3D Mapping of Tow Splices in Composite Laminates
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Solution Overview
Problem
Current methods cannot accurately determine and visualize the alignment of tow splices through the thickness of composite laminates, which can affect the load-bearing capability of the structure, leading to potential weaknesses in the laminate.
Innovation Solution
A method and apparatus for real-time 3-D mapping and display of tow splices during the lay-up process using optical sensing and camera systems to detect and record the location of splices, generating a 3-D data file and image to visualize any undesirable alignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visible markings are applied to identify splice locations, then splice identification is improved, but 3-D mapping and alignment detection through laminate thickness is not achieved
Solution Approach 1:
The patent transitions from 2-D surface markings to 3-D spatial mapping by using optical sensors to detect splice locations in multiple layers and reconstructing their positions in three-dimensional space. This allows visualization of splice alignment through the laminate thickness, providing complete spatial information rather than just surface-level identification.
Solution Approach 2:
The patent introduces an optical sensing system and data processing intermediary that captures, processes, and visualizes splice location data. This intermediary system transforms raw sensor data into a comprehensible 3-D graphical representation, enabling operators to see splice alignment through the laminate structure without direct physical access to internal layers.
2Device complexity
If manual inspection methods are used to estimate splice locations, then device complexity is reduced, but measurement precision and reliability of splice alignment detection deteriorate
Solution Approach 1:
The system performs self-service by automatically detecting, recording, and analyzing splice locations during the manufacturing process itself. The optical sensors and data processing operate autonomously without requiring separate manual inspection steps, integrating quality control directly into the production workflow.
Solution Approach 2:
The patent implements real-time feedback by continuously monitoring splice locations during manufacturing and providing immediate visual feedback on splice alignment. This allows operators to see the spatial distribution of splices as they are being created, enabling timely corrections if undesirable alignment patterns emerge.
3Productivity
If splice alignment is not monitored in real-time, then manufacturing speed is maintained, but structural reliability and load-bearing capability deteriorate due to potential splice alignment issues
Solution Approach 1:
The patent maintains continuous monitoring of splice locations throughout the entire manufacturing process without interrupting production. The optical sensing system operates continuously as tows are placed, ensuring uninterrupted data collection on splice positions while the manufacturing process proceeds at normal speed.
Solution Approach 2:
The system performs preliminary detection and analysis of potential splice alignment problems during manufacturing, before the laminate is completed. By identifying alignment issues early in the process, the system allows for corrective actions to be taken while the structure is still being built, preventing defective alignment from becoming locked into the final product.
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
Enables prompt corrective action during the manufacturing process to prevent excessive splice alignment, ensuring the laminate meets engineering specifications and maintaining structural integrity.
Implementation Method 1
sensing the location of each splice may include optically sensing the presence of a feature on the tows that represents the location of the splice. The sensing process may be performed by illuminating the tows as they are being placed and optically sensing the presence of the feature using a camera.
Data Source
AI summary
The three dimensional (3-D) locations of splices in pre-preg tows placed by an automatic fiber placement machine to form a laminated composite structure are mapped to allow visualization of alignment patterns in the splices.