Automated Fiber Placement End Effector with Infrared Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for inspecting composite structures during automated fiber placement in aerospace applications are labor-intensive and time-consuming, requiring full fuselage inspection after fabrication, which is costly due to rework and waste, and fail to detect inconsistencies in real time.
Innovation Solution
An automated fiber placement end effector with a cool laminar gas cooling jet and infrared camera for in-situ, ply-by-ply wrinkle and foreign object debris detection, allowing continuous layering and real-time inspection of composite materials by monitoring gas flow patterns and stagnation points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical laser templates are used for inspection, then inspection accuracy is improved, but inspection time and labor requirements increase significantly
Solution Approach 1:
The patent replaces manual optical inspection methods with an automated imaging system that captures images of the composite structure during fabrication. The system uses a camera array to take pictures and automatically detects wrinkles and defects through image processing, eliminating the need for manual optical laser template inspection while maintaining detection accuracy.
Solution Approach 2:
The inspection system performs detection during the fabrication process itself, before the structure is complete. By capturing images at intermediate stages and analyzing them in real-time, the system identifies defects early when they are easier to detect and correct, avoiding the need for time-consuming post-fabrication inspection.
2Reliability
If full fuselage inspection is performed after fabrication, then detection completeness is improved, but rework costs and waste increase
Solution Approach 1:
The system provides real-time feedback during the fabrication process by continuously monitoring the composite structure as it is being built. When defects are detected, the system can immediately alert operators to correct the issue, preventing defective plies from being layered over good ones and eliminating the need for costly post-fabrication rework.
Solution Approach 2:
The inspection system serves the fabrication process itself by integrating detection capabilities directly into the manufacturing workflow. The same equipment used for fabrication also performs inspection, eliminating the need for separate post-fabrication inspection processes and enabling immediate corrective action.
3Measurement precision
If manual inspection methods are used, then detection thoroughness is improved, but productivity and manufacturing speed decrease
Solution Approach 1:
The patent replaces manual inspection with an automated image capture and analysis system. Cameras mounted on the fabrication equipment continuously photograph the composite structure, and computer algorithms automatically analyze the images for defects, providing thorough inspection without interrupting the manufacturing process or requiring manual labor.
Solution Approach 2:
The inspection system operates continuously throughout the fabrication process, capturing images at every stage without stopping the manufacturing workflow. This continuous monitoring ensures thorough detection of defects while maintaining high productivity, as the inspection occurs simultaneously with fabrication rather than as a separate step.
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
Enables instantaneous detection of inconsistencies during the manufacturing process, reducing the need for post-fabrication inspection, minimizing rework, and lowering costs by allowing continuous layering and real-time data recording of inspection results.
Implementation Method 1
An automated fiber placement end effector with cool laminar gas cooling jet
Implementation Method 2
an infrared camera directed at an impingement point where a gas from the gas nozzle impinges on a surface of a workpiece
Data Source
AI summary
An inspection device. The inspection device includes a gas dispenser aimed at a workpiece; and a camera aimed at a gas impingement point on the workpiece.