Automated Resin Ridge Reduction for Composite Wing Surfaces
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Solution Overview
Problem
The manufacturing of composite aircraft wings is hindered by resin ridges formed due to caul plates, bagging creases, and transition areas, leading to increased time, expense, and ergonomic issues during inspection and reworking, with current manual processes being labor-intensive and prone to over-sanding or discarding of wings.
Innovation Solution
An automated guided vehicle system equipped with a surface inspection sensor and inconsistency reduction system that autonomously identifies and reduces resin ridges by generating inspection information, comparing measured profiles to expected profiles, and controlling sanding or grinding operations to maintain tolerance without exposing fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual inspection and reworking of resin ridges is performed, then flexibility and adaptability are maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical inspection and sanding operations with an automated system comprising optical sensors for detection and robotic sanding mechanisms for correction. The system uses cameras and light sources to automatically identify resin ridges, calculates their dimensions, and controls robotic sanding tools to reduce them to within specification, eliminating manual labor while maintaining operational effectiveness
Solution Approach 2:
The system enables the composite structure to be self-inspected and self-corrected through automated detection and sanding. The inspection system automatically identifies defects, the control system processes the data, and the sanding system executes corrections without external human intervention, allowing the manufacturing process to service itself
2Productivity
If automated inspection systems are implemented, then productivity and consistency improve, but system complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where a single automated apparatus performs multiple operations: optical detection of resin ridges, dimensional calculation, determination of sanding parameters, execution of sanding operations, and verification of correction results. This universal system handles the entire inspection and correction workflow, improving productivity while consolidating complexity into one coordinated unit rather than multiple separate systems
Solution Approach 2:
The control system acts as an intermediary that receives data from inspection sensors, processes the information to determine defect characteristics, and translates this into control signals for the sanding mechanism. This intermediary layer manages the complexity by creating a clear interface between detection and correction subsystems, enabling automated operation without requiring overly complex direct coupling between all system components
3Loss of time
If aggressive sanding is used to remove resin ridges, then manufacturing time is reduced, but risk of exposing fibers and creating new defects increases
Solution Approach 1:
The system incorporates continuous feedback through optical inspection before, during, and after sanding operations. The inspection system measures resin ridge dimensions, the control system calculates appropriate sanding parameters based on these measurements, executes the sanding, and then re-inspects to verify correction while preventing over-sanding. This closed-loop feedback ensures rapid correction while maintaining surface quality and preventing fiber exposure
Solution Approach 2:
The system dynamically adjusts sanding parameters including sanding depth, speed, and tool path based on real-time measurements of resin ridge characteristics. By changing these parameters according to the specific defect being corrected rather than using fixed aggressive settings, the system achieves efficient removal of resin while maintaining precision and avoiding damage to the composite structure
Data Source
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AI summary
An apparatus comprises an automated guided vehicle that moves on a surface of a composite structure during operation of the apparatus to inspect the composite structure, a surface inspection sensor system associated with the automated guided vehicle, and an automated guided vehicle and surface inspection sensor system controller in communication with the automated guided vehicle and the surface inspection sensor system.