Flatbed Scanner Composite Sample Defect Detection
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Solution Overview
Problem
Current methods for evaluating composite materials, such as Carbon Fibre Reinforced Polymer (CFRP), are limited by their inability to detect small defects with high resolution, speed, and cost-effectiveness, often leading to failures in aerospace and other industries.
Innovation Solution
A method utilizing a conventional high-resolution flatbed scanner to image composite samples with the scanning plane parallel to the scanning direction and ply edges perpendicular, allowing for detailed defect identification, including voids, fibre wrinkles, and fibre waviness, and optionally post-processing the images for enhanced defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonics, computed tomography (CT), or shearography are used to detect defects, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses a flatbed scanner to create a visual copy/image of the composite sample surface. This copying approach allows defect detection without requiring complex ultrasonic or CT equipment, achieving good measurement precision while keeping device complexity low. The scanner captures optical information that replicates the surface features and defects.
Solution Approach 2:
The patent employs a conventional flatbed scanner, which is a relatively inexpensive and simple device compared to ultrasonic or CT equipment. This allows defect detection to be performed using affordable, readily available technology rather than expensive specialized equipment, resolving the contradiction between measurement precision and device complexity.
2Measurement precision
If ultrasonics, computed tomography (CT), or shearography are used to detect defects, then measurement precision is improved, but productivity decreases
Solution Approach 1:
The flatbed scanner rapidly captures an optical copy of the entire sample surface in a single operation, enabling quick defect detection. This copying method is much faster than ultrasonic or CT scanning, which require sequential scanning and data processing, thus improving productivity while maintaining adequate measurement precision.
Solution Approach 2:
The patent replaces complex mechanical scanning systems (ultrasonic transducers, CT rotation mechanisms) with a simple optical scanning system using a flatbed scanner. This substitution eliminates the need for complex mechanical movements and data processing, significantly increasing evaluation speed and productivity.
3Ease of operation
If visual inspection is used to detect defects, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The flatbed scanner creates a high-resolution digital copy of the sample surface, which can then be inspected visually with enhanced detail. This copying approach combines the simplicity of visual inspection with the precision of digital imaging, allowing operators to easily examine defects at magnified resolution without the complexity of advanced equipment.
Solution Approach 2:
The patent changes the resolution parameter by using a high-resolution flatbed scanner that captures detailed images far beyond human eye capability. This parameter change enables visual inspection to achieve measurement precision previously only attainable through complex equipment, while maintaining the ease of visual evaluation.
Data Source
AI summary
A method of evaluating a composite sample comprises providing a flatbed scanner comprising a scanning head movable along a scanning direction; providing a composite sample comprising a plurality of plies arranged on planes parallel to a longitudinal direction and comprising a scanning plane containing ply edges, wherein the ply edges are oriented parallel to the longitudinal direction; arranging the composite sample on the flatbed scanner such that the scanning plane is parallel to the scanning direction and the ply edges of the scanning plane are perpendicular to the scanning direction; moving the scanning head along the scanning direction and perpendicularly to the ply edges to scan the scanning plane of the composite sample and obtain an image of the scanning plane; and evaluating the image to identify possible defects in the composite sample.