Apparatus and methods for inspecting tape lamination

• US 20060152712A1
• Filed: 01/12/2005
• Published: 07/13/2006
• Est. Priority Date: 01/12/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Hensley, Brian S., Hannebaum, Reed, Engelbart, Roger W., Pollock, Tim, Orr, Sam
• Granted Patent: US 7,889,907 B2
• Time in Patent Office: Days
• US Class Current: 356/237.100
• CPC Class Codes: B29C 70/388 Tape placement heads, e.g. component parts, details or accessories
• CPC Class Codes: G01N 2021/8411 Application to online plant, process monitoring
• CPC Class Codes: G01N 2021/8472 Investigation of composite materials
• CPC Class Codes: G01N 2021/8838 Stroboscopic illumination; synchronised illumination
• CPC Class Codes: G01N 21/8806 Specially adapted optical and illumination features
• CPC Class Codes: G01N 2201/0612 Laser diodes

Abstract

A system for inspecting a composite material laid onto a substrate by a lamination machine. An imaging assembly attached to a rear portion of a delivery head of the machine obtains an image of at least a portion of the laid material beneath the imaging assembly. A processor inspects the image to detect a flaw. This system can provide an image of laid tape obtained close to a tape compaction point and can be implemented as a retrofit or as original equipment in lamination machines.

Claims

1. A system for inspecting a composite material laid onto a substrate by a lamination machine, the system comprising:

an imaging assembly attached to a rear portion of a delivery head of the machine and configured to obtain an image of at least a portion of the laid material beneath the imaging assembly; and

a processor configured to inspect the image to detect a flaw.

2. The system of claim 1, wherein the imaging assembly is further configured to obtain an image of at least a portion of the laid material beneath the delivery head.

3. The system of claim 1, wherein the composite material includes a tape input to the machine, and wherein the imaging assembly images a complete tape width of the laid material.

4. The system of claim 1, further comprising a tracking wheel that tracks movement of backing paper from the composite material, the tracking wheel and the processor configured to actuate the imaging assembly based on the backing paper movement.

5. The system of claim 1, wherein the imaging assembly comprises a reflective surface and a camera configured to receive an image of the laid material reflected by the reflective surface.

6. The system of claim 1, further comprising a marking assembly that marks the laid material to indicate the detected flaw.

7. The system of claim 6, further comprising a tracking wheel that tracks movement of backing paper from the composite material, the tracking wheel and the processor configured to actuate the marking assembly based on the backing paper movement.

8. The system of claim 6, wherein the marking assembly comprises a plunger that applies ink to the composite material.

9. A method of inspecting composite material laid onto a substrate by a lamination machine delivery head, the method comprising the steps of:

detecting movement of a paper backing of the composite material away from the material;

obtaining an image of the laid composite material, the obtaining performed based on the detected movement;

inspecting the image to detect a flaw; and

identifying a location of the flaw in the laid material.

10. The method of claim 9, wherein identifying a location of the flaw comprises at least one of:

marking the laid material to indicate the detected flaw, the marking performed based on the detected movement; and

displaying the image and the detected flaw, the displaying performed using a user interface of the lamination machine.

11. The method of claim 9, wherein the detecting is performed using a tracking wheel moved by the backing paper.

12. The method of claim 9, wherein obtaining an image of the laid composite material comprises:

illuminating the laid material using at least one light source; and

imaging the illuminated material using a camera.

13. A tape lamination machine comprising:

a delivery head that lays a composite material as tape onto a substrate;

an imaging assembly positioned substantially between a rear portion of the delivery head and the substrate, the imaging assembly configured to obtain an image of the tape laid onto the substrate by the delivery head;

a processor configured to inspect the image to detect a flaw; and

a marking assembly behind the imaging assembly that marks the laid tape to indicate the detected flaw.

14. The machine of claim 13, wherein the imaging assembly images a complete width of the laid tape.

15. The machine of claim 13, further comprising a tracking wheel that tracks movement of backing paper from the tape, the tracking wheel and the processor configured to actuate at least one of the imaging and marking assemblies based on the backing paper movement.

16. The system of claim 13, wherein the imaging assembly comprises a reflective surface and a camera configured to receive an image of the laid tape reflected by the reflective surface.

17. The system of claim 13, wherein the marking assembly comprises a plunger that applies ink to the laid tape to indicate the flaw.

18. A system for inspecting material laid as tape by a tape lamination machine onto a substrate, the system comprising:

an imaging assembly mounted to a delivery head of the machine substantially between a rear portion of the delivery head and the substrate, the imaging assembly configured to obtain an image of the tape laid onto the substrate by the delivery head;

a processor configured to inspect the image to detect a flaw;

a marking assembly behind the imaging assembly that marks the laid tape to indicate the detected flaw; and

a tracking wheel that tracks movement of backing paper from the tape, the tracking wheel and the processor configured to actuate at least one of the imaging and marking assemblies based on the backing paper movement.

19. The system of claim 18, wherein the imaging assembly comprises a reflective surface and a camera configured to receive an image of the laid tape reflected by the reflective surface.

20. A system for inspecting output of a tape lamination machine, the system comprising:

means for producing an image of tape placed on a substrate by a delivery head of the machine;

means for inspecting the image to detect a flaw in the placed tape;

means for identifying a location of the flaw in the placed tape; and

means for detecting removal of a backing from the tape;

wherein operation of the image producing means and the identifying means are timed based on the detecting means.

21. The system of claim 20, wherein the means for producing an image comprises:

means for reflecting an image of the placed tape; and

means for obtaining the reflected image.

22. The system of claim 20, wherein the means for producing an image comprises means for illuminating at least a portion of the placed tape.

23. The system of claim 20, wherein the illuminating means comprises means for shielding the placed tape from light other than light produced by the illuminating means.

24. The system of claim 20, wherein the detecting means comprises an encoder wheel rotatably mounted in contact with the backing.

25. The system of claim 20, wherein the identifying means comprises at least one of:

means for marking a location of the flaw on the tape; and

means for displaying the image and the flaw.