Composite Part Validation Using CAD and Optical Ply Inspection
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Solution Overview
Problem
Current methods for validating and inspecting composite parts are time-consuming and inefficient, particularly in aircraft manufacturing, where manual verification of numerical control programs and ply stagger is challenging due to the complexity and accessibility issues of composite layers.
Innovation Solution
A part analysis tool that includes a verification control unit to compare numerical control data to CAD data, disregarding non-essential information, and an inspection control unit to compare inspection data to CAD data, ensuring conformance to engineering specifications, thereby automating the validation and inspection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual interrogation or verification of the composite part is performed during or after the layup process, then validation of numerical control programs can be achieved, but the process becomes tedious and time-consuming
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated optical scanning system. The system uses scanners to capture images of the composite part and automatically compares them against CAD data, eliminating the need for tedious manual measurement and verification while maintaining high validation accuracy
Solution Approach 2:
The patent creates a digital copy of the physical composite part by scanning it and generating a point cloud representation. This digital model is then compared against the CAD design data, allowing for rapid automated validation without physical contact with the actual part, thus reducing inspection time while preserving reliability
2Manufacturing precision
If physical inspection of composite layers is performed to check ply stagger, then validation can be achieved, but each successive layer covers the underlying layer making inspection difficult or impossible
Solution Approach 1:
The patent replaces physical probing and manual measurement of ply stagger with optical scanning technology. The scanner captures the surface geometry of the composite part, and software automatically analyzes the point cloud data to verify ply stagger without requiring physical access to or manipulation of the layered structure
Solution Approach 2:
The patent transitions from two-dimensional physical inspection attempts to three-dimensional digital analysis. By creating a complete 3D point cloud model of the part surface and comparing it digitally to the CAD model, the system can verify ply stagger and other geometric features without the limitations of physical accessibility
3Manufacturing precision
If validation of part angularity is performed by accessing various portions of plies, then manufacturing precision can be verified, but plies may be long and various portions may not be readily accessible
Solution Approach 1:
The patent replaces manual angular measurement tools and physical access requirements with automated optical scanning. The scanner captures the entire surface geometry including angular features, and computational algorithms automatically calculate angularity from the point cloud data without requiring physical access to measurement locations
Solution Approach 2:
The patent creates a universal inspection system that can verify multiple geometric features (angularity, ply stagger, surface finish, dimensions) through a single scanning operation. This multi-functional approach eliminates the need for specialized measurement tools and access to specific locations for each type of verification
4Adaptability or versatility
If independent software is used to create numerical control programs, then flexibility in programming can be achieved, but validation against CAD data becomes more complex
Solution Approach 1:
The patent introduces an intermediary validation system that acts as a bridge between independent NC programming software and CAD data. The system scans the manufactured part and automatically compares the physical result against the original CAD design, providing an objective validation mechanism that simplifies the verification process regardless of which programming software was used
Solution Approach 2:
The patent implements a closed-loop feedback system where the scanned point cloud data from the manufactured part is fed back and automatically compared against the CAD design data. This feedback mechanism provides immediate validation results and highlights any deviations, simplifying the validation process and reducing complexity by automating the comparison methodology
Data Source
AI summary
A part analysis tool is used to analyze aspects of a composite part. The part analysis tool includes a verification control unit that compares numerical control data used to control operation of a forming system that is used to form the composite part to computer-aided design (CAD) data that includes an authoritative part definition for the composite part. The verification control unit determines whether the numerical control data is within one or more conformance thresholds related to the CAD data. The part analysis tool may also include an inspection control unit that compares inspection data of one or more plies of the composite part to the CAD data. The inspection control unit determines whether the inspection data is within the conformance threshold(s) related to the CAD data.