Vision Inspection Reference Targets for Composite Structures
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Solution Overview
Problem
Manual inspection of composite structures using Automated Fiber Placement (AFP) or Automated Tape Layering (ATL) is time-consuming and dependent on operator skill, making it difficult to validate and certify dimensional requirements accurately, while online inspection systems face challenges with positioning accuracy due to poor robot positioning.
Innovation Solution
A method and system for referencing composite structures within an online vision inspection system, using reference targets on the contour of a lay-up surface to correlate the image reference system with a mold reference system, independent of the automated tool's positioning accuracy, involving the use of outer and inner reference targets, measuring calibration targets, and real-time calibration to correct pixel values and tool positioning errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection using hand-held probe and laser tracker is used, then measurement capability is achieved, but inspection time becomes extremely time consuming especially for composite structures with many plies
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated vision inspection system that uses cameras to capture images of reference targets and composite structure features. The system automatically processes images to extract dimensional data, eliminating the need for manual probe measurements and significantly reducing inspection time while maintaining measurement accuracy.
Solution Approach 2:
The patent uses reference targets with known geometries placed on the mold to create a reference framework. The vision system captures images of these targets and creates a digital copy of the reference coordinate system, which is then used to map and measure features on the composite structure without direct physical contact, enabling rapid automated measurement.
2Productivity
If online inspection system with camera attached to manufacturing robot head is used, then real-time inspection capability is achieved, but positioning accuracy deteriorates due to poor robot positioning
Solution Approach 1:
The patent introduces reference targets as intermediary objects with known, precise geometries placed on the mold. The vision system uses these targets as mediators to establish an accurate reference coordinate system that compensates for robot positioning errors. By measuring features relative to these stable reference targets rather than relying on robot head position, the system achieves accurate measurements despite robot positioning limitations.
Solution Approach 2:
The patent implements a feedback mechanism where the vision system continuously captures images of reference targets and measured features, processes the image data to determine positions and dimensions, and compares these measurements against specifications. The system provides real-time feedback on inspection results, enabling corrective actions during manufacturing while maintaining measurement accuracy independent of robot positioning drift.
3Adaptability or versatility
If manual inspection is performed, then flexibility in handling complex structures is maintained, but repeatability and certification validation become difficult due to dependence on operator skill
Solution Approach 1:
The patent enables the inspection system to be self-sufficient by automatically capturing images, processing data, extracting measurements, and generating inspection reports without human intervention. The automated image processing algorithms consistently apply the same measurement criteria and analysis methods to every inspection, eliminating variability introduced by different operators and ensuring repeatable, certifiable results while maintaining the ability to handle complex composite structures.
Data Source
AI summary
There is described a method for referencing a composite structure within an online vision inspection system. Referencing is performed independently from a positioning accuracy of an automated tool with which the composite structure is manufactured. Reference targets provided on a contour of a lay-up surface are used to correlate an image reference system with a mold reference system.