Optical Control for Patch Positioning Accuracy
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Solution Overview
Problem
Current methods for applying pre-impregnated patches on large surfaces lack precise control, leading to potential errors in positioning and adherence, resulting in incomplete coverage, extra costs due to excessive overlap, and increased weight of the final part.
Innovation Solution
An automatic method using optical control means to acquire images of the patch, detect defects in positioning, and map thickness variations, allowing for corrective actions to ensure precise placement and adherence without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a significant overlap is used between patches to prevent positioning errors, then the reliability of coverage is improved, but the weight and cost of the final part increase
Solution Approach 1:
The patent implements an optical feedback system that captures images of each patch after positioning, detects its actual position and overlap, and uses this information to guide subsequent patch placements. This real-time feedback eliminates the need for excessive overlap margins, allowing precise positioning that reduces material waste while ensuring complete coverage.
Solution Approach 2:
The patent replaces mechanical positioning systems with optical measurement and control systems. Instead of relying on mechanical precision and large overlap margins to compensate for positioning errors, the system uses optical imaging and digital processing to achieve precise patch placement with minimal overlap, thereby reducing weight and cost.
2Measurement precision
If manual inspection is performed at the end of covering to detect positioning errors, then the measurement precision is improved, but the productivity decreases
Solution Approach 1:
The patent implements continuous automated optical inspection throughout the patch application process rather than discrete manual inspection at the end. The optical system continuously monitors patch positioning as patches are applied, enabling real-time detection and correction without interrupting the manufacturing flow, thus maintaining both high precision and productivity.
Solution Approach 2:
The patent replaces manual inspection with automated optical inspection systems that continuously monitor patch positioning. This substitution eliminates the time-consuming manual measurement process while maintaining or improving detection precision, thereby significantly increasing manufacturing productivity.
3Ease of operation
If pneumatic grippers are used to grasp and position patches, then the ease of operation is improved, but the manufacturing precision deteriorates due to lack of control
Solution Approach 1:
The patent combines pneumatic gripper operation with optical feedback systems that monitor patch positioning in real-time. The feedback information allows the system to detect and correct positioning deviations, maintaining the ease of pneumatic operation while achieving high manufacturing precision through automated control.
Solution Approach 2:
The patent supplements the mechanical pneumatic gripper system with optical measurement and digital control systems. This hybrid approach retains the operational simplicity of pneumatic grasping while adding precision through optical detection and automated positioning control, eliminating the precision limitations of purely mechanical systems.
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
The method ensures accurate and consistent patch placement, identifies and corrects defects such as incorrect gluing, positioning, or spacing issues, reducing errors and excess material usage, thereby improving the quality and efficiency of the patch application process.
Implementation Method 1
acquiring by means of an optical control means at least one image of the positioned patch
Data Source
AI summary
A method for controlling the application of a patch can include the following steps:positioning a patch on a surface to be covered by means of a gripper and with or without partial overlapping with adjacent patches;acquiring by means of an optical control means at least one image of the positioned patch;detecting defects in the positioning of the patch by identifying differences in the thickness of the patch on the surface to be covered based on the at least one image of the positioned patch; andmapping the defects in the positioning of the patch.