Composite Contamination Detection via Spectral Imaging
Solution Overview
Problem
In the manufacturing of composite structures, contaminants on the surface of composite workpieces or tools can lead to inconsistencies such as voids, porosity, and delamination, resulting in increased rework and costs due to the difficulty in visually detecting these contaminants during the manufacturing process.
Innovation Solution
A method and apparatus that uses electromagnetic radiation to separate responses into wavelengths for each location on the surface of composite workpieces or tools, generating a two-dimensional image with graphical indicators to identify and visualize contaminants before curing, allowing for their removal or replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection methods are used to detect contaminants on composite workpieces, then the inspection process is simple and quick, but contaminants cannot be reliably detected leading to inconsistencies in composite structures
Solution Approach 1:
The patent replaces visual inspection methods with electromagnetic radiation-based spectroscopic analysis. The system uses electromagnetic radiation to interact with contaminants on the composite workpiece surface, detecting their spectral signatures instead of relying on human visual detection, thereby achieving reliable contaminant identification without physical contact.
Solution Approach 2:
The patent introduces electromagnetic radiation as an intermediary between the inspection system and contaminants. The radiation serves as a mediator that interacts with contaminants to produce detectable spectral responses, enabling indirect detection of contaminants that are otherwise invisible or indistinguishable to direct observation methods.
2Loss of time
If contaminants are detected after curing composite structures, then the composite structure is already complete, but rework or discarding is required causing delays and increased costs
Solution Approach 1:
The patent performs contaminant detection before the composite workpiece is cured and assembled into final structures. By conducting spectroscopic inspection at this preliminary stage, contaminants can be identified and removed before they cause damage during or after curing, preventing the need for time-consuming rework or discarding of completed structures.
Solution Approach 2:
The patent enables rapid spectroscopic analysis that quickly identifies contaminants without requiring slow, methodical visual inspection or destructive testing. The electromagnetic radiation method provides fast detection results, allowing the inspection process to be completed efficiently before curing proceeds.
3Measurement precision
If spectroscopic analysis is used to identify contaminants by separating electromagnetic radiation responses into wavelengths, then contaminants can be accurately detected, but the inspection process becomes more complex
Solution Approach 1:
The patent segments the electromagnetic radiation response into distinct wavelength components for analysis. By separating the spectral information into different wavelength bands, the system can identify specific contaminant types based on their unique spectral signatures, achieving precise identification through systematic breakdown of the complex spectral data.
Solution Approach 2:
The patent transforms the inspection problem from spatial visualization to spectral dimension analysis. Instead of relying on visual appearance in spatial domain, the system analyzes contaminants in the spectral domain by examining wavelength distributions, adding a new dimensional perspective that reveals contaminant characteristics invisible to conventional inspection.
4Duration of action of stationary object
If contaminants are present on composite workpieces during manufacturing, then the composite structure may have longer service life potential, but inconsistencies such as voids, porosity, and delamination occur
Solution Approach 1:
The patent applies preliminary anti-action by detecting and removing contaminants before they can cause harmful effects during curing. The spectroscopic inspection system identifies contaminants in advance, allowing preventive removal or remediation before the contaminants can create voids, porosity, or delamination that would compromise the composite structure's integrity and service life.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the occurrence of inconsistencies in composite structures by enabling the detection and removal of contaminants prior to curing, thereby minimizing rework and costs associated with manufacturing delays and discarded parts.
Implementation Method 1
A response to electromagnetic radiation directed to a surface of the composite workpiece is separated into a number of wavelengths
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method and apparatus for inspecting a composite workpiece. A response to electromagnetic radiation directed to a surface of the composite workpiece is separated into a number of wavelengths for each of a number of locations on the surface of the composite workpiece. A set of contaminants on the surface of the composite workpiece is identified from the number of wavelengths for the each of the number of locations. A two-dimensional image of the surface of the composite workpiece is generated with a set of graphical indicators indicating the set of contaminants identified from the number of wavelengths for the each of the number of locations on the surface of the composite workpiece.