Camera-Based Bonding Process Verification for Composite Structures
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Solution Overview
Problem
Existing manufacturing processes for composite structures, such as aircraft components, face challenges in ensuring the quality of structural bonds due to factors like foreign object debris (FOD) contamination and the difficulty in detecting and correcting deviations in step sequences and timing, leading to increased manufacturing time and costs.
Innovation Solution
A method and system utilizing cameras and a computer system to record and process images of the bonding process, comparing them against a reference library to detect deviations and generate process control data, ensuring adherence to preselected sequences and timelines, and alerting operators of any discrepancies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual bonding processes are used for composite structures, then manufacturing flexibility and adaptability are maintained, but detection of FOD contamination and process deviations becomes difficult and time-consuming
Solution Approach 1:
The patent uses optical cameras to create visual copies (images) of the bonding process and compares them against reference images to detect deviations. This copying approach enables objective detection of FOD contamination and process errors without interfering with the manual bonding process, directly resolving the contradiction between maintaining manual flexibility and improving detection capability.
Solution Approach 2:
The patent replaces manual visual inspection with an optical measurement system (cameras and image processing). This substitution transforms the subjective, time-consuming manual detection process into an automated optical measurement system that can reliably detect FOD and process deviations while maintaining the flexibility of manual bonding operations.
2Reliability
If comprehensive monitoring of bonding processes is implemented, then process quality and reliability are improved, but manufacturing time and system complexity increase
Solution Approach 1:
The patent captures images at predetermined critical points in the bonding process sequence (such as after surface preparation, before bonding, after bonding). This preliminary action approach ensures quality verification at key stages without requiring continuous monitoring throughout the entire process, thereby improving reliability while minimizing time loss.
Solution Approach 2:
The system automatically compares captured images against reference images and generates compliance reports without requiring manual inspection. This self-service capability allows the bonding process to be monitored and verified autonomously, reducing the time that would otherwise be required for manual quality checks while maintaining comprehensive quality control.
3Measurement precision
If automated image comparison systems are introduced, then detection precision and process control are improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent employs a multi-functional imaging system that performs multiple tasks: capturing bonding process images, comparing against reference images, detecting FOD contamination, verifying step sequence compliance, and generating compliance reports. This universal approach consolidates multiple quality control functions into a single system, improving measurement precision while limiting the increase in device complexity.
Data Source
AI summary
A method for monitoring and verifying a manufacturing process performed by an operator on a workpiece in a work area. The method includes positioning one or more cameras in the work area, such that the operator and the workpiece are in a field of view of each of the cameras. The method includes using a computer system configured for controlling the cameras to record and process images of the workpiece and images of operator actions relating to the manufacturing process, all recorded by the cameras during or at completion of each of a plurality of tasks in the manufacturing process to obtain recorded images. The method includes storing the recorded images, comparing the recorded images against a reference image library comprising references images corresponding to each recorded image to detect any differences between the recorded image and the respective corresponding reference image, and generating a data record.