coaxial cables, or other suitable network connections for connecting networks, servers, the Internet, or other systems or devices.

[0059] One or more computer communication devices 126 are configured to provide communication according to any number of wired or wireless communication standards. One or more computers 82, or one or more processor devices 132, are configured to facilitate communication through one or more computer communication devices 126 by, for example, controlling the hardware contained within one or more computer communication devices 126. One or more computer communication devices 126 include, for example, one or more antennas, transmitters, receivers, transceivers, and / or processors to enable communication.

[0060] As shown in Figure 2, the computer system 80 further comprises one or more input / output devices 128, a display 130, and a power supply 138. One or more input / output devices 128 provide data input and output by other devices connected to the computer system 80, such as a user interface 106 (see Figure 1B). One or more input / output devices 128 may include devices such as a keyboard, mouse, joystick, or other suitable input / output devices. For example, one or more input / output devices 128 provide connections for input via a keyboard and mouse and transmit output to a printer or other device.

[0061] The display 130 provides a mechanism for displaying information to the user. In one version, the user interface 106 (see Figure 1B), which is in the form of the display 130, provides means for displaying data to the user, a separate automation system, an automation computer program, an automation apparatus, an automation device, or another suitable separate system, program, or device. The power supply 138 of the computer system 80 comprises a battery, electricity, or other power supply element.

[0062] As shown in Figure 2, the computer program product 84 is used in the computer system 80. Instructions for at least one of the operating system 134, applications, and programs may be located in a storage device 118 that communicates with one or more computers 82 and one or more processor devices 132 via a data bus 116. Processes of different embodiments may be executed by one or more computers 82 and / or one or more processor devices 132 using computer implementation instructions that may be located in computer memory 120.

[0063] These instructions are referred to as system logic 140 (see Figure 2) and are part of the computer program product 84. As shown in Figure 2, the system logic 140 includes one or more of the following: algorithm 142, program code 144, computer software 146, computer firmware 148, or other preferred system logic. As shown in Figure 2, the computer program product 84 further comprises a computer-readable medium 150. The computer-readable medium 150 comprises a computer-readable storage medium 150a (see Figure 2), a computer-readable signaling medium 150b (see Figure 2), or another preferred computer-readable medium. In this exemplary embodiment, the computer-readable storage medium 150a is, for example, a physical storage device or tangible storage device used to store the program code 144, rather than a medium for propagating or transmitting the program code 144. Alternatively, the program code 144 may be transmitted to the computer system 80 using the computer-readable signaling medium 150b. The computer-readable signal medium 150b may be, for example, a propagated data signal including program code 144. For example, the computer-readable signal medium 150b may be at least one of electromagnetic signals, optical signals, or any other suitable type of signal. These signals may be transmitted by at least one of the computer communication device 126 or the networking communication device 136.

[0064] System logic 140, including algorithm 142, program code 144, computer software 146, and / or computer firmware 148, is stored in a computer-readable storage medium 150a, read from there, and loaded into one or more computers 82, one or more processor devices 132, or another programmable device, which then configure and instruct one or more computers 82, one or more processor devices 132, or other programmable devices, which then operate on or by one or more computers 82, one or more processor devices 132, or other programmable devices, functioning in a specific manner to produce a particular device or product. The execution of system logic 140, including algorithm 142, program code 144, computer software 146, and / or computer firmware 148, generates a computer implementation system, process, or method which is subsequently executed by one or more computers 82, one or more processor devices 132, or other programmable devices. System logic 140, including algorithm 142, program code 144, computer software 146, and / or computer firmware 148, provides operations for implementing the functions disclosed herein.

[0065] The various components illustrated with respect to the computer system 80 are not intended to impose structural limitations on the various forms in which executions may be implemented. Various exemplary embodiments may be implemented in the computer system 80 including components that are additional to or replace the components illustrated with respect to the computer system 80. Other components shown in Figure 2 may differ from those in the illustrated embodiments. Various embodiments may be implemented using any hardware device or system capable of executing system logic 140, including algorithm 142, program code 144, computer software 146, and / or computer firmware 148.

[0066] Referring here to Figure 3, Figure 3 is a side view illustration of a version of system 10 (e.g., in the form of system 10a) for in-process monitoring 12 (see Figure 1A) of the compression roller 14 of the composite layup machine 18. The composite layup machine 18 comprises an automatic fiber placement (AFP) machine 18a (see Figure 3). As shown in Figure 3, the composite layup machine 18 has a composite laying head 36 equipped with compression roller 14 mounted on the composite laying head 36, and an infrared (IR) camera 60 attached to the composite laying head 36. As shown in Figure 3, system 10 (e.g., in the form of system 10a) further comprises a heater 38 (e.g., in the form of an infrared (IR) heater 38a) attached to the composite laying head 36 at a position 152 in front of the front 17 of the compression roller 14. As shown in Figure 3, system 10 (for example, in the form of system 10a) further comprises a substrate 42 for receiving a tow 32 (such as a composite tow 32a).

[0067] As shown in Figure 3, the composite material laying head 36 moves in direction 154 to lay the tow 32 (such as the composite material tow 32a) onto the surface 156 of the substrate 42. As the composite material laying head 36 moves in direction 154, the heater 38 (for example, in the form of an IR heater 38a) heats the surface 156 of the substrate 42 before the tow 32 (such as the composite material tow 32a) is laid onto the surface 156 of the substrate 42 and compressed by the compression roller 14.

[0068] Figure 3 shows an IR camera 60 mounted on the composite material laying head 36 at a position 158 that is behind or to the rear of the back surface 16 of the compression roller 14. As shown in Figure 3, the lens 160 of the IR camera 60 is oriented towards the back portion 16a of the back surface 16 of the compression roller 14, and the IR camera 60 has a field of view 162 of the back portion 16a of the back surface 16 of the compression roller 14. The IR camera 60 is positioned behind the compression roller 14 and oriented toward the rear of the compression roller 14, and is preferably positioned to have the best possible resolution while including the back surface 16 of the compression roller 14 within the field of view 162. Although Figure 3 shows the IR camera 60 at position 158, the IR camera 60 may be positioned at another location suitable for imaging the back portion 16a of the back surface 16 of the compression roller 14 while the tow 32 (such as the composite material tow 32a) is laid on the substrate 42. Furthermore, although Figure 3 shows one IR camera 60, two or more IR cameras 60 may be positioned on the back portion 16a of the back surface 16 of the compression roller 14 and oriented toward the back portion 16a.

[0069] By focusing the IR camera 60 on the back surface 16 of the compression roller 14, it becomes possible to monitor the compression roller 14. Since there are no or minimal irregular or abnormal shifts within the field of view 162 of the IR camera 60, this monitoring has improved and higher uniformity compared to monitoring the front surface 17 of the compression roller 14 or monitoring other areas of the manufacturing environment 20 (see Figure 1A) of the composite material layup machine 18 (see Figure 1A). When the compression roller 14 comes into close contact with the tow 32 (composite material tow 32a, etc.) at the compression point 164 (see Figure 3), it becomes possible to make arbitrary temperature changes or thermal changes of the tow 32 (composite material tow 32a, etc.) that are imprinted in the form of one or more imprints 166 (see Figures 1B and 8A), also called thermal imprints 167, on the back surface 16a of the compression roller 14 as seen by the IR camera 60. The imprint 166, or thermal imprint 167, represents the transfer of heat 40 from the tow 32 (such as the composite tow 32a) to the surface 76 of the compression roller 14 (see Figure 3). The imprint 166 is a thermal imprint 167 rather than a physical imprint of the compression roller 14. Using one or more IR cameras 60 to view the back surface 16 of the compression roller 14 also avoids any problems with reflected energy from the heater 38.

[0070] As shown in Figure 3, system 10 (for example, in the form of system 10a) further comprises a control system 70 connected to the composite material layup machine 18. As shown in Figure 3, system 10 (for example, in the form of system 10a) further comprises a computer system 80 connected to an IR camera 60, and a computer program product 84 connected to the computer system 80.

[0071] Referring here to Figures 4A and 4B, Figure 4A is an illustration of a perspective side view of another version of system 10 (e.g., in the form of system 10b) for in-process monitoring 12 (see Figure 1A) of the compression rollers 14 of the composite layup machine 18. Figure 4B is an illustration of a perspective rear view of system 10 (e.g., in the form of system 10b) of Figure 4A. As shown in Figures 4A and 4B, system 10 (e.g., in the form of system 10b) comprises a composite layup machine 18 (e.g., in the form of a test composite layup machine 18b) used in a laboratory test environment, having a composite layup head 36 equipped with compression rollers 14 mounted on the composite layup head 36 and an infrared (IR) camera 60 attached to the composite layup head 36. Figure 4A further shows a heater 38 (for example, in the form of an infrared (IR) heater 38a) attached to the composite material laying head 36 at a position 152a in front of the front surface 17 of the compression roller 14.

[0072] As shown in Figures 4A and 4B, one IR camera 60 is mounted on the composite material laying head 36 at a position 158a that is behind or to the rear of the back surface 16 of the compression roller 14. As shown in Figures 4A and 4B, the lens 160 of the IR camera 60 is oriented towards the back portion 16a of the back surface 16 of the compression roller 14, and the IR camera 60 has a field of view 162a of the back portion 16a of the back surface 16 of the compression roller 14. The IR camera 60 is preferably positioned to have the highest possible resolution while including the back surface 16 of the compression roller 14 within the field of view 162a. Although Figures 4A and 4B show the IR camera 60 at position 158a, the IR camera 60 may be positioned at another preferred position for imaging the back surface 16 of the compression roller 14. Furthermore, although Figures 4A and 4B show one IR camera 60, two or more IR cameras 60 may be positioned and oriented towards the back surface 16 of the compression roller 14.

[0073] As shown in Figures 4A and 4B, system 10 (for example, in the form of system 10b) further comprises a control system 70 connected to the composite layup machine 18. As shown in Figures 4A and 4B, system 10 (for example, in the form of system 10b) further comprises a computer system 80 connected to an IR camera 60, and a computer program product 84 connected to the computer system 80. The tow 32 (see Figure 1A) (for example, composite tow 32a (see Figure 1A)) and the substrate 42 (see Figure 1A) are not shown in Figures 4A and 4B.

[0074] Referring now to Figure 5, Figure 5 illustrates a perspective side view of another version of system 10 (e.g., in the form of system 10c) for in-process monitoring 12 (see Figure 1A) of the compression rollers 14 of the composite layup machine 18. As shown in Figure 5, system 10 (e.g., in the form of system 10c) comprises a composite layup machine 18 (e.g., in the form of a manufacturing composite layup machine 18c) used in a manufacturing environment 20 (see Figure 1A) and having a composite layup head 36 equipped with compression rollers 14 mounted on the composite layup head 36 and two infrared (IR) cameras 60 connected to the composite layup head 36 of the composite layup machine 18.

[0075] As shown in Figure 5, the two IR cameras 60, including the first IR camera 60d and the second IR camera 60e, are both positioned at the rear or back of the back surface 16 of the compression roller 14. The first IR camera 60d is positioned at a location 158b in which its lens 160 is oriented to the front half 168, i.e., the left half, of the compression roller 14. The first IR camera 60d has a field of view 162b of the front half 168, of the back surface 16 of the compression roller 14. The second IR camera 60e is positioned at a location 158c in which its lens 160 is oriented to the rear half 170, i.e., the right half, of the compression roller 14. The second IR camera 60e has a field of view 162c of the rear half 170, of the back surface 16 of the compression roller 14.

[0076] As shown in Figure 5, system 10 (for example, in the form of system 10c) further comprises a control system 70 connected to the composite layup machine 18. As shown in Figure 5, system 10 (for example, in the form of system 10c) further comprises a computer system 80 connected to both of the two IR cameras 60, and shows a computer program product 84 connected to the computer system 80. Figure 5 further shows a tow 32 (e.g., composite tow 32a) held in a taut state by the composite laying head 36. The heater 38 (see Figure 1A) and substrate 42 (see Figure 1A) are not shown in Figure 5. Because some compression rollers 14 are larger in size and width, two or more IR cameras 60 may be used to capture all IR images 62 of the back portion 16a of the back surface 16 of the compression roller 14.

[0077] Referring now to Figure 6, which illustrates a flowchart of a version of Method 200 according to an embodiment of the present disclosure. The blocks in Figure 6 represent operations and / or parts thereof, or elements, and the lines connecting the various blocks do not suggest any particular order or dependency of operations and / or parts thereof, or elements. The disclosure of the steps of Method 200 as expressed herein and in Figure 6 should not necessarily be interpreted as determining the sequence in which the steps are performed. Rather, it should be understood that even if one exemplary order is shown, the order of those steps may be modified as appropriate. Thus, certain operations may be performed in different orders or simultaneously.

[0078] As shown in Figure 6, Method 200 includes step 202 of orienting one or more infrared (IR) cameras 60 (see Figures 1A and 1B) towards the compression rollers 14 (see Figure 1A) of the composite laying head 36 (see Figure 1A) of the composite laying machine 18 (see Figure 1A). The composite laying machine 18 comprises one or more of the following: an automatic fiber placement (AFP) composite laying machine 18a (see Figure 3), a test composite laying machine 18b (see Figures 4A and 4B), a manufacturing composite laying machine 18c (see Figure 5), or another suitable composite laying machine. One or more IR cameras 60 are mounted on the rear or back of the back surface 16 (see Figure 1A) of the compression roller 14. The IR cameras 60 include a photographic IR camera 60a (see Figure 1A), a video IR camera 60b (see Figure 1A), a combined photographic / video IR camera 60c (see Figure 1A), or another suitable IR camera.

[0079] As shown in Figure 6, method 200 further includes step 204 of applying heat 40 (see Figure 1A) to the substrate 42 (see Figure 1A) by a heater 38 (see Figure 1A). The heater 38 is mounted in front of the front surface 17 (see Figure 2) of the compression roller 14. The heater 38 comprises an infrared (IR) heater 38a (see Figure 1A), a laser heater 38b (see Figure 1A), or another preferred heater.

[0080] As shown in Figure 6, Method 200 further includes step 206 of using one or more IR cameras 60 to acquire one or more infrared (IR) images 62 (see Figure 1A) of the compression roller 14. The IR images 62 are acquired by one or more IR cameras 60 while the compression roller 14 lays one or more tows 32 (e.g., one or more composite tows 32a) of the composite layup 30 (see Figure 1A) onto the substrate 42. Step 206 of using one or more IR cameras 60 to acquire one or more IR images 62 of the compression roller 14 may further include using one or more IR cameras 60 to acquire one or more IR images 62, which include one or more infrared (IR) photographic images 62a (see Figure 1A), one or more infrared (IR) video images 62b (see Figure 1A), or one of other preferred infrared images. Step 206, which involves using one or more IR cameras 60 to acquire one or more IR images 62 of the compression roller 14, may further include using two or more synchronized IR cameras 60 to acquire two or more IR images 62 configured to be merged together in computer software 146 (see Figure 2) used by computer 82 (see Figures 1B and 2) of computer system 80 (see Figures 1B and 2).

[0081] As shown in Figure 6, Method 200 further includes step 208 of identifying one or more temperature profiles 24 (see Figure 1B) of the compression roller 14 based on one or more IR images 62 in order to obtain one or more identified temperature profiles 24a (see Figure 1B). Step 208 of identifying one or more temperature profiles 24 of the compression roller 14 based on one or more IR images 62 further includes identifying one or more temperature profiles 24 of the back portion 16a (see Figure 1A) of the compression roller 14 based on one or more IR images 62 in order to obtain one or more identified temperature profiles 24a, wherein one or more tows 32 (such as composite tow 32a) are in contact with the compression roller 14. Method 200 further includes the step of identifying one or more temperature profiles 24 of the compression roller 14 based on one or more IR images 62, and then using a computer 82 (see Figures 1B and 2) and a computer program product 84 (see Figure 2) (such as computer software 146 (see Figure 2)) to generate an integrated display 112 (see Figure 1B) of two or more identified temperature profiles 24a of the compression roller 14, and enabling a comparison 114 (see Figure 1B) of the two or more identified temperature profiles 24a.

[0082] As shown in Figure 6, Method 200 further includes a step 210 of analyzing one or more identified temperature profiles 24a. Analyzing one or more identified temperature profiles 24a 210 is done to determine one or more of the layup quality 26 (see Figure 1B) of the composite layup 30 and the heating history 28 (see Figure 1B) of the composite layup 30. Method 200 enables in-process monitoring 12 (see Figure 1A) of the back surface 16 of the compression rollers 14 of the composite layup machine 18.

[0083] As shown in Figure 6, the method 200 may further include, optionally, a step 212 in which, after analyzing one or more identified temperature profiles 24a 210, a determination of at least one layup state 74 (see Figure 1B) of the composite layup 30 based on one or more identified temperature profiles 24a. The step 212 in which a determination of at least one layup state 74 (see Figure 1B) of the composite layup 30 based on one or more identified temperature profiles 24a further includes determining at least one layup state 74 that includes one or more of the following: layup defects 88 (see Figure 1B), foreign object debris (FOD) 90 (see Figure 1B), tape tack quality 92 (see Figure 1B), or another preferred layup state. Step 212, which determines at least one layup state 74 of the composite layup 30 based on one or more identified temperature profiles 24a, further comprises determining at least one layup state 74 based on one or more identified temperature profiles 24a, where the layup defect 88 includes a toe twist 88a, misaligned toe end 88b, missing toe 88c, toe fold 88d, fuzz ball 88e, gap 88f, overlap 88g, or another preferred layup defect, as shown in Figure 1B.

[0084] As shown in Figure 6, Method 200, after step 212 in which one or more identified temperature profiles 24a determine at least one layup state 74 of the composite layup 30, optionally, based on one or more of the one or more identified temperature profiles 24a and at least one layup state 74, determines one or more tows 32 (one or more composite tows 32a, etc.) of material 34 (see Figure 1B) (composite material 34a (Figure 1B) The step 214 may further include adjusting one or more of the compression speed 54 of the compression roller 14 (see Figure 1A), the compression pressure 56 applied by the compression roller 14 (see Figure 1A), and the temperature output 58 of the heater 38 (see Figure 1A) (see Figure 1A), in order to limit the adhesion of the material 34 (such as composite material 34a) to the surface 76 (see Figure 3) of the compression roller 14 and to prevent the material 34 (such as composite material 34a) from wrapping around all or part of the outer circumference 78 (see Figure 3) of the compression roller 14.

[0085] Step 212, which determines at least one layup state 74 of the composite layup 30 based on one or more identified temperature profiles 24a, may further include using machine vision 110 (see Figure 1B) to identify at least one layup state 74 and automatically alerting the user interface 106 (see Figure 1B) of the computer system 80 to at least one layup state 74.

[0086] Step 212, which determines at least one layup state 74 of the composite layup 30 based on one or more identified temperature profiles 24a, may further include: identifying the size 100 (see Figure 1B) of the at least one layup state 74 based on one or more IR images 62; determining whether the size 100 of the at least one layup state 74 is greater than a threshold size 102 (see Figure 1B) based on a known reference size 108 (see Figure 1B); and receiving an instruction 104 (see Figure 1B) at the user interface 106 (see Figure 1B) of the computer system 80 if the size 100 of the at least one layup state 74 is greater than the threshold size 102.

[0087] Referring here to Figure 7, which illustrates a flowchart of another version of Method 220 according to an embodiment of the present disclosure. Another version of the present disclosure provides Method 220 for in-process monitoring 12 (see Figure 1A) of the compression rollers 14 (see Figure 1A) of a composite layup machine 18 (see Figure 1A). The composite layup machine 18 comprises one or more of an automated fiber placement (AFP) composite layup machine 18a (see Figure 3), a test composite layup machine 18b (see Figures 4A and 4B), a manufacturing composite layup machine 18c (see Figure 5), or another preferred composite layup machine.

[0088] The blocks in Figure 7 represent operations and / or parts thereof, or elements, and the lines connecting the various blocks do not suggest any particular order or dependency of operations and / or parts thereof, or elements. The disclosure of the steps of Method 220 as expressed in Figure 7 and herein should not necessarily be interpreted as determining the sequence in which the steps are performed. Rather, even if one exemplary order is shown, it should be understood that the order of those steps may be modified as appropriate. Thus, certain operations may be performed in different orders or simultaneously.

[0089] As shown in Figure 7, Method 220 includes step 222 of orienting one or more infrared (IR) cameras 60 to the back surface 16 (see Figure 1A) of the compression roller 14 of the composite laying head 36 (see Figure 1A) of the composite laying machine 18. One or more IR cameras 60 are mounted on the rear or rear of the back surface 16 of the compression roller 14.

[0090] As shown in Figure 7, method 220 further includes step 224 of applying heat 40 (see Figure 1A) to the substrate 42 (see Figure 1A) by a heater 38 (see Figure 1A). The heater 38 is mounted in front of the compression roller 14. The heater 38 comprises an IR heater 38a (see Figure 1A), a laser heater 38b (see Figure 1A), or another preferred heater.

[0091] As shown in Figure 7, Method 220 further includes step 226 of monitoring the back surface 16 of the compression roller 14 by using one or more IR cameras 60 to acquire one or more infrared (IR) images 62 (see Figure 1A) of the back surface 16 (such as the back portion 16a of the back surface 16 of the compression roller 14). The IR images 62 are acquired by one or more IR cameras 60 while the compression roller 14 lays one or more tows 32 (e.g., one or more composite tows 32a) of the composite layup 30 (see Figure 1A) onto the substrate 42. The IR cameras 60 include a photographic IR camera 60a (see Figure 1A), a video IR camera 60b (see Figure 1A), a combined photographic / video IR camera 60c (see Figure 1A), or another preferred IR camera.

[0092] Step 226 of monitoring the back surface 16 of the compression roller 14 using one or more IR cameras 60 may further include monitoring the back surface 16 of the compression roller 14 using two or more synchronized IR cameras 60 to acquire two or more IR images 62 configured to be merged together in computer software 146 (see Figure 2) of a computer system 80 (see Figure 2). Step 226 of monitoring the back surface 16 of the compression roller 14 using one or more IR cameras 60 may further include monitoring the back surface 16 of the compression roller 14 using one or more IR cameras 60 to acquire one or more IR images 62 including one or more IR photographic images 62a (see Figure 1A), one or more IR video images 62b (see Figure 1A), or one of another preferred infrared images.

[0093] As shown in Figure 7, Method 220 further includes step 228 of identifying one or more temperature profiles 24 (see Figure 1B) of the back portion 16a (see Figure 1A) of the back surface 16 of the compression roller 14 based on one or more IR images 62 in order to obtain one or more identified temperature profiles 24a (see Figure 1B). One or more tows 32 (such as one or more composite tows 32a) are in contact with the compression roller 14.

[0094] As shown in Figure 7, method 220 further includes step 230 of analyzing one or more identified temperature profiles 24a. Analyzing one or more identified temperature profiles 24a 230 is done to determine one or more of the layup quality 26 (see Figure 1B) of the composite layup 30 and the heating history 28 (see Figure 1B) of the composite layup 30.

[0095] As shown in Figure 7, the method 220 may further include, optionally, a step 232 in which, after analyzing one or more identified temperature profiles 24a 230, a determination of at least one layup state 74 (see Figure 1B) of the composite layup 30 based on one or more identified temperature profiles 24a. The step 232 in which a determination of at least one layup state 74 of the composite layup 30 based on one or more identified temperature profiles 24a further includes determining at least one layup state 74 that includes one or more of the following: layup defects 88 (see Figure 1B), foreign object debris (FOD) 90 (see Figure 1B), tape tack quality 92 (see Figure 1B), or another preferred layup state. Step 232, which determines at least one layup state 74 of the composite layup 30 based on one or more identified temperature profiles 24a, further comprises determining at least one layup state 74 based on one or more identified temperature profiles 24a, where the layup defect 88 includes a toe twist 88a, misaligned toe end 88b, missing toe 88c, toe fold 88d, fuzz ball 88e, gap 88f, overlap 88g, or another preferred layup defect, as shown in Figure 1B.

[0096] As shown in Figure 7, Method 220 determines at least one layup state 74 of the composite layup 30 based on one or more identified temperature profiles 24a, and then optionally determines one or more of the materials 34 (see Figure 1B) (composite material 34a (Figure 1B)) of one or more tows 32 (e.g., one or more composite tows 32a) based on one or more of the identified temperature profiles 24a and at least one layup state 74. The step 234 may further include adjusting one or more of the compression speed 54 (see Figure 1A) of the compression roller 14, the compression pressure 56 (see Figure 1A) applied by the compression roller 14, and the temperature output 58 (see Figure 1A) of the heater 38 (see Figure 1A) in order to limit the material 34 (such as composite material 34a) from sticking to the surface 76 (see Figure 3) of the compression roller 14 and to prevent the material 34 (such as composite material 34a) from wrapping around all or part of the outer circumference 78 (see Figure 3) of the compression roller 14.

[0097] As shown in Figure 7, the method 220 further optionally includes, after step 234 which adjusts based on one or more identified temperature profiles 24a and one or more of at least one layup states 74, step 236 which uses a composite layup 30 to form a part 48 (see Figure 15) (e.g., composite part 48a (see Figure 15)) on a vehicle 50 (see Figure 15) (e.g., aircraft 50a (see Figure 15)).

[0098] Referring to Figure 8A, Figure 8A is an illustration of an infrared (IR) image 62 (in the form of a toe-twisted infrared (IR) image 62c) of the region of interest 240 on the back portion 16a of the back surface 16 of the compression roller 14 of system 10 (see Figure 1A). Figure 8A shows the total width 242 of the compression roller 14 and the width 244 of the region of interest 240.

[0099] The regions of interest 240 shown in Figures 8A, 9A, 10A, 11A, 12A, and 13 include the imprint 166 or thermal imprint 167 of the tow 32 (composite material tow 32a, etc.) at the compression point 164 (see Figure 3) when the compression roller 14 rides onto the tow 32 (composite material tow 32a, etc.) and the tow is laid on the substrate 42 (see Figure 3). By the compression roller 14 making close contact with the tow 32 (composite material tow 32a, etc.) at the compression point 164 (see Figure 3), arbitrary temperature changes or thermal changes of the tow 32 (composite material tow 32a, etc.) are imprinted in the form of an imprint 166 on the back portion 16a of the back surface 16 of the compression roller 14, and the IR camera 60 can acquire an IR image 62 of the imprint 166. The imprint 166 represents the transfer of heat 40 (see Figure 1A) from the tow 32 (such as the composite tow 32a) to the surface 76 (see Figure 3) of the compression roller 14.

[0100] As shown in Figure 8A, the IR image 62 (in the form of a toe-twisted IR image 62c) shows eight imprints 166, or thermal imprints 167, of the toe 32 (such as a composite toe 32a), including the first imprint 166a, the second imprint 166b, the third imprint 166c, the fourth imprint 166d, the fifth imprint 166e, the sixth imprint 166f, the seventh imprint 166g, and the eighth imprint 166h. As shown in Figure 8A, the first imprint 166a, the second imprint 166b, the fourth imprint 166d, the fifth imprint 166e, the sixth imprint 166f, and the eighth imprint 166h are toe 32 imprints 166 representing a good or acceptable toe 32. As further shown in Figure 8A, the third imprint 166c and the seventh imprint 166g are imprints 166 representing the tow 32 which has been transformed into a tow twist 88a, and the tow 32 is laid on the substrate 42 and is deformed and twisted as the compression roller 14 rolls over it.

[0101] Referring here to Figure 8B, Figure 8B is an illustration of a graph 246 by plotting 247 of temperature profiles 24, such as the identified temperature profile 24a (in the form of a tow twist temperature profile 24b) of the region of interest 240 in Figure 8A. The graph 246 shows pixels 64 along the x-axis and the temperature 68 of the tow 32 (e.g., composite tow 32a) in Fahrenheit (°F) along the y-axis. Plot 247 takes the average value from the column of pixels 64 along the width 244 of the region of interest 240 and displays it on the graph 246. This also applies to the graphs in Figures 9B, 10B, 11B, and 12B. Furthermore, the compression roller 14 provides the average value of the temperature 68 of the tow 32 by conduction of heat 40 from the substrate 42. In other embodiments, the region of interest from which the graph is obtained may be in the shape of a line rather than a box, and since the line provides data without averaging across the column of pixels, it may be suitable for detecting smaller and more delicate display values.

[0102] As shown in Figure 8B, the temperature profile 24 (in the form of a toe-twisted temperature profile 24b) displays a first portion 248a having a higher temperature (120°F, 110°F) peak 250 and a lower temperature (80°F) trough 252 between the peaks 250, so as to show a third imprint 166c with a toe-twist 88a in Figure 8A. Further shown in Figure 8B, the temperature profile 24 (in the form of a toe-twisted temperature profile 24b) displays a second portion 248b having a higher temperature (110°F) peak 250, so as to point out a seventh imprint 166g with a toe-twist 88a in Figure 8A. The toe twist temperature profile 24b shown in Graph 246 may be used to indicate the presence of a layup condition 74 (e.g., a layup defect 88), and the toe twist IR image 62c can be used to indicate and verify that the toe twist 88a occurred at the location of the composite layup 30.

[0103] Referring now to Figure 9A, Figure 9A is an illustration of an infrared (IR) image 62 (in the form of an unaligned tow-end infrared (IR) image 62d) of a region of interest 240 on the back portion 16a of the back surface 16 of the compression roller 14 of system 10 (see Figure 1A). Figure 9A shows the total width 242 of the compression roller 14 and the width 244 of the region of interest 240. As shown in Figure 9A, the IR image 62 (in the form of an unaligned tow-end IR image 62d) shows eight imprints 166 or thermal imprints 167 of the tow 32 (such as a composite tow 32a), including a first imprint 166a, a second imprint 166b, a third imprint 166c, a fourth imprint 166d, a fifth imprint 166e, a sixth imprint 166f, a seventh imprint 166g, and an eighth imprint 166h. As shown in Figure 9A, the first imprint 166a, the second imprint 166b, and the third imprint 166c are imprints 166 of the tow 32, each representing a misaligned tow end 88b, where the end of the tow 32 is cut or added by the composite layup machine 18, which is not aligned or conforming to the end of the component when laid on the substrate 42, and occurs where the compression roller 14 continues to rotate over the end between the tow 32 laid on the substrate 42 and the surface 156 (see Figure 3) (metal surface, etc.) of the substrate 42 (see Figures 1A and 3). As further shown in Figure 9A, the fourth imprint 166d, the fifth imprint 166e, the sixth imprint 166f, the seventh imprint 166g, and the eighth imprint 166h are imprints 166 of the tow 32, each representing a good or acceptable tow 32.

[0104] Referring here to Figure 9B, Figure 9B is an illustration of a graph 254 by plotting temperature profiles 24 such as the identified temperature profile 24a (in the form of a tow-end temperature profile 24c) of the region of interest 240 in Figure 9A. Graph 254 shows the temperature 68 of the tow 32 (e.g., composite tow 32a) in Fahrenheit (°F) along the x-axis, with pixels 64 along the x-axis. As shown in Figure 9B, the temperature profile 24 (in the form of a tow-end temperature profile 24c) shows a low-temperature region (65-75°F) 256 to point out the first imprint 166a, second imprint 166b, and third imprint 166c with misaligned tow ends 88b in Figure 9A, where the compression roller 14 is in contact with the unheated or low-temperature portion of the substrate 42 or tow 32. The tow-end temperature profile 24c shown in Graph 254 may be used to indicate the presence of a layup condition 74 (e.g., a layup defect 88), and by looking at the misaligned tow-end IR image 62d, it can be pointed out and verified that the misaligned tow-end 88b occurred at the location of the composite layup 30.

[0105] Referring now to Figure 10A, Figure 10A is an illustration of an infrared (IR) image 62 (in the form of a missing tow infrared (IR) image 62e) of a region of interest 240 on the back portion 16a of the back surface 16 of the compression roller 14 of system 10 (see Figure 1A). Figure 10A shows the total width 242 of the compression roller 14 and the width 244 of the region of interest 240. As shown in Figure 10A, the IR image 62 (in the form of a missing tow IR image 62e) shows eight imprints 166 or thermal imprints 167 of the tow 32 (such as a composite tow 32a), including the first imprint 166a, the second imprint 166b, the third imprint 166c, the fourth imprint 166d, the fifth imprint 166e, the sixth imprint 166f, the seventh imprint 166g, and the eighth imprint 166h. As shown in Figure 10A, the first imprint 166a, the second imprint 166b, the third imprint 166c, the fourth imprint 166d, the fifth imprint 166e, the seventh imprint 166g, and the eighth imprint 166h are tow 32 imprints 166 representing good or acceptable tows 32. As further shown in Figure 10A, the sixth imprint 166f is a tow 32 imprint 166 representing a missing tow 88c that was not fed out of the composite material laying head 36 or dropped and was not laid on the substrate 42.

[0106] Referring now to Figure 10B, Figure 10B is an illustration of a graph 258 by plotting temperature profiles 24 such as the identified temperature profile 24a (in the form of a missing tow temperature profile 24d) in the region of interest 240 of Figure 10A. Graph 258 shows the temperature 68 of the tow (e.g., composite tow 32a) in Fahrenheit (°F) along the x-axis, with pixels 64 along the x-axis. As shown in Figure 10B, the temperature profile 24 (in the form of a missing tow temperature profile 24d) shows a portion 260 with a higher temperature (140°F) peak 250, pointing to the seventh imprint 166g with a missing tow 88c in Figure 10A. The tow 32 (e.g., composite tow 32a) is dispensed from the composite laying head 36 at a temperature 68 lower than the ambient temperature, and the lower temperature tow 32 shields the compression roller 14 from the heated substrate 42 warmed by the heater 38. If there is a missing tow 88c where the tow 32 does not fall from or is not fed out from the composite laying head 36, the compression roller 14 has a hot imprint 166 at the location of the missing tow 88c on the composite layup 30. The missing tow temperature profile 24d shown in graph 258 may be used to indicate the presence of a layup condition 74 (e.g., a layup defect 88), and the missing tow IR image 62e can be used to indicate and verify that the missing tow 88c occurred at the location of the composite layup 30.

[0107] Referring here to Figure 11A, Figure 11A is an illustration of an infrared (IR) image 62 (in the form of a towfold infrared (IR) image 62f) of a region of interest 240 on the back portion 16a of the back surface 16 of the compression roller 14 of system 10 (see Figure 1A). Figure 11A shows the total width 242 of the compression roller 14 and the width 244 of the region of interest 240. As shown in Figure 11A, the IR image 62 (in the form of a towfold IR image 62f) shows eight imprints 166, or thermal imprints 167, of the tow 32 (such as a composite tow 32a), including a first imprint 166a, a second imprint 166b, a third imprint 166c, a fourth imprint 166d, a fifth imprint 166e, a sixth imprint 166f, a seventh imprint 166g, and an eighth imprint 166h. As shown in Figure 11A, the first imprint 166a is an imprint 166 of the tow 32 representing the tow fold 88d, which is the tow 32 or the end of the tow 32 that is folded over itself when laid on the substrate 42. As further shown in Figure 11A, the second imprint 166b, the third imprint 166c, the fourth imprint 166d, the fifth imprint 166e, the sixth imprint 166f, the seventh imprint 166g, and the eighth imprint 166h are imprints 166 of the tow 32 representing a good or acceptable tow 32.

[0108] Referring here to Figure 11B, Figure 11B is an illustration of a graph 262 by plot 263 of temperature profiles 24, such as the identified temperature profile 24a (in the form of a towfold temperature profile 24e) of the region of interest 240 in Figure 11A. Graph 262 shows the temperature 68 of the tow 32 (e.g., composite tow 32a) in Fahrenheit (°F) along the x-axis, with pixels 64 along the x-axis. As shown in Figure 11B, the temperature profile 24 (in the form of a towfold temperature profile 24e) shows a first portion 264 having a higher temperature (90°F) peak 250 and a lower temperature (80°F) valley 252 between the peaks 250, as shown in Figure 11A with a first imprint 166a having a towfold 88d. The towfold temperature profile 24e shown in Graph 262 may be used to indicate the presence of a layup condition 74 (e.g., a layup defect 88), and the towfold IR image 62f can be used to indicate and verify that the towfold 88d occurred at the location of the composite layup 30.

[0109] Referring now to Figure 12A, Figure 12A is an illustration of an infrared (IR) image 62 (in the form of a fuzzball infrared (IR) image 62g) of a region of interest 240 on the back portion 16a of the back surface 16 of the compression roller 14 of system 10 (see Figure 1A). Figure 12A shows the total width 242 of the compression roller 14 and the width 244 of the region of interest 240. As shown in Figure 12A, the IR image 62 (in the form of a fuzzball IR image 62g) shows eight imprints 166, or thermal imprints 167, of the tow 32 (such as a composite tow 32a), including the first imprint 166a, the second imprint 166b, the third imprint 166c, the fourth imprint 166d, the fifth imprint 166e, the sixth imprint 166f, the seventh imprint 166g, and the eighth imprint 166h. As shown in Figure 12A, the first imprint 166a, the second imprint 166b, the third imprint 166c, the fourth imprint 166d, the fifth imprint 166e, the seventh imprint 166g, and the eighth imprint 166h are tow 32 imprints 166 representing a good or acceptable tow 32. As shown in Figure 12A, the sixth imprint 166f is a tow 32 imprint 166 representing a tow 32 with a fuzz ball 88e, where the compression roller 14 rides on top of the fuzz ball 88e that fell onto the tow 32 when it was laid on the substrate 42.

[0110] Referring now to Figure 12B, Figure 12B is an illustration of a graph 266 by plotting temperature profiles 24 such as the identified temperature profile 24a (in the form of a fuzzball temperature profile 24f) in the region of interest 240 of Figure 12A. Graph 266 shows the temperature 68 of the tow 32 (e.g., composite tow 32a) in Fahrenheit (°F) along the x-axis, with pixels 64 along the x-axis. As shown in Figure 12B, the temperature profile 24 (in the form of a fuzzball temperature profile 24f) shows a portion 268 with a lower temperature (85°F) peak 250, pointing to the sixth imprint 166f of the tow 32 having a fuzzball 88e in Figure 12A. The fuzzball temperature profile 24f shown in Graph 266 may be used to indicate the presence of a layup condition 74 (e.g., a layup defect 88), and by looking at the fuzzball IR image 62g, it can be pointed out and verified that the fuzzball 88e occurred at the location of the composite layup 30.

[0111] Figure 13A is an illustration of an infrared (IR) image 62 (in the form of a gap infrared (IR) image 62h) of a region of interest 240 on the back portion 16a of the back surface 16 of the compression roller 14 of system 10 (see Figure 1A). Figure 13A shows the total width 242 of the compression roller 14 and the width 244 of the region of interest 240. As shown in Figure 13A, the IR image 62 (in the form of a gap IR image 62h) shows eight imprints 166, or thermal imprints 167, of the tow 32 (such as a composite tow 32a), including a first imprint 166a, a second imprint 166b, a third imprint 166c, a fourth imprint 166d, a fifth imprint 166e, a sixth imprint 166f, a seventh imprint 166g, and an eighth imprint 166h. As shown in Figure 13A, the first imprint 166a, the third imprint 166c, the fourth imprint 166d, the fifth imprint 166e, the sixth imprint 166f, the seventh imprint 166g, and the eighth imprint 166h are tow 32 imprints 166 representing a good or acceptable tow 32. As further shown in Figure 13A, the second imprint 166b is a tow 32 imprint 166 representing a tow 32 having a gap 88f between the second imprint 166b and the adjacent third imprint 166c, where the tow 32 is not properly laid on the substrate 42 and a gap 88f is formed between the two tows 32.

[0112] Referring here to Figure 13B, Figure 13B is an illustration of Graph 270 by plot 272 of temperature profiles 24, such as the identified temperature profile 24a (in the form of a gap temperature profile 24g) of the region of interest 240 in Figure 13A. Graph 270 shows the temperature 68 of the tow 32 (e.g., composite tow 32a) in Fahrenheit (°F) along the x-axis, with 64 pixels along the x-axis. As shown in Figure 13B, the temperature profile 24 (in the form of a gap temperature profile 24g) shows a portion 274 with a higher temperature (155°F) peak 250 to point out the second imprint 166b of the tow 32 having a gap 88f in Figure 13A. The gap temperature profile 24g shown in Graph 270 may be used to point out the presence of a layup condition 74 (e.g., a layup defect 88), and by looking at the gap IR image 62h, it can be pointed out and verified that the gap 88f occurred at the location of the composite layup 30.

[0113] Referring now to Figure 14, Figure 14 is an illustration of an infrared (IR) image 62 (in the form of an infrared (IR) image 62i of good tack quality / poor tack quality) of a region of interest 240 on the back portion 16a of the back surface 16 of the compression roller 14 of system 10 (see Figure 1A). Figure 14 shows the total width 242 of the compression roller 14 and the width 244 of the region of interest 240. As shown in Figure 14, the IR image 62 (in the form of an IR image 62i of good tack quality / poor tack quality) shows eight imprints 166 or thermal imprints 167 of the tow 32 (such as a composite tow 32a), including the first imprint 166a, the second imprint 166b, the third imprint 166c, the fourth imprint 166d, the fifth imprint 166e, the sixth imprint 166f, the seventh imprint 166g, and the eighth imprint 166h. As shown in Figure 14, the first imprint 166a, the second imprint 166b, the third imprint 166c, and the fourth imprint 166d are imprints 166 of tow 32 representing a tow with poor tack quality 92b (see also Figure 1B). Further shown in Figure 14, the fifth imprint 166e, the sixth imprint 166f, the seventh imprint 166g, and the eighth imprint 166h are imprints 166 of tow 32 representing a good or acceptable tow 32 with good tack quality 92a (see also Figure 1B). Although a graph showing the temperature profile 24 (such as the identified temperature profile 24a) of the region of interest 240 in Figure 14 is not shown, an indicator of good tack quality 92a is that the imprint 166 of the tow 32 on the compression roller 14 shows a uniformly warm temperature region with respect to the temperature profile 24, while an indicator of poor tack quality 92b is that the imprint 166 of the tow 32 on the compression roller 14 shows a non-uniform cold temperature region with respect to the temperature profile 24.

[0114] Referring now to Figure 15, Figure 15 is an illustration of a perspective view of a vehicle 50 (aircraft 50a, etc.) incorporating a component 48 (composite component 48a, etc.) formed from a composite layup 30 (see Figure 1A) of a tow 32 (see Figure 1A) (composite tow 32a (see Figure 1A)), which can be monitored using System 10 (see Figure 1A) and exemplary versions of Method 200 (see Figure 6) or Method 220 (see Figure 7) of the present disclosure. As shown in Figure 15, the vehicle 50 (aircraft 50a, etc.) includes a fuselage 280, a nose 282, wings 284, engines 286, and a tail wing 288. As shown in Figure 15, the tail wing 288 includes a horizontal stabilizer 290 and a vertical stabilizer 292. In one exemplary version, as shown in Figure 15, the component 48 (composite component 48a, etc.) is used in the manufacture of the vehicle 50 (aircraft 50a, etc.). Component 48 (such as composite component 48a) may be made in the manufacture of a vehicle 50, including rotary-wing aircraft, spacecraft, ships, and other suitable vehicles, or in the manufacture of a suitable structure.

[0115] Referring here to Figures 16 and 17, Figure 16 is an illustration of a flowchart of an exemplary aircraft and service method 300, and Figure 17 is an illustration of an exemplary block diagram of an aircraft 316. With reference to Figures 16 and 17, a version of this disclosure may be described in light of the aircraft manufacturing and maintenance method 300 shown in Figure 16 and the aircraft 316 shown in Figure 17.

[0116] An exemplary aircraft manufacturing and maintenance method 300 may include, in the pre-manufacturing stage, the specification and design 302 of the aircraft 316 and the procurement of materials 304. In the manufacturing stage, the manufacturing 306 of the components and subassemblies of the aircraft 316 and system integration 308 are carried out. The aircraft 316 is then licensed and delivered 310 for operation 312. While in operation 312 by the customer, the aircraft 316 may be scheduled for periodic maintenance and upkeep 314 (which may also include modifications, reconfigurations, refurbishments, and other suitable maintenance).

[0117] Each process of the aircraft manufacturing and maintenance method 300 may be carried out or performed by a system integrator, a third party, and / or an operator (e.g., a customer). In this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors. A third party may include, but is not limited to, any number of suppliers, subcontractors, and other suppliers. An operator may include an airline, leasing company, military organization, service organization, and other suitable operator.

[0118] As shown in Figure 17, an aircraft 316 manufactured by the exemplary aircraft manufacturing and maintenance method 300 may include a fuselage 318 having multiple systems 320 and interior 322. Examples of the multiple systems 320 may include one or more of the propulsion system 324, electrical system 326, hydraulic system 328, and environmental system 330. Any number of other systems may also be included. Although an example from the aerospace industry has been given, the principles of this disclosure may also be applied to other industries such as the automotive industry.

[0119] The methods and systems embodied herein may be employed at any stage of one or more of the aircraft manufacturing and maintenance methods 300. For example, components or subassemblies corresponding to component and subassembly manufacturing 306 may be manufactured in a similar manner to components or subassemblies manufactured during the operation 312 of the aircraft 316. Also, one or more embodiments of devices, embodiments of methods, or combinations thereof may be used in component and subassembly manufacturing 306 and system integration 308, for example, to expedite the assembly of the aircraft 316 or to reduce the cost of the aircraft 316. Similarly, one or more embodiments of devices, embodiments of methods, or combinations thereof may be used in maintenance and servicing 314 during the operation 312 of the aircraft 316, for example, but not limited to these.

[0120] The disclosed versions of System 10 (see Figures 1A, 1B, 3-5), Method 200 (see Figure 6), and Method 220 (see Figure 7) monitor the field of view 162 (see Figure 3) of one or more infrared (IR) cameras focused on the rear portion 16a (see Figure 3) of the back surface 16 (see Figure 3) of the compression roller 14 (see Figure 3) of the composite material laying head 36, i.e., the tape layup head, The system provides in-process monitoring 12 (see Figure 1B) of layup quality 26 (see Figure 1B), an overall layup condition including layup defects 88 (see Figure 1B), foreign object debris (FOD) 90 (see Figure 1B), and tape tack quality 92 (see Figure 1B), and a heating history 28 (see Figure 1B) of the composite layup 30 (see Figure 1A). An exemplary version recognizes and considers that, during automated composite layup using a composite layup machine 18, in-process monitoring 12 of the back portion 16a of the back of the compression roller 14 identifies one or more temperature profiles 24 (see Figure 1B) of the compression roller 14 and obtains one or more identified temperature profiles 24a (see Figure 1B) to determine the layup quality 26 and heating history 28 of the composite layup 30 (see Figure 1A).

[0121] By focusing one or more IR cameras 60 on the rear portion 16a of the back surface 16 of the compression roller 14, monitoring of the compression roller 14 becomes possible, and because there are no or minimal irregular or abnormal shifts within the field of view 162 of the IR cameras 60, for example, the IR cameras 60 are not set to look at tools or other objects while moving, which would unnecessarily look at the material. As a result, monitoring is improved and has greater uniformity than monitoring the front surface 17 of the compression roller 14 or monitoring other areas of the manufacturing environment 20 (see Figure 1A) of the composite material layup machine 18 (see Figure 1A). When the compression roller 14 makes close contact with the tow 32 (composite tow 32a, etc.) of the composite layup 30 at the compression point 164 (see Figure 3), any temperature changes 68 (see Figure 1B) or thermal changes of the tow 32 (composite tow 32a, etc.) imprinted on the back portion 16a of the back surface 16 of the compression roller 14 in the form of an imprint 166 (see Figure 8A) can be observed with the IR camera 60. Using one or more IR cameras 60 to view the back surface 16 of the compression roller 14 also avoids any problems with reflected energy from the heater 38. One or more IR cameras 60, or thermal cameras, are focused on the back portion 16a of the back surface 16 of the compression roller 14 on the composite layup machine 18 and are used to monitor the thermal artifacts or temperature profile 24 of the compression roller 14 and determine the layup quality 26 and heating history 28.

[0122] In addition, the disclosed versions of System 10 (see Figures 1A, 1B, 3-5), Method 200 (see Figure 6), and Method 220 (see Figure 7) avoid the need for monitoring the component surface and avoid confusion due to the presence of surface contour changes and various reflections and deviations within the field of view of the IR camera. Rather, the compression roller 14 has a more uniform material profile compared to the surface contour changes of the substrate 42. The compression roller 14 brings about an average temperature 68 of the tow 32 by conduction of heat 40 from the substrate 42.

[0123] Moreover, the disclosed versions of System 10 (see Figures 1A, 1B, 3-5), Method 200 (see Figure 6), and Method 220 (see Figure 7) avoid the need to measure actual layups which can be subject to a large amount of noise and processing. Furthermore, the disclosed versions of System 10 (see Figures 1A, 1B, 3-5), Method 200 (see Figure 6), and Method 220 (see Figure 7) allow for real-time rapid adjustment or correction of settings, controls, and parameters 52 (see Figure 1A), namely the compression speed 54 (see Figure 1A), compression pressure 56 (see Figure 1A), and temperature output 58 (see Figure 1A) of the composite laying head 36 and compression roller 14 of the composite layup machine 18, if signs 104 of layup defects 88, foreign object debris (FOD) 90, and / or tape tack quality 92 are observed during monitoring of the compression roller 14. Such adjustments or modifications may be made before the next or subsequent round of the tow 32 (e.g., composite tow 32a) is laid on the substrate 42. Furthermore, the disclosed versions of System 10 (see Figures 1A, 1B, 3-5), Method 200 (see Figure 6), and Method 220 (see Figure 7) provide a method for verifying that there are no layup defects 88, foreign object debris (FOD) 90, and / or tape tack quality 92 issues that could require the composite layup machine 18 to be shut down. As a result, the composite layup machine 18 can be operated at optimal efficiency, and delays due to the shutdown of the composite layup machine 18 for inspection or monitoring of such issues can be eliminated or minimized.

[0124] In addition, the disclosed versions of System 10 (see Figures 1A, 1B, 3-5), Method 200 (see Figure 6), and Method 220 (see Figure 7) quantitatively evaluate the layup quality 26 and layup state 74 of the composite layup 30 during the layup process and automate the verification of the layup quality 26. Furthermore, the disclosed versions of System 10 (see Figures 1A, 1B, 3-5), Method 200 (see Figure 6), and Method 220 (see Figure 7) use one or more IR cameras 60 positioned to view an optimal location on the back surface 16 of the compression roller 14 in a way that is easily and unobstructedly visible in order to determine the layup quality 26 and / or heating history 28 of the composite layup 30.

[0125] Furthermore, exemplary and non-limiting embodiments of this disclosure are described in the following paragraphs.

[0126] In embodiments of the present disclosure, the method includes the steps of orienting one or more infrared cameras to a compression roller of a composite laying head of a composite laying machine, wherein one or more infrared cameras are mounted on the rear of the compression roller; heating a substrate with a heater mounted in front of the compression roller; using one or more infrared cameras to acquire one or more infrared images of the compression roller (14) while laying one or more composite tows of a composite layup on a substrate with the compression roller; identifying one or more temperature profiles of the compression roller based on one or more infrared images to acquire one or more identified temperature profiles; and analyzing one or more identified temperature profiles to determine one or more of the layup quality of the composite layup and the heating history of the composite layup.

[0127] Optionally, the method described in the preceding paragraph further includes, after the step of analyzing one or more identified temperature profiles, determining at least one layup state of a composite layup based on one or more identified temperature profiles.

[0128] Optionally, determining at least one layup state of a composite layup based on one or more identified temperature profiles in one of the methods of the preceding paragraph further includes determining at least one layup state that includes one or more of layup defects, foreign matter fragments, and tape tack quality based on one or more identified temperature profiles.

[0129] Optionally, determining at least one layup state of a composite layup based on one or more identified temperature profiles in one of the methods of the preceding paragraph includes determining at least one layup state based on one or more identified temperature profiles, wherein the layup defects further include toe twist, misaligned toe ends, missing toe, toe fold, fuzz ball, gap, or overlap.

[0130] Optionally, one of the methods in the preceding paragraph further includes, after determining at least one layup state of a composite layup based on one or more identified temperature profiles, adjusting one or more of the compression speed of the compression rollers, the compression pressure applied by the compression rollers, and the temperature output of the heaters, based on one or more identified temperature profiles and one or more of the at least one layup state, in order to limit the material of one or more composite tows from sticking to the surface of the compression rollers and to prevent the material from wrapping around the compression rollers.

[0131] Optionally, determining at least one layup state of a composite layup based on one or more identified temperature profiles in one of the methods of the preceding paragraph further includes using machine vision to identify at least one layup state and to automatically alert the user interface to at least one layup state.

[0132] Optionally, determining at least one layup state of a composite layup based on one or more identified temperature profiles in one of the methods of the preceding paragraph further includes identifying the size of the at least one layup state based on one or more infrared images, determining whether the size of the at least one layup state is greater than a threshold size based on a known reference size, and receiving instructions to the user interface if the size of the at least one layup state is greater than the threshold size.

[0133] Optionally, one of the methods in the preceding paragraph further includes, after the step of identifying one or more temperature profiles of a compression roller based on one or more infrared images, the step of enabling a comparison of the two or more identified temperature profiles using a computer and computer program product that generates an integrated display of the two or more identified temperature profiles of the compression roller.

[0134] Optionally, using one or more infrared cameras to acquire infrared images of one or more compression rollers in one of the methods of the preceding paragraph further includes using one or more infrared cameras to acquire one or more infrared images including one or more infrared photographic images and one or more infrared video images.

[0135] Optionally, using one or more infrared cameras to acquire infrared images of one or more compression rollers in one of the methods of the preceding paragraph further includes using two or more synchronized infrared cameras to acquire two or more infrared images configured to be merged together in computer software of a computer system.

[0136] Optionally, identifying one or more temperature profiles of a compression roller based on one or more infrared images in one of the methods of the preceding paragraph further includes identifying one or more temperature profiles of the back portion of the compression roller based on one or more infrared images.

[0137] In another embodiment of the present disclosure, a method for in-process monitoring of a compression roller of a composite layup machine includes the steps of: orienting one or more infrared cameras to the back of a compression roller of a composite laying head of a composite layup machine, wherein the one or more infrared cameras are mounted on the rear of the compression roller; applying heat to a substrate with a heater, wherein the heater is mounted on the front of the compression roller; monitoring the back of the compression roller by using one or more infrared cameras to acquire one or more infrared images of the back of the compression roller while laying one or more composite tows of a composite layup onto a substrate with the compression roller; identifying one or more temperature profiles of the back portion of the compression roller based on one or more infrared images to acquire one or more identified temperature profiles; and analyzing one or more identified temperature profiles to determine one or more of the layup quality of the composite layup and the heating history of the composite layup.

[0138] Optionally, the method described in the preceding paragraph further includes, after the step of analyzing one or more identified temperature profiles, determining at least one layup state of a composite layup based on one or more identified temperature profiles.

[0139] Optionally, determining at least one layup state of a composite layup based on one or more identified temperature profiles in one of the methods of the preceding paragraph further includes determining at least one layup state that includes one or more of layup defects, foreign matter fragments, and tape tack quality based on one or more identified temperature profiles.

[0140] Optionally, determining at least one layup state of a composite layup based on one or more identified temperature profiles in one of the methods of the preceding paragraph further includes determining at least one layup state based on one or more identified temperature profiles, wherein the layup defects include toe twist, misaligned toe ends, missing toe, toe fold, fuzz ball, gap, or overlap.

[0141] Optionally, one of the methods in the preceding paragraph further includes, after determining at least one layup state of a composite layup based on one or more identified temperature profiles, adjusting one or more of the compression speed of the compression rollers, the compression pressure applied by the compression rollers, and the temperature output of the heaters, based on one or more identified temperature profiles and one or more of the at least one layup state, in order to limit the material of one or more composite tows from sticking to the surface of the compression rollers and to prevent the material from wrapping around the compression rollers.

[0142] Optionally, one of the methods in the preceding paragraph further includes the step of using the composite layup to form a composite component for an aircraft, after the step of adjusting based on one or more identified temperature profiles and one or more of at least one layup states.

[0143] Optionally, monitoring the back of the compression roller by using one or more infrared cameras in one of the methods described in the preceding paragraph further includes monitoring the back of the compression roller by using two or more synchronized infrared cameras to acquire two or more infrared images configured to be merged together in computer software of a computer system.

[0144] In another embodiment of the present disclosure, a system for in-process monitoring of compression rollers of a composite layup machine comprises: (i) a composite layup head having compression rollers connected to a composite layup head; (ii) a heater mounted in front of the compression rollers and configured to heat a substrate; and (iii) one or more infrared cameras mounted behind the compression rollers for monitoring the compression rollers, wherein one or more infrared cameras are configured to capture one or more infrared images of the compression rollers while laying one or more composite tows of a composite layup onto a substrate by the compression rollers; and a computer system having a composite analyzer configured to identify one or more temperature profiles of the compression rollers based on one or more infrared images in order to acquire one or more identified temperature profiles and enable analysis of one or more identified temperature profiles and to determine one or more of the layup quality and heating history of the composite layup.

[0145] Optionally, in the system described in the previous paragraph, one or more identified temperature profiles are used to determine at least one layup state of the composite layup.

[0146] Optionally, in a system according to one of the preceding paragraphs, at least one layup condition includes one or more of layup defects, foreign matter fragments, and tape tack quality.

[0147] By choice, in a system according to one of the preceding paragraphs, layup defects include toe twist, misaligned toe end, missing toe, toe fold, fuzz ball, gap, or overlap.

[0148] Optionally, in a system according to one of the preceding paragraphs, to limit the material of one or more composite tows from adhering to the surface of the compression rollers and to prevent the material from wrapping around the compression rollers, the control system comprises one or more controllers configured to adjust one or more of the compression speed of the compression rollers, the compression pressure applied by the compression rollers, and the temperature output of the heaters, based on one or more identified temperature profiles and one or more of at least one layup states.

[0149] Optionally, in a system according to one of the preceding paragraphs, the computer system further comprises a computer and computer program products to generate an integrated display of two or more identified temperature profiles of compression rollers and to enable comparison of the two or more identified temperature profiles.

[0150] Optionally, in a system according to one of the preceding paragraphs, one or more infrared cameras are synchronized to acquire two or more infrared images configured to be merged together within the computer software of the computer system.

[0151] Optionally, in a system according to one of the preceding paragraphs, one or more infrared images include one or more infrared photographic images and one or more infrared video images.

[0152] A person skilled in the art relating to this disclosure, who understands the merits of the teachings presented in the above description and the accompanying drawings, will be able to recall numerous modifications and other versions of this disclosure. The versions described herein are illustrative and are not intended to be limiting or exhaustive. Certain terms are used herein, but these are used only in a general and descriptive sense and are not intended to be limiting. Within the scope of this disclosure, functionally equivalent methods and apparatus are possible from the above description in addition to those enumerated herein. Such modifications and variations are intended to fall within the scope of the appended claims. This disclosure should be limited by the appended claims and the entire scope of equivalents to which such claims may be found.

Claims

1. A step (202) of directing one or more infrared cameras (60) onto the compression roller (14) of the composite material laying head (36) of the composite material layup machine (18), wherein the one or more infrared cameras (60) are attached to the rear of the compression roller (14), and a step (202) of directing one or more infrared cameras (60), The steps include: (204) applying heat (40) to the substrate (42) by a heater (38) attached in front of the compression roller (14), Step (206) of using one or more infrared cameras (60) to acquire infrared images (62) of one or more of the compression rollers (14) while laying one or more composite tows (32a) of the composite material layup (30) onto the substrate (42) with the compression rollers (14), To obtain one or more identified temperature profiles (24a), the steps include: (208) identifying one or more temperature profiles (24) of the compression roller (14) based on the one or more infrared images (62); Step (210) to analyze the one or more identified temperature profiles (24a) in order to determine one or more of the layup quality (26) of the composite material layup (30) and the heating history (28) of the composite material layup (30), A method including (200).

2. After the step (210) of analyzing the one or more identified temperature profiles (24a), The method according to claim 1 (200), further comprising the step (212) of determining at least one layup state (74) of the composite layup (30) based on the one or more identified temperature profiles (24a).

3. The step (212) of determining the at least one layup state (74) of the composite layup (30) based on the one or more identified temperature profiles (24a) is: A step (212) of determining the at least one layup state (74) including one or more of layup defects (88), foreign matter fragments (90), and tape tack quality (92) based on the one or more identified temperature profiles (24a), Step (212) of determining the at least one layup state (74) based on the one or more identified temperature profiles (24a), wherein the layup defect (88) includes a toe twist (88a), misaligned toe end (88b), missing toe (88c), toe fold (88d), fuzz ball (88e), gap (88f), or overlap (88g), The method according to claim 2 (200), further comprising:

4. After the step (212) of determining the at least one layup state (74) of the composite layup (30) based on the one or more identified temperature profiles (24a), The method according to claim 2 or 3 (200), further comprising the step (214) of adjusting one or more of the compression speed (54) of the compression roller (14), the compression pressure (56) applied by the compression roller (14), and the temperature output (58) of the heater (38) based on one or more of the one or more identified temperature profiles (24a) and one or more of the at least one layup states (74).

5. The step (212) of determining the at least one layup state (74) of the composite layup (30) based on the one or more identified temperature profiles (24a) is: The method according to claim 2 or 3 (200), further comprising identifying the at least one layup state (74) and using machine vision (110) to automatically warn the user interface (106) of the at least one layup state (74).

6. The step (212) of determining the at least one layup state (74) of the composite layup (30) based on the one or more identified temperature profiles (24a) is: Based on the one or more infrared images (62), the size (100) of the at least one layup state (74) is identified, Determining whether the size (100) of the at least one layup state (74) is greater than a threshold size (102) based on a known reference size (108), When the size (100) of at least one layup state (74) is greater than the threshold size (102), the user interface (106) receives an instruction (104), The method according to claim 2 or 3 (200), further comprising:

7. After the step (208) of identifying the one or more temperature profiles (24) of the compression roller (14) based on the one or more infrared images (62), The method according to any one of claims 1 to 3 (200), further comprising the step of using a computer (82) and a computer program product (84) that generate an integrated display (112) of two or more identified temperature profiles (24a) of the compression roller (14) to enable comparison (114) of the two or more identified temperature profiles (24a) of the compression roller (14).

8. The step (206) of using one or more infrared cameras (60) to acquire one or more infrared images (62) of the compression roller (14) is: The method according to any one of claims 1 to 3 (200), further comprising the step (206) of using the one or more infrared cameras (60) to obtain the one or more infrared images (62) which include one of the infrared photographic images (62a) and one or more infrared video images (62b).

9. The step (206) of using one or more infrared cameras (60) to acquire one or more infrared images (62) of the compression roller (14) is: The method (200) according to any one of claims 1 to 3, further comprising the step (206) of using two or more infrared cameras (60) to acquire two or more infrared images (62) configured to be merged together in computer software (146) of a computer system (80).

10. The step (208) of identifying the one or more temperature profiles (24) of the compression roller (14) based on the one or more infrared images (62) is: The method according to any one of claims 1 to 3 (200), further comprising the step (208) of identifying the one or more temperature profiles (24) of the back portion (16a) of the compression roller (14) based on the one or more infrared images (62), wherein the one or more composite tows (32a) are in contact with the compression roller (14).

11. A method (220) for in-process monitoring (12) of a compression roller (14) of a composite material layup machine (18), wherein the method (220) is Step (222) of directing one or more infrared cameras (60) to the back surface (16) of the compression roller (14) of the composite material laying head (36) of the composite material layup machine (18), wherein the one or more infrared cameras (60) are attached to the rear of the compression roller (14), and Step (222) of directing one or more infrared cameras (60), Step (224) of applying heat (40) to the substrate (42) by a heater (38), wherein the heater (38) is mounted in front of the compression roller (14), The steps include: (226) monitoring the back surface (16) of the compression roller (14) by using one or more infrared cameras (60) to acquire one or more infrared images (62) of the back surface (16) of the compression roller (14) while laying one or more composite tows (32a) of the composite layup (30) onto the substrate (42) using the compression roller (14); Step (228) to obtain one or more identified temperature profiles (24a), wherein, based on the one or more infrared images (62), one or more temperature profiles (24) of the back portion (16a) of the compression roller (14) are in contact with the compression roller (14), and the step (228) to obtain one or more identified temperature profiles (24), Step (230) to analyze the one or more identified temperature profiles (24a) in order to determine one or more of the layup quality (26) of the composite material layup (30) and the heating history (28) of the composite material layup (30), Methods including (220).

12. After the step (230) of analyzing the one or more identified temperature profiles (24a), The method according to claim 11 (220), further comprising the step (232) of determining at least one layup state (74) of the composite layup (30) based on the one or more identified temperature profiles (24a).

13. The step (232) of determining the at least one layup state (74) of the composite layup (30) based on the one or more identified temperature profiles (24a) is: A step (232) of determining the at least one layup state (74) including one or more of layup defects (88), foreign matter fragments (90), and tape tack quality (92) based on the one or more identified temperature profiles (24a), Step (232) of determining the at least one layup state (74) based on the one or more identified temperature profiles (24a), wherein the layup defect (88) includes a toe twist (88a), misaligned toe end (88b), missing toe (88c), toe fold (88d), fuzz ball (88e), gap (88f), or overlap (88g), The method according to claim 12, further comprising (220).

14. After the step (232) of determining the at least one layup state (74) of the composite layup (30) based on the one or more identified temperature profiles (24a), Step (234) to adjust one or more of the compression speed (54) of the compression roller (14), the compression pressure (56) applied by the compression roller (14), and the temperature output (58) of the heater (38) based on one or more of the one or more identified temperature profiles (24a) and one or more of the at least one layup state (74), in order to limit the material (34) of the one or more composite tow (32a) to adhere to the surface (76) of the compression roller (14) and to prevent the material (34) from wrapping around the compression roller (14), The steps include using the composite material layup (30) to form a composite material part (48a) for an aircraft (50a), The method according to claim 12 or 13, further comprising (220).

15. The step (226) of monitoring the back surface (16) of the compression roller (14) by using one or more infrared cameras (60) is, The method according to any one of claims 11 to 13 (220), further comprising the step (226) of monitoring the back (16) of the compression roller (14) by using two or more synchronized infrared cameras (60) to acquire two or more infrared images (62) configured to be merged together in computer software (146) of a computer system (80).

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