Prism-Based Profilometry for Composite Strip Clearance
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Solution Overview
Problem
Current methods for checking the clearance between strips laid up by a draping head in composite component manufacturing are unreliable and difficult to implement due to the complex geometry and limited space within the layup zone, leading to low visual inspection reliability and challenges with camera focusing.
Innovation Solution
A profilometry device using a laser light source and camera with a prism to redirect the image at an angle, allowing the camera to be positioned remotely and freely, enabling accurate measurement of strip clearances and surface profiles within the constrained layup zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a camera is positioned close to the layup zone to capture strip clearance images, then measurement accuracy is improved, but the available space is insufficient due to the narrow gap between compacting members
Solution Approach 1:
The patent introduces a prism as an intermediary optical element that redirects light at a 90-degree angle. This allows the camera to be positioned in an adjacent area with sufficient space while still capturing images of the strip clearance in the constrained layup zone, effectively decoupling the camera's physical location from the measurement location
Solution Approach 2:
The patent changes the spatial dimension by using the prism to redirect the optical path perpendicular to the original line of sight. This enables the camera to capture measurements in the layup zone from a different spatial dimension (side view through the prism) rather than requiring direct access from the limited front space
2Device complexity
If visual inspection is performed manually to check strip clearances, then equipment complexity is reduced, but inspection reliability deteriorates due to difficulty in visualizing clearances and operator safety risks
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical measurement system consisting of a laser, prism, and camera. This substitution eliminates the limitations of human vision and physical access while providing objective, quantifiable measurements of strip clearances, significantly improving inspection reliability
Solution Approach 2:
The patent uses a laser light source that projects a visible line onto the strip surface, creating a high-contrast visual reference that enhances the visibility of strip edges and clearances. This optical enhancement allows the camera to capture precise measurements that would be difficult to discern with ambient lighting alone
3Productivity
If the draping head moves at high speed to increase productivity, then production efficiency is improved, but the time available for quality checking deteriorates
Solution Approach 1:
The patent implements continuous quality checking by integrating the laser and camera system directly into the draping head, allowing measurements to be taken continuously as the head moves at high speed. The system captures strip clearance data in real-time without requiring the draping process to slow down or pause, maintaining continuous productive operation
Solution Approach 2:
The patent establishes a feedback loop where the camera captures images of strip clearances, the measurements are processed, and results are provided back to the control system. This enables real-time quality monitoring and immediate corrective action if clearances fall outside specifications, ensuring quality control keeps pace with high-speed production
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 solution provides a reliable and efficient method for checking strip clearances and surface profiles, improving the quality control of composite components by allowing for high-speed, accurate measurements and reducing the risk of operator error.
Implementation Method 1
a profilometry device which comprises a laser light source that projects a line of light onto the surface to be checked and a camera for capturing the image of the line of light that has been projected
Implementation Method 2
the device comprises a prism situated close to the surface to be checked along the camera axis so as to return to the camera the image of the projected line of light that reaches it at a given angle
Data Source
AI summary
The present disclosure relates to a sub-assembly of a drape-forming head (20), comprising, downstream, at least one member (23) for depositing the prepreg strip, at least one roller (30, 30′) for compacting the prepreg strip, and a device (10) for checking the play between the strips, consisting of a profilometer including a camera (13), a laser light source (11) projecting a line of light onto the surface to be checked, and a prism (16) arranged near the surface to be checked, in the axis of the camera (13), so as to send, to the camera (13), the image of the projected line of light that reaches the camera at a certain angle. The camera (13) and the light source (11) are placed side-by-side in an offset housing (18) arranged remotely from the compacting rollers (30, 30′), the prism (16) being connected to the housing (18) and to the camera (13) via an elongate casing (19) vertically arranged between the compacting rollers (30, 30′).