Fiber Batch Testing for Composite Undulation Detection

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Solution Overview

Problem

Current methods for producing composite material components with embedded fibers lack a non-destructive test to ensure the absence of undulations in fibers before the manufacturing process, leading to potential defects in the final product.

Innovation Solution

A method involving a specimen of fibers from the batch, where a tensile force is applied and the specimen is heated to relax any stresses, followed by measuring residual extension to determine compliance, with thresholds set to prevent undulations in the final component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a non-destructive test is implemented to detect fiber undulations before manufacturing, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvefiber undulation detection accuracyVSAvoidtest system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical inspection systems with a thermal field-based testing method. By applying heat to relax fiber stresses and measuring residual extension, the system detects undulations through thermal-mechanical response rather than complex mechanical measurement equipment, achieving non-destructive testing with simpler apparatus.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state parameters of the fiber specimen by controlling temperature and mechanical stress during testing. By heating the specimen to specific temperature ranges and applying controlled tensile forces, the method transforms the fiber structure to reveal undulations through measurable extension changes, enabling detection without complex equipment.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If fiber layers are stacked automatically to increase productivity, then productivity is improved, but manufacturing precision deteriorates due to potential undulation defects

Engineering Contradiction:

Improvelayer stacking speedVSAvoidfiber layer alignment quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements preliminary testing of fiber batches before they are used in automatic stacking. By testing individual fiber specimens for stress and undulation potential prior to layer formation, the method identifies problematic batches early, preventing defective layers from being produced during high-speed automatic stacking operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The testing method provides feedback about fiber batch quality to the manufacturing process. By measuring residual extension and comparing it against thresholds, the system generates quality information that can control or adjust the automatic stacking process, ensuring only compliant fiber batches are used while maintaining high productivity.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If stress relaxation heating is applied to fiber specimens, then manufacturing precision is improved by eliminating undulations, but use of energy increases

Engineering Contradiction:

Improvefiber stress relaxation qualityVSAvoidheating energy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies partial heating only to the extent necessary for stress relaxation, rather than heating to maximum temperatures or for excessive durations. By applying heat selectively to achieve the minimum required temperature for fiber stress relaxation and undulation elimination, the method achieves manufacturing precision while minimizing energy consumption.

Inventive Principle:

Principle #16Partial or excessive action

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 method allows for the identification of non-compliant fiber batches before use, preventing undulations and ensuring the quality of composite material components by eliminating defective materials early in the process.

Implementation Method 1

heating the specimen so as to relax the fibres if the specimen contains stresses

Methodology Applied

Scientific EffectThermal relaxation: Heat Treatment

Implementation Method 2

exerting a tensile force on the specimen... measuring a residual extension of the specimen which corresponds to a variation in length

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS9417167B2Method for testing a batch of material used for obtaining layers of fibres intended for manufacturing a composite material component

Publication Date: 2016.08.16 AIRBUS OPERATIONS (SAS)

AI summary

A method for testing a batch of material used to obtain layers of fibers includes taking a specimen from the batch of material, exerting a tensile force on the specimen, heating the specimen so as to relax the fibers if the specimen contains stresses, after a predetermined period of time, no longer heating and no longer exerting the tensile force on the specimen, measuring a residual extension of the specimen which corresponds to a variation in length of at least a part of the specimen in the direction of the tensile force, before and after the tensile force, and considering the batch of material not to be compliant if the residual extension exceeds a given threshold.