Composite Repair Guidance Using 3D Scanning and DLP Projection
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Solution Overview
Problem
Current composite structure repair processes are time-consuming and prone to errors due to the lack of expertise on-site, especially in scarfing operations, as technicians may not have the necessary training or experience, and relying on visual cues can lead to inaccuracies.
Innovation Solution
A system and process that enables real-time guidance and monitoring from an off-site expert using optical 3-D surface measurement, illumination, and digital light processing (DLP) projection to provide direct visual feedback and warnings during scarfing and other repair operations, ensuring accurate composite structure repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If technicians perform scarfing operations using visual cues alone, then the repair process can proceed without additional equipment, but errors are introduced and manufacturing precision deteriorates
Solution Approach 1:
The patent replaces the mechanical/visual estimation method with an optical measurement system. A scanner captures 3D surface data of the composite structure, and a processor automatically calculates scarfing boundaries and generates guidance patterns, substituting technician visual judgment with automated optical-mechanical-optical system
Solution Approach 2:
The system creates a digital 3D copy of the physical composite structure surface through scanning. This digital replica is then used to calculate and visualize the precise scarfing geometry, allowing technicians to work from an accurate digital model rather than visual estimation
2Manufacturing precision
If an expert is present on-site to provide real-time guidance, then repair quality improves, but cost increases significantly
Solution Approach 1:
The system enables self-service by providing automated calculations and visual guidance that technicians can use independently. The computer automatically processes scan data, determines scarfing parameters, and projects guidance patterns, allowing technicians to perform expert-level repairs without actual expert presence
Solution Approach 2:
The computer system acts as an intermediary between the expert's knowledge base (embedded in software algorithms) and the technician's execution. The system translates complex expert judgment into simple visual guidance patterns that technicians can follow directly
3Productivity
If automated/robotic scarfing is used, then productivity improves, but setup complexity increases and errors may be introduced
Solution Approach 1:
The system creates a digital 3D model of the actual workpiece and uses it to generate toolpath instructions for automated scarfing equipment. This digital replica approach allows automated systems to adapt to actual part geometry without complex mechanical fixtures or elaborate setup procedures
4Device complexity
If technicians rely on visual shapes of ply boundaries, then no additional measurement equipment is needed, but measurement precision deteriorates
Solution Approach 1:
The patent substitutes visual inspection with optical scanning technology. A scanner systematically measures surface geometry with high precision, replacing the imprecise human visual system with an optical measurement system that provides quantitative data
Solution Approach 2:
The system transitions from 2D visual surface observation to 3D spatial measurement. The scanner captures depth and surface topology information, providing three-dimensional data that reveals ply boundaries and geometry that are not apparent from visual inspection alone
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 errors, enhances repair quality, and allows for faster composite structure repairs by providing expert guidance and monitoring, resulting in improved process control and automatic documentation.
Implementation Method 1
optical three-dimensional (3-D) surface measurement
Implementation Method 2
digital light processing (DLP) projection to provide step-by-step monitoring
Implementation Method 3
illumination by at least one of visible, ultraviolet and infrared light
Data Source
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AI summary
Systems and processes for enabling an off-site expert to interact with an on-site technician during repair of composite structure. The off-site expert can provide real-time guidance to an on-site technician before and during the performance of repair procedures to avoid errors. The off-site expert is also able to monitor the repair procedures in real time to verify that correct procedures are being employed. In particular, the systems and processes disclosed herein can provide direct visual guidance, feedback, and out-of-plan warnings for manual or automated scarfing and other operations during repair of composite structure. In some embodiments, the repair process combines optical three-dimensional surface measurement, illumination by at least one of visible, ultraviolet and infrared light, and digital light processing projection to provide step-by-step monitoring of the repair.