Multispectral Imaging for Composite Layup Debris Detection
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Solution Overview
Problem
The challenge in composite material fabrication is the difficulty in detecting and removing foreign object debris, such as water, oil, and small parts, which can reduce the integrity and strength of composite structures, and are often missed during visual inspections due to time constraints and visibility issues, especially when increasing the speed of layup processes.
Innovation Solution
A multispectral imaging system using near infrared light to illuminate and detect foreign object debris by analyzing the spectrum of reflected light, allowing for timely and efficient identification and removal during the composite layup process, even at higher layup speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection is performed to detect foreign object debris, then detection reliability is improved, but productivity deteriorates due to time consumption
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system that uses light sources and sensors to automatically detect foreign object debris. This substitution eliminates the time-consuming human inspection process while maintaining high detection reliability, allowing the system to operate at speeds matching modern composite layup processes.
Solution Approach 2:
The patent introduces an intermediary detection system positioned between the composite plies during layup. This system uses light transmission through the plies to detect foreign objects without requiring停顿 in the layup process, effectively mediating between the need for continuous high-speed production and the requirement for thorough inspection.
2Measurement precision
If visual inspection is performed thoroughly to detect transparent or low-contrast foreign object debris, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The patent changes the detection parameter from visible light reflection (used in visual inspection) to light transmission through the composite plies. This parameter change enables the detection of transparent and low-contrast foreign objects that are invisible to the human eye, achieving high measurement precision without time loss because the detection occurs automatically during the layup process.
Solution Approach 2:
The automated optical detection system replaces human visual inspection, providing consistent and precise detection of all types of foreign objects including transparent and low-contrast materials. The system processes data rapidly and continuously, eliminating the time penalty associated with thorough manual inspection while maintaining or improving detection precision.
3Productivity
If layup speed is increased to improve productivity, then productivity is improved, but detection reliability deteriorates due to reduced inspection time
Solution Approach 1:
The patent implements continuous detection throughout the entire layup process without interruption. The optical detection system operates continuously as plies are being laid up, maintaining constant monitoring capability. This eliminates the need to slow down or pause for inspection, allowing high productivity to be maintained while ensuring reliable detection of foreign objects at all times.
Solution Approach 2:
The automated detection system operates at speeds matched to high-speed automated layup equipment, replacing slow manual inspection. The system processes optical data in real-time, enabling reliable foreign object detection to keep pace with increased layup speeds rather than becoming a bottleneck that limits productivity.
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 reliable detection and removal of foreign object debris, maintaining the quality and integrity of composite structures while allowing for faster and more efficient fabrication of composite materials, reducing the risk of incorporating defects into the final product.
Implementation Method 1
a near infrared light source configured to illuminate a surface of a composite material with near infrared light
Implementation Method 2
a detector configured to detect the near infrared light following interaction of the near infrared light with the composite material
Data Source
AI summary
A multispectral imaging system and method and a system for composite layup are provided in order to detect foreign object debris during the fabrication of a composite structure. In the context of a method, a surface of a composite material is illuminated with near infrared light. The method also detects the near infrared light following interaction of the near infrared light with the composite material. Following detection, the method analyzes a spectrum of the near infrared light to detect foreign object debris upon the composite material. The method analyzes the spectrum of near infrared light by distinguishing between different types of foreign object debris as a result of comparing the spectrum of near infrared light to predefined spectral signatures of a plurality of different types of foreign object debris. The method may also determine the size and location of the foreign object debris.