Inductive Sensor for Fiber Fabric Strand Gap Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In the manufacturing of composite material parts, fiber fabrics with strands oriented at 0° often experience spacing issues exceeding 2 mm due to loss of tension during the manufacturing process, leading to defects that can weaken the composite material, especially when these defects are not visible and difficult to detect.

Innovation Solution

A method using an inductive sensor to detect spacing defects between adjacent strands by displacing it relative to the fiber fabric, identifying defects based on signal variations, and employing a configuration with a metal plate and air-tight casing to ensure accurate detection, allowing the sensor to move perpendicular to the fabric and cover the entire width for comprehensive inspection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If visual inspection is used to detect strand gaps, then the detection process is simple, but defects in invisible layers cannot be detected

Engineering Contradiction:

Improvedetection simplicityVSAvoiddefect detection capability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces visual inspection (optical/mechanical system) with electromagnetic sensing. The inductive sensor detects strand gaps by measuring changes in electromagnetic field properties caused by variations in fiber density, enabling detection of defects in invisible layers without direct visual contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an electromagnetic field as an intermediary between the sensor and the fiber fabric. The inductive sensor generates an electromagnetic field that penetrates the fabric layers, and variations in the field caused by strand gaps provide indirect information about defect locations that visual inspection cannot access.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If strands are maintained under tension to prevent spacing defects, then strand spacing is controlled, but the manufacturing process complexity increases

Engineering Contradiction:

Improvestrand spacing controlVSAvoidtension maintenance system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical tension maintenance system with an electromagnetic detection system. Instead of using clamps and tensioning devices to control strand spacing, the inductive sensor detects spacing defects non-contactually by measuring electromagnetic field variations, eliminating the need for complex mechanical control systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electromagnetic field generated by the inductive sensor automatically penetrates the fabric and provides detection information without requiring additional mechanical intervention. The system uses the inherent electromagnetic properties of the materials to perform detection, reducing the need for external control mechanisms.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If the inductive sensor is positioned close to the fabric for accurate detection, then detection precision is improved, but the risk of damaging delicate fibers increases

Engineering Contradiction:

Improvedefect detection accuracyVSAvoidfiber damage risk

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent uses electromagnetic sensing instead of mechanical contact for detection. The inductive sensor generates an electromagnetic field that can be positioned very close to or even in contact with the fabric without applying mechanical force that would damage the delicate fibers, achieving high precision detection without the harmful effects of mechanical pressure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Effectively prevents the use of non-compliant fiber fabrics by accurately detecting spacing defects, ensuring homogeneous fiber surface density and preventing weaknesses in composite material parts.

Implementation Method 1

displacement of an inductive sensor relative to the fiber fabric, identification of a defect based on a signal generated by the inductive sensor

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10101144B2Method for detecting a strand gap in fiber fabric and a device for its implementation

Publication Date: 2018.10.16 AIRBUS OPERATIONS (SAS)

AI summary

A method for detecting a spacing defect between two adjacent strands of a layer of a fiber fabric includes positioning of the fiber fabric on a metal plate, the fiber fabric covered by an air-tight casing, removing air from between the metal plate and the casing, displacing an inductive sensor relative to the fiber fabric and identifying a defect based on a signal generated by the inductive sensor.