Optical Ply Orientation Mapping for Composite Machining Inspection
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Solution Overview
Problem
Current methods for repairing composite materials in aeronautics lack reliable non-destructive inspection techniques to validate the quality of ply-by-ply machining and gluing, leading to variability and uncertainty in mechanical strength, especially due to the unique characteristics of long fiber composite materials.
Innovation Solution
An automated optical characterization method using image analysis to inspect the surface state of machined parts, capturing images from different orientations, analyzing pixel brightness to determine ply orientations, constructing a map of surface distribution, and estimating machining quality, with an automated system employing linear lighting strips and a video camera to provide digital data processing for rapid and reproducible results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated optical characterization with image analysis is implemented, then measurement precision and reproducibility of machining quality assessment are improved, but device complexity increases
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical characterization system using image analysis. The system captures images with lighting from different orientations, analyzes pixel brightness to determine ply orientations, and constructs maps of surface distribution. This substitution of mechanical/manual inspection with automated optical analysis directly improves measurement precision while the modular system design manages the complexity through standardized components.
2Measurement precision
If multiple lighting orientations are used for image capture, then measurement precision and reliability of ply orientation detection are improved, but use of energy and inspection time increase
Solution Approach 1:
The inspection system uses periodic action by capturing images with lighting from different orientations in sequential steps rather than simultaneous illumination. The method captures images with lighting of different orientation as a function of the orientations and optical characteristics of the machined plies, analyzing pixel brightness to determine which orientation shows greater brightness. This periodic illumination approach reduces total energy consumption compared to continuous multi-directional lighting while maintaining measurement precision.
3Productivity
If automated inspection system is implemented, then productivity and rapidity of quality assessment are improved, but device complexity and initial cost increase
Solution Approach 1:
The automated inspection system performs self-service by autonomously capturing images, analyzing pixel brightness, determining ply orientations, and constructing surface distribution maps without requiring manual intervention. The system processes images and estimates machining quality automatically, significantly improving productivity and rapidity of quality assessment. The modular architecture with standardized components (lighting strips, video camera, processing unit) manages device complexity through reusable, interchangeable elements.
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 significantly enhances the rapidity, reproducibility, and reliability of machining quality assessment, reducing variability and ensuring accurate validation of repair processes, thereby improving the mechanical integrity of composite material repairs.
Implementation Method 1
capturing images with lighting of different orientation of a surface of the machined part to be inspected as a function of the orientations and the optical characteristics of the machined plies
Data Source
AI summary
The invention relates to achieve a rapid, reproducible and reliable characterization of the quality of ply-by-ply machining of multilayer materials. This method for inspecting ply-by-ply machining of a part (10) made of multilayer composite material under repair by machining a ply-by-ply staggered or continuously sloped cut out in a stack of plies of various successive orientations includes taking images (IA to ID), under lighting of different orientations (12), of a surface area (10a) of the machined part (10) to be inspected; performing an analysis by comparing the images (IA to ID) pixel by pixel (P0) in order to define the orientation of each pixel (P0) as corresponding to that of the image in which this pixel has a higher brightness; if the pixel has a similar brightness in all the images (IA à ID), this pixel (Pr) is attributed to a resin; constructing a map (5) in units of ply of the surface area to be inspected (10a) by applying the preceding analysis to all of the pixels; estimating a machining quality level from the map (5) produced, and archiving (2m) each map (5) thus produced as a machining result.