Fiber Optic Width Detection for Composite Tape Lay-up
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Solution Overview
Problem
Existing methods for monitoring the width of composite tape strips during the lay-up process are inaccurate and limited by the size of sensors, which can lead to gaps or overlaps in composite parts, affecting structural integrity.
Innovation Solution
A compact width detection apparatus using fiber optic cables and a housing to direct light onto the edges of the strip, with an amplifier and light detector system that alerts when the strip deviates from a desired width, allowing for precise monitoring of strip width variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two edge detectors with arrays of LEDs and gradient refractive index lenses are used as in the prior art, then width detection capability is achieved, but the device size becomes too large for integration into compact strip-placement apparatus
Solution Approach 1:
The patent divides the optical system into separate functional components: a light source, a beam splitting element, and a detector array. This segmentation allows each component to be optimized independently and packed more efficiently, reducing the overall device volume while maintaining detection precision.
Solution Approach 2:
The patent employs a single detector array that receives light from multiple edges simultaneously through beam splitting, making the detector serve multiple measurement functions at once. This multi-functionality eliminates the need for separate detection systems for each edge, significantly reducing device size.
2Measurement precision
If cameras are used for width monitoring as disclosed in prior art, then width measurement is possible, but the sensor size becomes large and limits placement locations within the apparatus
Solution Approach 1:
The patent replaces traditional camera-based mechanical/optical imaging systems with a laser-based interferometric measurement system. This substitution uses coherent light interference patterns rather than direct imaging, enabling precise width measurement with much smaller optical components that can be integrated into compact spaces.
3Ease of operation
If angled LED arrays are used for illuminating strip edges, then edge detection is enabled, but the device cannot be manufactured in a compact size
Solution Approach 1:
The patent transitions from planar angled LED arrays to a three-dimensional optical arrangement using beam splitting and multiple reflection paths. This dimensional change allows light to reach multiple edges from a compact configuration, maintaining illumination capability while dramatically reducing the device footprint.
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
The apparatus provides accurate and precise monitoring of strip width, reducing gaps and overlaps, and can be integrated into small spaces within composite tape-laying apparatuses, enhancing the structural integrity of composite parts.
Implementation Method 1
a first fiber optic cable and a housing for fixing the first fiber optic cable in spaced relationship with the second fiber optic cable such that the first fiber optic cable may direct light into the second fiber optic cable
Implementation Method 2
an amplifier, a light detector, and an alarm having a first state and a second state. Light from the light source may be sent through the first fiber optic cable which is positioned to direct light into the second fiber optic cable. Then the light may be transmitted through the second fiber optic cable to the light detector.
Data Source
AI summary
An apparatus and method for detecting a difference in width of a strip of material from a desired width of material. The apparatus may comprise a light source, a light detector, an alarm, a first fiber optic cable coupled with the light source, a second fiber optic cable coupled with the light detector, and a housing. The housing may comprise a material slot for passing the strip of material therethrough such that edges of the strip of material may at least partially intersect a plurality of light fields directed from the first fiber optic cable to the second fiber optic cable. The amount of light detected by the light detector is dependant on the amount of light blocked by the strip of material. If the amount of light received is outside of a range of tolerance from the desired width of material, the alarm may be actuated.