Composite Laminate Ply Orientation Verification Using Off-Axis Light Scanning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for determining and verifying the ply orientation of composite laminates are labor-intensive, time-consuming, and costly, requiring extensive polishing and high-magnification microscopy, especially for distinguishing between +45° and -45° ply orientations, which increases manufacturing time and costs.
Innovation Solution
A method and system using an off-axis inclined light source to scan a prepared edge of the composite laminate at two different angles, with optical resolution of 1200 dpi or greater, to produce scanned images that are compared manually or automatically to determine ply orientation, reducing the need for extensive polishing and multiple cuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high magnification microscope (100x or greater) is used to observe individual fibers, then measurement precision of ply orientation is improved, but device complexity and time consumption increase due to multiple images and editing requirements
Solution Approach 1:
The patent replaces the mechanical microscope system with an optical scanning system using light sources and cameras. This substitution eliminates the need for high magnification microscopes and complex image editing software, while maintaining the ability to determine ply orientation through optical reflection patterns at different light angles
Solution Approach 2:
The patent creates optical copies (scanned images) of the composite laminate surface using light reflection. By capturing images at different light source angles and comparing the reflection patterns, the system determines ply orientation without needing to physically examine individual fibers under high magnification
2Measurement precision
If extensive polishing process is performed to obtain sufficient visibility of fiber orientation, then measurement precision is improved, but loss of time and ease of manufacture deteriorate
Solution Approach 1:
The patent changes the measurement parameters by using multiple light source angles instead of relying on polished surface visibility. By varying the angle of incident light and analyzing the reflection patterns, the system can determine ply orientation from unpolished or minimally prepared surfaces, eliminating the time-consuming polishing step
3Measurement precision
If multiple cuts and polishing steps are performed to distinguish +45° and -45° ply orientations, then measurement precision is improved, but productivity and ease of manufacture worsen
Solution Approach 1:
The patent applies partial action by using only the necessary light angle variations to distinguish ply orientations. By strategically selecting specific light source angles and analyzing the resulting reflection patterns, the system can differentiate between +45° and -45° plies without requiring multiple physical cuts and extensive polishing of each sample
4Ease of operation
If mounting process is performed to secure large samples during polishing, then ease of operation improves, but device complexity and time consumption increase
Solution Approach 1:
The patent extracts the sample preparation step from the measurement process. By designing a system that can analyze ply orientation on unmounted, unpolished, or minimally prepared surfaces, the mounting process is completely removed from the workflow, eliminating the time and complexity associated with securing large samples in epoxy resin
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 significantly reduces the time and labor required for ply orientation determination, allowing for faster and more cost-effective verification of composite laminate designs, while maintaining consistency and compliance with quality requirements.
Implementation Method 1
an off-axis inclined light source directing light at a first angle to a first area on the prepared edge to produce a first scanned image... rotating an orientation of the off-axis inclined light source relative to the prepared edge... directing light at a second angle to the first area on the prepared edge
Data Source
Figure 1
Figure 2~3
Figure 4A
AI summary
A method (66) for determining and verifying ply orientation (98) of composite laminates (28) includes performing a first scan (104) of a prepared edge (92a) of a composite laminate (28) using an off-axis inclined light source (106) directing light (108) at a first acute angle (110) to a first area (112) on the prepared edge (92a) to produce a first scanned image (116); rotating an orientation (117) of the off-axis inclined light source (106) relative to the prepared edge (92a), such that the off-axis inclined light source (106) directs light at a second acute angle (130) symmetrically opposite the first acute angle (110); and performing a second scan (126) of the prepared edge (92a) using the off-axis inclined light source (106) directing light (108) at the second acute angle (130) to the first area (112) on the prepared edge (92a) to produce a second scanned image (128). The method (66) includes comparing the first and second scanned images (116, 128) to determine a ply orientation (98) of each ply (94), and verifying the ply orientation (98) against a baseline ply orientation (99).