Composite Layer Width Scanning for In-Process Tolerance Control
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Solution Overview
Problem
Existing systems for forming composite parts are prone to delays and material waste due to inspection processes and out-of-tolerance conditions, as they do not effectively address dimensional variances in real-time, leading to potential rejection of composite parts.
Innovation Solution
A method and system that dynamically adjust the production process by scanning each layer to determine its dimensions, comparing them to target specifications, and making adjustments in real-time to ensure compliance with engineering tolerances, thereby mitigating out-of-tolerance conditions without halting the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inspection processes are implemented to detect dimensional variances, then manufacturing precision is improved, but production time increases and productivity decreases
Solution Approach 1:
The system performs inspection of each layer immediately after it is deposited, before the next layer is added. This preliminary inspection allows dimensional variances to be detected early in the manufacturing process, enabling corrective actions to be taken before they propagate through subsequent layers, thereby maintaining precision without requiring a separate post-manufacturing inspection phase
Solution Approach 2:
The system implements real-time feedback by continuously monitoring dimensional variances of each layer and automatically adjusting processing parameters for subsequent layers. The inspection data feeds back to the manufacturing system, enabling dynamic compensation for dimensional deviations and maintaining overall part precision while keeping the production process continuous
2Manufacturing precision
If real-time inspection and adjustment are implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system combines multiple functions into integrated components: the inspection device is integrated directly with the manufacturing system, allowing the same system to both manufacture and inspect layers. The control system performs multiple functions including data acquisition, analysis, and automatic parameter adjustment, reducing the need for separate standalone inspection and control systems
Solution Approach 2:
The system is self-regulating through automatic feedback control. The inspection system automatically detects dimensional variances, the control system automatically analyzes the data and determines corrective actions, and the manufacturing system automatically adjusts parameters without requiring external intervention. This self-service capability reduces the complexity of external monitoring and adjustment systems
3Loss of substance
If layers are inspected and adjusted during production, then material waste is reduced, but inspection and measurement time increases
Solution Approach 1:
The system inspects each layer immediately after deposition, before subsequent layers are added that would cover and protect the inspected layer. This preliminary inspection allows detection of dimensional issues while the layer is still accessible, preventing material waste by enabling corrective actions before the entire part is manufactured, without requiring time-consuming post-manufacturing disassembly and reinspection
Solution Approach 2:
The inspection process is integrated into the continuous manufacturing flow, with no interruption to the overall production sequence. Layers are deposited and inspected in continuous succession, with the inspection occurring during the natural transitions between layer deposition operations. This continuous approach minimizes idle time while ensuring each layer is verified before proceeding to the next
Data Source
Figure 1A~1C
Figure 2
Figure 3A~3B
AI summary
In an example, a method for forming a composite part includes, based on a part specification, cutting layers (110) of material in a sequence and positioning the layers to form a stack (112). For each layer, after positioning the layer and before cutting a next layer in the sequence, the method includes (i) scanning along a length of the layer to determine an image, (ii) determining, based on the image, at least two edges (116) of the layer (110), (iii) determining, based on the edges, a measured width at locations along the length of the layer, (iv) comparing the measured width at each location to a target width at the location, (v) deciding, based on the comparison, whether to adjust the production process, and (vi) if the decision is to adjust the production process, then adjusting the production process based on the comparison. The part specification specifies the target width at each location.