Automated Infrared Inspection for Composite Layup FOD Detection
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Solution Overview
Problem
Current methods for detecting foreign object debris (FOD) and defects in composite materials during the high-speed composite layup process are slow, unreliable, and often miss subsurface issues due to manual visual inspection, leading to costly rejections and delays in manufacturing.
Innovation Solution
An automated system using multiple thermal excitation sources and infrared cameras mounted on a gantry, capable of scanning the surface and subsurface of composite parts in real-time, analyzing differences in infrared energy to identify FOD and defects, including those under the outer layer, and providing real-time feedback for remediation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual visual inspection is used for FOD and defect detection, then the system complexity is low, but the detection speed is slow and reliability is poor
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system that uses a camera to capture images of the composite material surface. The system substitutes human visual detection with machine-based image capture and analysis, significantly improving detection reliability and speed while reducing the need for manual labor.
Solution Approach 2:
The patent introduces an intermediary imaging system that captures visual information of the composite material surface. The camera acts as an intermediary between the inspection object and the detection system, enabling automated analysis of FOD and defects without direct human intervention while maintaining detection accuracy.
2Productivity
If high-speed composite layup is used to increase productivity, then the production speed increases, but the detection of FOD and defects becomes more difficult due to reduced inspection time
Solution Approach 1:
The patent implements continuous inspection during the composite layup process. The imaging system operates continuously as the composite material is being laid up, capturing images without interrupting the production flow. This eliminates the need for separate inspection stages and maintains productivity while ensuring constant monitoring for FOD and defects.
Solution Approach 2:
The patent performs inspection during the layup process itself, before the composite material is cured. By detecting FOD and defects at this early stage, the system enables immediate remediation actions such as removing contaminants or re-laying affected areas, preventing defects from becoming permanent after curing.
3Measurement precision
If multiple thermal excitation sources and infrared cameras are used for subsurface detection, then the detection capability for subsurface FOD improves, but the device complexity and cost increase
Solution Approach 1:
The patent divides the inspection system into multiple independent detection units, each with its own thermal excitation source and infrared camera. Each unit is responsible for detecting specific areas or aspects of the composite material, allowing the system to cover subsurface detection requirements through modular segmentation rather than requiring a single complex system.
Solution Approach 2:
The patent uses a multi-functional detection system where thermal excitation sources and infrared cameras serve multiple purposes. The same imaging infrastructure is used for both surface inspection and subsurface defect detection by varying the thermal excitation parameters, eliminating the need for separate dedicated systems for different detection depths.
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 fast and reliable detection of surface and subsurface FOD and defects, reducing the likelihood of manufacturing defects and costly rejections by providing immediate identification and remediation during the composite layup process.
Implementation Method 1
A thermal (infrared) excitation source...directs a beam of infrared energy at a workpiece
Implementation Method 2
An associated infrared camera...scans the workpiece and outputs information based on the infrared energy output therefrom
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A system and method for the detection of foreign object debris materials or defects on and/or under a surface (e.g., outer ply) of a composite part being formed by a composite layup machine. A gantry (203, 205, 215, 220, 305) moves over the composite part (140, 201) along a predetermined length thereof. A thermal excitation source (110) fixed to the gantry (203, 205, 215, 220, 305) directs infrared radiation across the width of the surface of the composite part (140, 201). An infrared camera (120, 206, 210, 211, 212, 216, 221, 310, 320, 330) fixed to the gantry (203, 205, 215, 220, 305) a predetermined distance away from the thermal excitation source (110) scans the surface as the gantry (203, 205, 215, 220, 305) moves to detect and output scan information thereof. A controller (170) is coupled to the thermal excitation source (110) and to the infrared camera (120, 206, 210, 211, 212, 216, 221, 310, 320, 330). The controller (170) processes the sequence of infrared images to identify a foreign object debris material or defect located on and/or under the surface.