Composite Layup Tape End Detection Using Optical Discontinuity
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Solution Overview
Problem
Existing composite layup machines face challenges in accurately placing fiber tapes due to potential slippage and errors, leading to incorrect positioning, which reduces the strength and quality of the composite structure and increases material and labor costs for correction.
Innovation Solution
A system and method using a light source and image capturing unit to project a line of light on the fiber tape, allowing the controller to detect discontinuities and automatically identify the tape end, ensuring precise placement and reducing manual inspection requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an operator visually identifies and inspects tape ends, then tape placement can be monitored, but the process requires continuous manual attention and is difficult to perform accurately due to lighting conditions and tape visibility issues
Solution Approach 1:
The patent replaces the manual visual inspection system with an automated optical detection system. A light source projects illumination on the tape, and a camera captures images of the tape end. The system uses image processing to automatically detect tape end positions and generate alerts, eliminating the need for continuous manual visual monitoring by operators.
Solution Approach 2:
The patent introduces an intermediary optical system consisting of a light source and camera between the tape and the detection process. The light source provides controlled illumination to enhance tape visibility, while the camera acts as an intermediary to capture and transmit visual information to the control system for automated analysis.
2Reliability
If tape placement is monitored manually, then errors can be detected, but by the time errors are identified, multiple layers may already be laid on incorrect tape requiring costly rework
Solution Approach 1:
The patent implements preliminary detection by continuously monitoring tape placement in real-time as the layup machine operates. The system detects tape end positions and placement accuracy before multiple layers are applied, enabling early error detection and immediate correction without requiring peeling and rework of subsequent layers.
Solution Approach 2:
The patent establishes a feedback loop where the camera continuously captures tape position information, the control system analyzes the images to detect placement errors, and alerts are generated in real-time. This closed-loop feedback system enables immediate correction of placement errors before they propagate to subsequent layers.
3Illumination intensity
If the fiber tape surface is illuminated, then the tape can be seen, but the fiber nature causes the tape to appear bright in some orientations and very dark in others making edge detection difficult
Solution Approach 1:
The patent applies local quality by using a light source positioned at a specific angle to create localized illumination patterns on the tape surface. The lighting is designed to highlight the tape edge and end regions while minimizing glare from the fiber surface, creating optimal local visibility conditions for the camera to detect tape boundaries accurately.
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 enables real-time identification and correction of tape placement errors, reducing material and labor costs while improving the quality and precision of composite structures by automating the detection of tape ends and preventing the laying of additional layers on incorrectly positioned tapes.
Implementation Method 1
a light source disposed proximate to the composite structure and configured to project a line of light at a first angle on the fiber tape rolling over the composite structure
Implementation Method 2
an image capturing unit disposed proximate to the composite structure and configured to capture an image of the line of light on the fiber tape at a second angle
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A device (100) for identifying an end of a fiber tape (110) rolling over a composite structure (102) is presented. The device includes a light source (116) disposed proximate to the composite structure (102) and configured to project a line of light at a first angle on the fiber tape (110) rolling over the composite structure (102). Also, the device (100) includes an image capturing unit (118) disposed proximate to the composite structure (102) and configured to capture an image of the line of light on the fiber tape at a second angle. Further, the device (100) includes a controller (108) coupled to the image capturing unit (118) and configured to process the captured image to detect a discontinuity in the line of light on the fiber tape (110) and identify the end of the fiber tape based on the detected discontinuity in the line of light on the fiber tape (110).