automatic inspection of composite parts · automatic inspection of omposite parts • scott lake 14...

Automatic Inspection of Composite Parts ID 015 ● Enabling Technologies

Sept 7-9, 2016

Scott Blake

1

Automatic Inspection of Composite Parts • Scott Blake 2

Topics

• Composite Manufacturing Goals

• Critical Manufacturing Characteristics

• Automatic Inspection with a Laser Projector and Camera

• Manufacturing Defects

• Automatic Composite Inspection in Aerospace

• Automatic Inspection in Automated Layup – Fiber Orientation and Material Shear

– Wrinkles

– Bridging and Secondary Bridging

– Material Location

– FOD

• Automatic Inspection Systems: Nodes in Deep Learning Networks

• Features, Benefits and Conclusions

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Composite Manufacturing Goals

• Build what was designed

• Build in the shortest time

• Build at the lowest cost

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Critical Manufacturing Characteristics

• Material location

• Fiber orientation

• Interlaminar curing

• Cosmetics

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Automatic Inspection with Laser Projector and Camera

• Projector and camera are indexed into coordinate system of part

• Laser projects reference patterns for camera

• Laser pinpoints areas of concern (Examples to follow)

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Manufacturing Defects

• Incorrect Shear

• Incorrect Fiber Orientation

• Wrinkles

• Bridging

• Material Location

• FOD

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Automatic Composite Inspection in Aerospace

• Boeing 777X Wingskin and Spar: 110’ part

• Automatic Inspection and Documentation

• Near Real Time

• Material Location Verification

0.5” wide strips of material captured from 15’

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Auto Inspection in Auto Layup: Shear

Sheared material in press

Curvature of fiber path shown as white curve. Label is max CCW/CW

Automatic discovery of fiber paths

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Auto Inspection in Auto Layup: Wrinkles

• Green indications are where projected references would be found with no wrinkles

• Red indications are projected references displaced by surface distortion

1.6mm wide 0.25mm thick bump in 10cm square field

Automatic detection of 0.8 mm wrinkle in Robotic Layup System

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Auto Inspection in Auto Layup: Bridging

• Green represent expected location of projected references without bridging

• Red is where projected references were found

• Difference between red and green is proportional to bridge displacement

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Auto Inspection in Auto Layup: Material Location

• High resolution, high magnification images are automatically captured with photogrammetric transforms

• Transforms enable the calculation of tolerance bands in the image

• Automatic inspection of material location is achieved

• Out of tolerance locations are pinpointed by the laser projector

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Auto Inspection in Auto Layup: FOD and Pinpointing

• Foreign Objects and Debris (FOD)can contaminate parts and compromise performance

• When a problem is detected, the projector identifies the location

• Problems are resolved in the shortest time and at the lowest cost

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Automatic Inspection Systems: Nodes in Deep Learning Networks

• Laser projectors with vision systems have value beyond sensing defects on individual parts during production

• Detailed documentation is available for each defect as it occurs

• Analysis of the conditions resulting in the creation of the defect yields process changes

• Process changes are implemented across all systems on the network

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Features, Benefits and Conclusions

• Integrated laser projection and camera systems can provide real time inspection to monitor processes for: – Shear

– Fiber orientation

– Wrinkles

– Bridging and secondary bridging

– Material location

– FOD

• The detailed observation of defect formation will enable process improvement across all similar automatic manufacturing and inspection systems

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Thank You!

Questions?