Fiber Thickness Measurement on Impregnation Mandrel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for measuring the thickness of fiber texture on an impregnation mandrel during the fabrication of composite material fan retention casings for gas turbine engines are manual, time-consuming, inaccurate, and operator-dependent, leading to inefficiencies and potential defects such as wrinkles or under-compaction.
Innovation Solution
An automated method using multiple distance sensors positioned around the impregnation mandrel to continuously measure and calculate the real thickness of the fiber texture wound on the mandrel, allowing for real-time adjustments to winding parameters and eliminating the need for frequent stops during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement with caliper is used to measure fiber texture thickness, then measurement can be performed, but the process is time-consuming, inaccurate, and requires frequent stops during winding
Solution Approach 1:
The patent replaces manual mechanical measurement with caliper with an automated optical/laser measurement system. A laser sensor or optical sensor is positioned to continuously measure the distance between the impregnation mandrel surface and the fiber texture surface, automatically calculating thickness without mechanical contact. This substitution eliminates manual intervention, achieves continuous measurement during winding operation, and provides higher precision through electronic sensing.
Solution Approach 2:
The patent implements continuous thickness measurement during the winding operation. The sensor system operates throughout the entire winding process, continuously monitoring fiber texture thickness as it is being applied to the mandrel. This eliminates the need to stop the winding operation for periodic measurements, maintaining continuous productive action while providing real-time measurement data.
2Reliability
If frequent stops are made during winding for manual measurement, then thickness can be monitored, but productivity is significantly reduced with stops amounting to 40% of winding time
Solution Approach 1:
The automated sensor system enables continuous thickness monitoring throughout the entire winding operation without interruption. The laser or optical sensor continuously measures the distance to the fiber texture surface, providing uninterrupted thickness data while the winding process proceeds without stops, eliminating the 40% time loss associated with manual measurement interruptions.
Solution Approach 2:
The patent implements a feedback system where the sensor continuously measures fiber texture thickness and provides real-time data to a control system. This feedback enables automatic monitoring and control of thickness parameters during winding, ensuring reliability of thickness control while maintaining continuous operation without time-consuming manual interventions.
3Productivity
If automated distance sensors are used to continuously measure fiber thickness, then real-time monitoring is achieved, but device complexity increases
Solution Approach 1:
The patent replaces complex manual measurement procedures with a relatively simple automated sensor system. A laser sensor or optical distance sensor, positioned to measure the gap between the mandrel and fiber texture, provides automatic continuous measurement. This electronic/optical system is simpler than the coordinated manual operations of stopping, caliper measurement, recording, and resuming, even though it introduces new equipment.
Solution Approach 2:
The measurement system is designed to be self-operating during the winding process. The sensor automatically measures thickness, the system automatically calculates the distance based on sensor position and measured gap, and the data is automatically recorded without requiring operator intervention. This self-service capability reduces the operational complexity despite the added equipment.
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 provides accurate, real-time monitoring of fiber thickness, enabling immediate corrections to prevent over-expansion or under-expansion, thus improving the consistency and efficiency of the winding process and reducing the risk of defects.
Implementation Method 1
a step of acquiring at least one real distance between the distance sensor and the outside surface of the fiber texture wound on impregnation mandrel
Data Source
AI summary
A method of measuring the thickness of a fiber texture wound on an impregnation mandrel for fabricating an annular structural part of a turbine engine out of composite material, the method including, prior to winding the fiber texture, acquiring a reference distance between an outside surface of the impregnation mandrel and a distance sensor positioned facing the outside surface of the impregnation mandrel, while winding the fiber texture, acquiring at least one real distance between the distance sensor and the outside surface of the fiber texture wound on the impregnation mandrel, and calculating the real thickness of the fiber texture wound on the impregnation mandrel by subtracting the real distance from the reference distance.