Fibrous Preform Weaving Machine with Hidden-Face Anomaly Detection
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Solution Overview
Problem
The production of composite material gas turbine casings, particularly fan retention casings, faces challenges in detecting anomalies such as pollution and weaving defects on the hidden face of the preform during the winding operation, which are obscured and cannot be identified until the final step, leading to potential manufacturing issues.
Innovation Solution
A method utilizing cameras and an image analysis module on a machine that weaves or winds fibrous preforms to detect anomalies in real-time by comparing the hidden face of the preform to reference patterns, allowing for immediate correction or scrapping before impregnation, and providing statistical analysis for quality monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the preform is wound in superimposed layers onto the impregnation mandrel, then the housing structure is formed, but the hidden face of the preform cannot be visually inspected for anomalies
Solution Approach 1:
The patent positions cameras and lighting devices to capture images of the hidden face of the preform during the winding operation, before the preform is completely wound and hidden. This preliminary detection allows anomalies to be identified while the preform is still accessible to inspection devices.
Solution Approach 2:
The patent introduces an intermediary inspection system consisting of cameras, lighting devices, and image processing equipment that acts as a mediator between the hidden face of the preform and the operators. This intermediary system makes the hidden face visible and detectable without disrupting the winding operation.
2Ease of operation
If operators are positioned on a work platform above the winding machine, then they can operate the machine, but they cannot detect anomalies on the hidden face of the preform
Solution Approach 1:
The patent replaces the mechanical visual inspection system (operators positioned above the machine) with an optical detection system (cameras and image processing equipment) that can capture and analyze the hidden face of the preform from positions that do not interfere with operator work.
Solution Approach 2:
The patent creates optical copies (images) of the hidden face of the preform using cameras positioned strategically around the winding machine. These copies are then processed and displayed, allowing operators to inspect anomalies without being in a position to directly view the hidden face.
3Reliability
If the winding operation is the final step where anomalies can still be detected, then quality control is possible, but anomalies on the hidden face remain undetected and are concealed by overlapping layers
Solution Approach 1:
The patent ensures continuous detection of the preform's hidden face throughout the winding operation by positioning cameras to continuously capture images as the preform is wound. This continuous monitoring maintains quality control capability without interruption by the winding process.
Solution Approach 2:
The patent uses multiple cameras positioned at different angles and heights to capture the hidden face of the preform from multiple dimensions. This multi-dimensional approach ensures that anomalies are not obscured by the winding geometry and can be detected from various perspectives.
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 real-time control and correction of anomalies during the weaving or winding process, ensuring the quality of composite material casings and reducing manufacturing cycle time by allowing for automated operation and precise identification of defects.
Implementation Method 1
several cameras directed under the fibrous texture scan the hidden face of the fibrous preform and acquire images of this hidden face
Data Source
Figure 1A~2
Figure 1B
Figure 3~4
AI summary
The invention relates to a machine for weaving (10) or winding (20) a fibrous preform (28) onto a mandrel having a substantially horizontal axis of rotation (30) and intended to accept same, comprising a plurality of cameras (42) aimed under the fibrous preform in order to scrutinize the hidden face of the fibrous preform and capture images of this hidden face; an image analysis module (40) for processing these images of the hidden face of the fibrous preform, in a number of adjacent scrutinizing windows, extract weaving patterns therefrom and compare same against reference weaving patterns prerecorded in the module; a motor (34, 36) for driving the mandrel in rotation about the axis of rotation of same; and a control unit (40) for halting the rotation of the mandrel if the result of the comparison reveals, in at least one scrutinizing window, a difference in appearance between these two weaving patterns that is characteristic of the presence of an anomaly resulting from contamination in and/or defective weaving of the fibrous preform.