Real-Time Fiber Placement Inspection via Image Comparison
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Solution Overview
Problem
Current automated fiber placement machines face challenges in performing real-time, on-the-fly inspection of composite structures due to high speeds and complex geometries, which limits the detection of anomalies like fiber twists, resin buildup, and gaps, and does not allow for convenient in-process correction.
Innovation Solution
A method and apparatus that compare visual images of the composite structure to virtual images, using a composite comparison device and vision capture elements attached to the fiber placement head, to detect anomalies and provide real-time feedback for correction, allowing for precise location identification and repair during fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated fiber placement machines operate at high feed-rates to maximize productivity, then production efficiency is improved, but the ability to perform real-time visual inspection and detect anomalies deteriorates
Solution Approach 1:
The patent replaces traditional mechanical inspection methods with an optical vision system. Cameras and image processing technology are used to capture and analyze fiber placement in real-time, enabling inspection at high feed-rates without the mechanical constraints of contact-based measurement systems.
Solution Approach 2:
The vision system creates visual copies (images) of the actual fiber placement process, allowing inspection and analysis of the placed tows without physically interfering with the high-speed placement operation. The digital images serve as replicas that can be analyzed in real-time.
2Strength
If complex shaped and large sized composite structures are fabricated, then structural capability is improved, but the difficulty of detecting and measuring placement accuracy deteriorates
Solution Approach 1:
The patent transitions from two-dimensional image capture to three-dimensional spatial analysis. The vision system captures images from multiple perspectives and uses stereo vision or structured light techniques to reconstruct the three-dimensional geometry of complex structures, enabling accurate measurement of placement deviations on large, complex geometries.
Solution Approach 2:
The patent introduces a computer vision system as an intermediary between the fiber placement process and the inspection function. This intermediary captures optical information from the placement process and translates it into measurable data about tow placement accuracy, bridging the gap between complex geometries and measurement capabilities.
3Measurement precision
If real-time inspection is implemented during high-speed fiber placement, then anomaly detection capability is improved, but the device complexity increases
Solution Approach 1:
The vision system is designed to perform multiple functions: capturing images of fiber placement, detecting anomalies such as gaps and overlaps, measuring placement accuracy, and providing feedback for process control. This multi-functionality reduces the need for separate specialized inspection devices, thereby limiting the increase in overall system complexity.
Solution Approach 2:
The patent implements a closed-loop feedback system where the vision system continuously monitors fiber placement and provides real-time feedback to the control system. This feedback enables automatic adjustment of placement parameters to correct detected anomalies, improving measurement precision while using the feedback mechanism to simplify the overall inspection architecture.
Data Source
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AI summary
An apparatus and method are provided for performing, on-the-fly, real time inspection of a composite structure (102) formed by an automated fiber placement machine (110), through comparison of a visual image of at least a portion of the composite structure to a virtual image of the composite structure. Proper formation of the structure, and/or anomalies within the structure, are determined by comparing the visual image to the virtual image. The automated fiber placement machine, and/or tooling upon which the fiber is placed, are manipulated, and a visual indicator arc provided to facilitate inspection and/or repair of any detected anomalies during fabrication of the composite structure.