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


Composite Manufacturing Goals

• Build what was designed

• Build in the shortest time

• Build at the lowest cost


Critical Manufacturing Characteristics

• Material location

• Fiber orientation

• Interlaminar curing

• Cosmetics


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)


Manufacturing Defects

• Incorrect Shear

• Incorrect Fiber Orientation

• Wrinkles

• Bridging

• Material Location

• FOD


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’


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


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


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


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


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


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


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


Thank You!

Questions?

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

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