CA2575189A1 - Visual fiber placement inspection - Google Patents
Visual fiber placement inspectionInfo
- Publication number
- CA2575189A1 CA2575189A1 CA002575189A CA2575189A CA2575189A1 CA 2575189 A1 CA2575189 A1 CA 2575189A1 CA 002575189 A CA002575189 A CA 002575189A CA 2575189 A CA2575189 A CA 2575189A CA 2575189 A1 CA2575189 A1 CA 2575189A1
- Authority
- CA
- Canada
- Prior art keywords
- fiber placement
- visual image
- tows
- composite structure
- placement machine
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/382—Automated fiber placement [AFP]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/382—Automated fiber placement [AFP]
- B29C70/384—Fiber placement heads, e.g. component parts, details or accessories
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C2037/90—Measuring, controlling or regulating
- B29C2037/903—Measuring, controlling or regulating by means of a computer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C2037/90—Measuring, controlling or regulating
- B29C2037/906—Measuring, controlling or regulating using visualisation means or linked accessories, e.g. screens, printers
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N2021/8472—Investigation of composite materials
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
Abstract
An apparatus and method are provided for performing, on-the-fly, real time inspection of a composite structure formed by an automated fiber placement machine, through comparison of a visual image of at least a portion of the composite structure to a virtual image of the composite structure. Proper formation of the structure, and/or anomalies within the structure, are determined by comparing the visual image to the virtual image. The automated fiber placement machine, and/or tooling upon which the fiber is placed, are manipulated, and a visual indicator are provided to facilitate inspection and/or repair of any detected anomalies during fabrication of the composite structure.
Claims (36)
1. A method for inspecting a composite structure formed from one or more composite tows by an automated fiber placement machine, the method comprising, comparing a visual image of at least a portion of the composite structure to a virtual image of the at least a portion of the composite structure.
2. The method of claim 1, further comprising, determining proper formation of the structure, by comparing the visual image of at least a portion of the part to the virtual image of the part.
3. The method of claim 1, further comprising, determining improper formation of the structure, by comparing the visual image of at least a portion of the structure to the virtual image of the part.
4. The method of claim 3, further comprising manipulating the automated fiber placement machine to facilitate inspection and/or repair of the improper formation.
5. The method of claim 3, wherein, the method includes providing a visual indication of a detected imperfection.
6. The method of claim 3, further comprising, providing a location of the imperfection on the structure.
7. The method of claim 6, further comprising, providing a visible indication of the location of the imperfection.
8. The method of claim 7, wherein, the visible indication is provided by an automatically directed laser pointer.
9. The method of claim 8, further comprising, moving the structure and/or at least a portion of the automated fiber placement machine to a position whereat the imperfection may by indicated by the laser pointer.
10. The method of claim 1, wherein the structure is formed from one or more plies having multiple tows, and the method further includes comparing a visual image of the tows in a given ply to a virtual image of the tows in a given ply.
11. The method of claim 10, wherein the visual image of the tows is a two dimensional profile plot of an outer surface of the tows.
12. The method of claim 1, wherein the automated fiber placement machine includes a fiber placement head, and the visual image is taken by a vision capture element operatively connected to the fiber placement head.
13. The method of claim 12, wherein the vision capture element is mounted on the fiber placement head.
14. The method of claim 12, wherein the fiber placement head includes a feed roller for feeding out one or more tows of material, and the method further comprises utilizing a rotation sensor operatively connected to the feed roller for synchronization of the visual image with the virtual image.
15. The method of claim 1, wherein one or both of the virtual image and the visual image are located along a U-axis extending through at least a portion of at least one course of material laid down by the automated fiber placement head during formation of the composite structure.
16. A computer-readable medium having computer executable instructions for performing the method of claim 1.
17. The computer-readable medium of claim 16, having further computer executable instructions for performing the step of determining proper formation of the structure, by comparing the visual image of at least a portion of the part to the virtual image of the part.
18. The computer-readable medium of claim 16, having further computer executable instructions for performing the step of determining improper formation of the structure, by comparing the visual image of at least a portion of the structure to the virtual image of the part.
19. The computer-readable medium of claim 18, having further computer executable instructions for performing the step of manipulating the automated fiber placement machine to facilitate inspection and/or repair of the improper formation.
20. The computer-readable medium of claim 16, having further computer executable instructions for performing the step of providing a location of the imperfection on the structure.
21. The computer-readable medium of claim 16, having further computer executable instructions for performing the step of providing a visible indication of the location of the imperfection.
22. A method for inspecting a composite structure, formed by an automated fiber placement machine from a plurality of fiber tows laid down by the automated fiber placement machine, the method comprising.
constructing a virtual image of the structure, prior to forming the composite structure, defining a proper placement and configuration of each of the plurality of fiber tows within the composite structure;
taking a visual image of the appearance of the tows forming at least a portion of the composite structure, in real time, as the composite structure is formed by the automated fiber placement machine; and then comparing the visual image of the appearance of the tows in the at least a portion of the structure to the proper configuration and placement of the fiber tows as defined in the virtual image of the at least a portion of the composite structure.
constructing a virtual image of the structure, prior to forming the composite structure, defining a proper placement and configuration of each of the plurality of fiber tows within the composite structure;
taking a visual image of the appearance of the tows forming at least a portion of the composite structure, in real time, as the composite structure is formed by the automated fiber placement machine; and then comparing the visual image of the appearance of the tows in the at least a portion of the structure to the proper configuration and placement of the fiber tows as defined in the virtual image of the at least a portion of the composite structure.
23. The computer-readable medium of claim 22, having further computer executable instructions for performing the step of determining proper formation of the structure, by comparing the visual image of at least a portion of the part to the virtual image of the part.
24. The computer-readable medium of claim 22, having further computer executable instructions for performing the step of determining improper formation of the structure, by comparing the visual image of at least a portion of the structure to the virtual image of the part.
25. The computer-readable medium of claim 24, having further computer executable instructions for performing the step of manipulating the automated fiber placement machine to facilitate inspection and/or repair of the improper formation.
26. The computer-readable medium of claim 22, having further computer executable instructions for performing the step of providing a location of the imperfection on the structure.
27. The computer-readable medium of claim 22, having further computer executable instructions for performing the step of providing a visible indication of the location of the imperfection.
28. An apparatus for inspecting a composite structure formed from one or more composite tows by an automated fiber placement machine, the apparatus comprising, a composite comparison device (CCD), for comparing a visual image of at least a portion of the composite structure to a virtual image of the at least a portion of the composite structure.
29. The apparatus of claim 28, further comprising, a vision capture element, for taking a visual image of a ply profile in the at least a portion of the composite structure, in real-time, on-the-fly, as the ply is laid down by the automated fiber placement machine, and for providing the visual image to the CCD.
30. The apparatus of claim 28, further comprising:
a composite programming system (CPS); and a machine control system (MCS);
the CPS being configured for determining where all tows will be dropped and/or added to meet boundary and interband gap/overlap criteria set out by a designer of a composite structure, and providing CPS outputs including, a numerical control (NC) file and a theoretical ply profile;
the NC file representing the path of a compaction roller in a fiber placement head of a fiber placement machine, and being provided as an input to the MCS;
the theoretical ply profile representing each band of tows as it is laid, as a course, onto the surface of a tool, or the surface of a previously laid ply of the composite structure, and being provided as an input to the CCD ;
the MCS being configured for utilizing the NC file for driving the fiber placement machine and/or a tool in such a manner as to lay a tow, or band of tows, at a desired location on the tool;
the MCS also being configured for providing synchronization commands to the CCD, so that both the MCS and the CCD can be calibrated to the same position along each course;
the CCD being configured for capturing a visual image of the actual lay-up surface of the tows, as they are laid down by the placement head, and for comparing the actual ply profile as captured in the visual image to the theoretical ply profile.
a composite programming system (CPS); and a machine control system (MCS);
the CPS being configured for determining where all tows will be dropped and/or added to meet boundary and interband gap/overlap criteria set out by a designer of a composite structure, and providing CPS outputs including, a numerical control (NC) file and a theoretical ply profile;
the NC file representing the path of a compaction roller in a fiber placement head of a fiber placement machine, and being provided as an input to the MCS;
the theoretical ply profile representing each band of tows as it is laid, as a course, onto the surface of a tool, or the surface of a previously laid ply of the composite structure, and being provided as an input to the CCD ;
the MCS being configured for utilizing the NC file for driving the fiber placement machine and/or a tool in such a manner as to lay a tow, or band of tows, at a desired location on the tool;
the MCS also being configured for providing synchronization commands to the CCD, so that both the MCS and the CCD can be calibrated to the same position along each course;
the CCD being configured for capturing a visual image of the actual lay-up surface of the tows, as they are laid down by the placement head, and for comparing the actual ply profile as captured in the visual image to the theoretical ply profile.
31. The apparatus of claim 28, further comprising, a vision capture element, for taking a visual image of a ply profile in the at least a portion of the composite structure, in real-time, on-the-fly, as the ply is laid down by the automated fiber placement machine, and for providing the visual image to the CCD.
32. The apparatus of claim 30, wherein, the CCD is further configured for producing a transferable file record of results of the CCD comparison of the visual image to the theoretical ply profile.
33. The apparatus of claim 32, wherein, the CCD is further configured for detecting and recording any discrepancies and/or anomalies between the actual and theoretical ply profiles.
34. The apparatus of claim 33, wherein, the MCS is further configured for receiving the results of the CCD comparison, and providing an output for guiding an operator of the fiber placement machine to each discrepancy and/or anomaly location, to thereby facilitate evaluation, repair, or any other action that may be deemed appropriate.
35. The apparatus of claim 34, further including, a pointing device, producing an output in the form of a visible light beam directed by the MCS for indicating the location of one or more discrepancy and/or anomaly in the composite structure.
36. The apparatus of claim 35, wherein, the visible light beam is a laser beam.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US76166406P | 2006-01-24 | 2006-01-24 | |
| US60/761,664 | 2006-01-24 | ||
| US11/656,768 | 2007-01-23 | ||
| US11/656,768 US7835567B2 (en) | 2006-01-24 | 2007-01-23 | Visual fiber placement inspection |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2575189A1 true CA2575189A1 (en) | 2007-07-24 |
| CA2575189C CA2575189C (en) | 2012-03-06 |
Family
ID=37988978
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2575189A Expired - Fee Related CA2575189C (en) | 2006-01-24 | 2007-01-24 | Visual fiber placement inspection |
Country Status (4)
| Country | Link |
|---|---|
| US (2) | US7835567B2 (en) |
| EP (1) | EP1810816B1 (en) |
| CA (1) | CA2575189C (en) |
| ES (1) | ES2546459T3 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2017061140A (en) * | 2015-08-12 | 2017-03-30 | ゼネラル・エレクトリック・カンパニイ | System and method for controlling at least one variable during layup of composite part using automated fiber lamination |
| RU2629881C2 (en) * | 2012-05-15 | 2017-09-04 | Зе Боинг Компани | System of identification of pollutants |
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| US7289656B2 (en) | 2003-12-02 | 2007-10-30 | The Boeing Company | Systems and methods for determining inconsistency characteristics of a composite structure |
| US7807002B2 (en) * | 2007-12-17 | 2010-10-05 | The Boeing Company | Verification of tow cut for automatic fiber placement |
| US9694546B2 (en) * | 2008-02-12 | 2017-07-04 | The Boeing Company | Automated fiber placement compensation |
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| DE102010044175A1 (en) * | 2010-11-19 | 2012-05-24 | Mag Ias Gmbh | Method and production unit for the production of fiber composite components |
| US10169492B2 (en) * | 2011-06-20 | 2019-01-01 | The Boeing Company | Fiber placement optimization for steered-fiber plies |
| US9310317B2 (en) | 2012-01-25 | 2016-04-12 | The Boeing Company | Automated system and method for tracking and detecting discrepancies on a target object |
| EP2914488A4 (en) | 2012-11-01 | 2016-06-29 | Israel Aerospace Ind Ltd | Folded structures formed of composite materials |
| US8983171B2 (en) | 2012-12-26 | 2015-03-17 | Israel Aerospace Industries Ltd. | System and method for inspecting structures formed of composite materials during the fabrication thereof |
| US9595096B2 (en) | 2014-03-10 | 2017-03-14 | The Boeing Company | Composite inspection and structural check of multiple layers |
| EP3140706B1 (en) | 2014-05-09 | 2018-06-27 | Bombardier Inc. | A method and system for quantifying the impact of features on composite components |
| US9759547B2 (en) * | 2014-08-19 | 2017-09-12 | The Boeing Company | Systems and methods for fiber placement inspection during fabrication of fiber-reinforced composite components |
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| EP3009833B1 (en) | 2014-10-14 | 2020-12-02 | Airbus Defence And Space Gmbh | In-process error checking by means of augmented reality |
| CN104570955B (en) * | 2014-11-24 | 2018-06-22 | 中国科学院自动化研究所 | A kind of composite material automatic fiber placement machine control system and control method |
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| WO2016100081A1 (en) | 2014-12-17 | 2016-06-23 | Sikorsky Aircraft Corporation | Composite laminate tooling and method of forming a composite part using the tooling |
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| US9545759B2 (en) | 2015-01-30 | 2017-01-17 | CGTech | Automated fiber placement with course trajectory compensation |
| US10192298B2 (en) | 2015-04-20 | 2019-01-29 | General Electric Company | System and method for monitoring tape ends of a composite layup machine |
| EP3304054A4 (en) | 2015-06-08 | 2019-01-23 | National Research Council of Canada | Real-time inspection of automated ribbon placement |
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| DE102016003543A1 (en) * | 2016-03-22 | 2017-01-26 | Bundesrepublik Deutschland, vertr. durch das Bundesministerium der Verteidigung, vertr. durch das Bundesamt für Ausrüstung, Informationstechnik und Nutzung der Bundeswehr | display means |
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| CN109219678B (en) * | 2016-06-02 | 2022-02-01 | 应用材料公司 | Authentication and repair station |
| FR3054476B1 (en) * | 2016-07-27 | 2020-01-17 | Institut De Recherche Technologique Jules Verne | DEVICE AND METHOD FOR MANUFACTURING A FIBROUS PREFORM |
| DE102016125528B4 (en) * | 2016-12-22 | 2023-06-22 | Deutsches Zentrum für Luft- und Raumfahrt e.V. | Method of inspecting a fibrous material deposit and computer program product |
| US11307029B2 (en) * | 2018-04-02 | 2022-04-19 | The Boeing Company | Method for analyzing the surface quality of composite laminates |
| US11020913B2 (en) * | 2018-05-11 | 2021-06-01 | The Boeing Company | Process and system for improving surface quality of composite structures |
| CN110738029A (en) * | 2018-12-29 | 2020-01-31 | 威海光威精密机械有限公司 | Composite material layering data importing method |
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| WO2022067765A1 (en) * | 2020-09-30 | 2022-04-07 | 深圳烯湾科技有限公司 | Control method for fiber winding and curing, and fiber winding and manufacturing device |
| TWI772991B (en) * | 2020-12-02 | 2022-08-01 | 財團法人工業技術研究院 | Braiding path generation method and device, and dynamic correction method and braiding system |
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2007
- 2007-01-23 US US11/656,768 patent/US7835567B2/en active Active
- 2007-01-24 CA CA2575189A patent/CA2575189C/en not_active Expired - Fee Related
- 2007-01-24 EP EP07101121.7A patent/EP1810816B1/en active Active
- 2007-01-24 ES ES07101121.7T patent/ES2546459T3/en active Active
-
2010
- 2010-10-05 US US12/897,932 patent/US20110017381A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| RU2629881C2 (en) * | 2012-05-15 | 2017-09-04 | Зе Боинг Компани | System of identification of pollutants |
| JP2017061140A (en) * | 2015-08-12 | 2017-03-30 | ゼネラル・エレクトリック・カンパニイ | System and method for controlling at least one variable during layup of composite part using automated fiber lamination |
| US10399276B2 (en) | 2015-08-12 | 2019-09-03 | General Electric Company | System and method for controlling at least one variable during layup of a composite part using automated fiber placement |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2575189C (en) | 2012-03-06 |
| ES2546459T3 (en) | 2015-09-23 |
| US7835567B2 (en) | 2010-11-16 |
| EP1810816A3 (en) | 2013-03-20 |
| US20110017381A1 (en) | 2011-01-27 |
| EP1810816B1 (en) | 2015-08-12 |
| US20070173966A1 (en) | 2007-07-26 |
| EP1810816A2 (en) | 2007-07-25 |
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