Automated Tow Gap Width Measurement in Composite Structures
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Solution Overview
Problem
Existing methods for inspecting cumulative tow gap width in composite structures are labor-intensive, prone to errors, and inefficient, especially for large surface areas, relying on manual visual inspection which is time-consuming and prone to inaccuracies.
Innovation Solution
A system and method utilizing an in-process vision system with cameras and data analysis computers to automatically record and calculate cumulative tow gap widths, reducing inspection cycle times and enhancing accuracy by comparing measured gaps to maximum allowable criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection is used to measure tow gap widths, then inspection can be performed with simple equipment, but inspection cycle time increases and measurement accuracy decreases
Solution Approach 1:
The patent replaces manual mechanical measurement tools (scales, calipers) with an automated vision system using cameras and image processing software. The system captures images of the composite structure surface and automatically detects, measures, and calculates cumulative tow gap widths through digital image analysis, eliminating the need for physical contact tools and manual operations.
Solution Approach 2:
The vision system performs self-measurement and self-analysis by automatically processing images to identify tow gaps, calculate their widths, and determine cumulative values within specified areas. The system independently completes the entire inspection workflow without requiring human operators to manually measure each gap, thereby reducing both time and labor while maintaining high precision.
2Reliability
If multiple inspectors are deployed to reduce measurement errors, then measurement reliability improves, but touch labor and inspection cost increase
Solution Approach 1:
The patent replaces human inspectors with an automated vision system that eliminates subjectivity and human error in measurement. The system uses consistent digital imaging and algorithmic analysis to provide reliable, repeatable measurements across all inspections, achieving high reliability without requiring multiple human operators or their associated labor costs.
3Device complexity
If manual inspection methods are used, then equipment complexity remains low, but the system becomes unmanageable for large surface areas
Solution Approach 1:
The patent transitions from one-dimensional linear measurement (using scales or calipers moved across the surface) to two-dimensional area-based inspection using camera imaging. The vision system captures the entire inspection area in an image or series of images, allowing simultaneous measurement of multiple tow gaps across large surfaces, effectively expanding the inspectable area capacity while maintaining manageable system complexity.
Data Source
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AI summary
A system (22) for determining cumulative tow gap (33) width includes an in-process vision system (1) having at least one camera (18) adapted to record images of a composite material (30) and a data analysis computer (24) communicating with and adapted to receive image data from the in-process vision system (1). The data analysis computer (24) may be adapted to calculate a cumulative gap width of tow gaps (33) in the composite material (30). A user interface (26) may communicate with and be adapted to receive data analysis results from the data analysis computer (24). A method for determining cumulative tow width gap of tow gaps (33) in a composite structure (30) is also disclosed.