Composite Layup Vision Control for Real-Time Defect Inspection

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Solution Overview

Problem

Manual inspection of composite materials in the manufacturing process is time-consuming and prone to introducing inconsistencies, especially for large components, where operators may inadvertently cause additional defects while inspecting, and existing automated systems fail to identify all types of inconsistencies effectively.

Innovation Solution

An automated system comprising an automated composite placement head, a vision system, and a computer system that images the composite material during or after laying, identifies inconsistencies in real-time, and adjusts the inconsistency allowance threshold based on properties like size, density, location, and randomness, employing a probabilistic approach to make metrology decisions and modify laydown parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual inspection is performed on composite plies, then inconsistencies can be detected, but manufacturing time increases significantly

Engineering Contradiction:

Improvedetection of inconsistenciesVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated optical vision system that uses cameras and image processing algorithms to detect inconsistencies in composite plies during the manufacturing process, eliminating the need for operators to physically examine each ply

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The vision system enables the manufacturing process to self-inspect by automatically capturing images of plies as they are being laid down and processing these images through computer algorithms to identify defects without requiring separate manual inspection steps

Inventive Principle:

Principle #25Self-service

2Reliability

If operators walk across large components to inspect plies, then inspection coverage is achieved, but additional inconsistencies are introduced

Engineering Contradiction:

Improveinspection coverageVSAvoidadditional inconsistencies

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent introduces a vision system as an intermediary between the inspection requirement and the composite ply, allowing defects to be detected through optical imaging without physical contact, thereby eliminating the harmful effect of operators walking across and potentially damaging the plies

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The manual mechanical inspection process is replaced with a non-contact optical inspection system that uses cameras and image analysis to detect inconsistencies, eliminating the physical presence of operators on the component surface

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If lifting platforms are used to access large components for inspection, then inspection accessibility is improved, but inspection time increases

Engineering Contradiction:

Improveinspection accessibilityVSAvoidinspection time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The vision system is pre-positioned and integrated with the automated composite placement head, allowing inspection to occur automatically as plies are being laid down, eliminating the need for separate inspection operations and time-consuming platform movements

Inventive Principle:

Principle #10Preliminary action

4Productivity

If automated vision system inspects composite material, then manufacturing time is reduced, but system complexity increases

Engineering Contradiction:

Improvemanufacturing timeVSAvoidinspection system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines the vision system with the automated composite placement head, integrating inspection functionality into the existing manufacturing equipment rather than adding separate standalone inspection systems, thereby reducing overall system complexity

Inventive Principle:

Principle #5Merging (Combining)

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 system significantly reduces manufacturing time, minimizes rework, and enhances the quality control of composite components by identifying and addressing inconsistencies promptly, thereby reducing labor costs and equipment downtime, and improving the overall efficiency of the composite fabrication process.

Implementation Method 1

The vision system is connected to the automated composite placement head and is configured to produce image data during an inspection of the composite material

Methodology Applied

Scientific EffectOptical imaging: Photography

Data Source

PatentEP3396484B1Process control of a composite fabrication process

Publication Date: 2022.09.28 THE BOEING CO

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AI summary

A system for process control of a composite fabrication process comprises an automated composite placement head, a vision system, and a computer system. The automated composite placement head is configured to lay down composite material. The vision system is connected to the automated composite placement head and configured to produce image data during an inspection of the composite material, wherein the inspection takes place at least one of during or after laying down the composite material. The computer system is configured to identify inconsistencies in the composite material visible within the image data, and make a number of metrology decisions based on the inconsistencies.