Fluorescent Indicator for Composite Ply Contamination Detection
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Solution Overview
Problem
Existing methods for detecting foreign material contamination in composite parts, such as backing paper, during assembly processes are ineffective due to difficulty in distinguishing flat black composite ply from contamination, especially under varying ambient light conditions, leading to false alarms and inability to ensure contamination is removed before assembly, resulting in costly scrapage of composite parts.
Innovation Solution
A method involving the use of a fluorescent indicator marked on potential sources of contamination, which is illuminated at a specific wavelength to differentiate its fluorescence from the composite material, allowing for accurate detection using a camera sensor, even for small particles, by isolating the fluorescence from ambient light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If color video camera is used to detect contamination based on color differences, then contamination detection capability is improved, but detection accuracy deteriorates due to inability to distinguish flat black composite ply from contamination
Solution Approach 1:
The patent applies fluorescent indicators that change color properties under specific illumination. The indicator material fluoresces at a different wavelength than the composite ply, creating distinctive color/ wavelength differences that enable accurate discrimination between contamination and legitimate composite material, resolving the fundamental detection accuracy problem
Solution Approach 2:
The system changes the illumination parameter by using specific wavelength light sources that excite the fluorescent indicator. This parameter change causes the indicator to fluoresce at a distinguishable wavelength, transforming the detection approach from relying on ambient light color variations to using controlled fluorescence emission, thereby improving detection accuracy
2Device complexity
If ambient light is used for color-based detection, then detection process simplicity is improved, but false alarm rate increases due to color balance variations and reflections
Solution Approach 1:
The patent introduces an intermediary fluorescent indicator material that mediates between the illumination source and the detection system. This indicator absorbs specific wavelength light and re-emits at a different wavelength, creating a controlled signal that is independent of ambient light conditions and reflections, thereby eliminating false alarms while maintaining system simplicity
Solution Approach 2:
The system replaces reliance on ambient light conditions with an active illumination and fluorescence emission mechanism. By substituting passive color detection under variable ambient light with active controlled-wavelength illumination and fluorescence detection, the system eliminates the reliability issues caused by ambient light variations
3Measurement precision
If fluorescent indicator is used to mark contamination sources, then detection accuracy is improved, but material formulation complexity increases
Solution Approach 1:
The patent applies fluorescent indicators to known contamination sources such as backing paper, which is a disposable component that is removed during the composite manufacturing process. The indicator is applied to this temporary material rather than the permanent composite structure, keeping the formulation complexity localized to consumable items rather than critical structural components
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 approach provides high-contrast detection of foreign material, significantly improving the ability to identify and locate contamination before assembly, reducing false alarms and ensuring higher accuracy in contamination removal, thereby minimizing production losses and ensuring composite part integrity.
Implementation Method 1
A source of foreign material is marked with a fluorescent indicator. An illumination source for illuminating the ply is provided so that the ply reflects light at a different wavelength than the fluorescent indicator fluoresces.
Data Source
AI summary
A method of detecting a presence of foreign material in a ply is disclosed. A source of foreign material is marked with a fluorescent indicator. The source of foreign material is separated from the ply. An illumination source is provided for illuminating the ply at a different wavelength than the fluorescent indicator fluoresces so that the ply reflects light at a different wavelength. A sensor detects illumination of the ply and fluorescent indicator included in the foreign material disposed upon the ply. Differences in light reflected from the ply and fluorescence of the indicator disposed in the foreign material are detected thereby identifying existence of the foreign material in the ply.