Defect Stencil for AFP In Situ Inspection Calibration
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Solution Overview
Problem
Automated Fiber Placement (AFP) systems face challenges in creating predictable and accurate artificial defects for calibrating in situ inspection systems, as current methods either rely on out-of-process or post-process inspections or create unpredictable defects.
Innovation Solution
The method involves using a defect stencil to create artificial gap and overlap defects with known sizes and geometries during the layup process, allowing for precise calibration of in situ inspection systems by simulating real defects that are indistinguishable from actual ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current calibration methods are used (out-of-process or post-process inspection), then inspection coverage is maintained, but manufacturing precision and reliability of calibration are deteriorated due to inability to create predictable artificial defects during active AFP process
Solution Approach 1:
A defect stencil serves as an intermediary tool that enables precise creation of artificial defects during the active AFP process. The stencil acts as a mediator between the AFP system and the inspection system, providing known defect geometries without requiring complex calibration equipment or post-process analysis.
Solution Approach 2:
The defect stencil allows preliminary creation of artificial defects before inspection occurs. By pre-defining defect locations and geometries using the stencil during layup, the system enables subsequent inspection systems to be calibrated against known defects, improving both precision and reliability.
2Measurement precision
If unpredictable defects are created and identified post layup, then calibration data can be obtained, but measurement precision and reliability are worsened due to inability to know true defect characteristics
Solution Approach 1:
The defect stencil enables the system to self-calibrate by providing known defect characteristics directly during the layup process. The stencil itself serves as the reference standard, eliminating the need for separate calibration procedures or post-layup defect analysis, thereby reducing calibration time while maintaining high measurement precision.
3Productivity
If manual inspection methods are used, then labor intensity is high, but manufacturing precision is maintained through careful manual examination
Solution Approach 1:
The defect stencil creates precise copies of known defect geometries during the layup process. By stamping or imprinting standardized defect patterns onto the composite material, the system generates repeatable artificial defects that enable automated inspection systems to be calibrated efficiently, increasing productivity without sacrificing detection accuracy.
Data Source
AI summary
Systems, methods, and devices are provided for the creation of predictable and accurate defects in a fiber tow of an Automated Fiber Placement (AFP) process, with such artificial defects being useful to support calibration of an in situ inspection system used in the AFP process. Various embodiments include methods for creating such artificial defects that support calibration of an in situ inspection system of an AFP system or process. Various embodiments may also include a defect stencils for an AFP system or process.