Composite Material Inconsistency Detection for Real-Time Fiber Tracking
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Solution Overview
Problem
Current methods for testing unconsolidated composite materials, such as prepreg rolls, are inefficient as they require testing multiple portions to identify out-of-tolerance sections, leading to time-consuming quality control processes and potential delays in manufacturing due to the inability to determine the cause of quality issues in real-time during production.
Innovation Solution
A system comprising a computer-based inconsistency analyzer that detects fiber inconsistencies in real-time during composite material manufacturing, using sensor data to predict material properties and track inconsistencies, allowing for immediate identification of out-of-tolerance sections and corrective actions before the manufacturing process is complete.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple portions of unconsolidated composite material are tested using current methods, then quality control accuracy is improved, but manufacturing time and productivity are significantly reduced
Solution Approach 1:
The system performs preliminary quality assessment during the manufacturing process itself, rather than after completion. Sensors monitor fiber placement, resin distribution, and consolidation in real-time, enabling early detection of defects and immediate corrective actions before the entire manufacturing cycle is complete.
Solution Approach 2:
Traditional mechanical testing methods are replaced with optical sensors, cameras, and non-contact measurement systems. These systems use light reflection, transmission, and other optical phenomena to detect material inconsistencies without physical contact or destruction of the sample.
2Measurement precision
If traditional quality testing methods are used to identify out-of-tolerance sections, then measurement accuracy is improved, but time consumption and production delays increase
Solution Approach 1:
The quality monitoring system operates continuously throughout the manufacturing process without interruption. Sensors are integrated into the production line to provide uninterrupted real-time data streams, eliminating the need to stop production for separate testing phases.
Solution Approach 2:
A computer system acts as an intermediary between the manufacturing process and quality assessment. It receives raw sensor data, processes images and measurements, compares them against tolerance specifications, and generates actionable quality reports in real-time.
3Productivity
If real-time inconsistency detection is implemented, then manufacturing efficiency and waste reduction are improved, but system complexity and initial investment increase
Solution Approach 1:
The monitoring system is designed to detect multiple types of inconsistencies simultaneously using the same sensor array and processing platform. It can identify fiber misalignment, resin pooling, voids, and contamination all through a unified system, reducing the need for multiple specialized testing devices.
Data Source
AI summary
A method, apparatus, system, and computer program product for detecting inconsistencies in an unconsolidated composite material. Fiber inconsistencies are detected in sections of the fibers input into a composite material manufacturing system in real time during operation of the composite material manufacturing system. Material inconsistencies are detected in the unconsolidated composite material in real time as the unconsolidated composite material is being manufactured by the composite material manufacturing system using the fibers. A determination is made as to whether the material inconsistencies are present in a number of the sections in which the fiber inconsistencies are detected in real time as the unconsolidated composite material is being manufactured by the composite material manufacturing system. The fiber inconsistencies in the number of the sections in which the fibers with fiber inconsistencies resulted in the material inconsistencies in the number of the sections in the unconsolidated composite material are tracked.