Systems and methods for in-process vision inspection for automated machines

• US 20070034313A1
• Filed: 08/11/2005
• Published: 02/15/2007
• Est. Priority Date: 08/11/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Hannebaum, Reed, Engelbart, Roger, Pollock, Timothy
• Granted Patent: US 8,668,793 B2
• Time in Patent Office: Days
• US Class Current: 156/64
• CPC Class Codes: B29C 70/32 on a rotating mould, former or core
• CPC Class Codes: B29C 70/386 Automated tape laying [ATL]
• CPC Class Codes: B29C 70/541 Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B32B 41/00 Arrangements for controlling or monitoring lamination processes; Safety arrangements
• CPC Class Codes: G01N 2021/8472 Investigation of composite materials

Abstract

Systems and methods for in-process vision inspection for automated machines are disclosed. In one embodiment, a head assembly includes a tool moveable over a workpiece and adapted to perform a manufacturing operation on the workpiece, and an inspection unit operatively positioned proximate the tool and moveable with the tool relative to the workpiece. The inspection unit is adapted to perform a vision inspection of a portion of the workpiece simultaneously with the performance of the manufacturing operation on the workpiece. In a particular embodiment, the inspection unit includes a camera adapted to monitor an area including the portion of the workpiece upon which the tool has performed the manufacturing operation, and a processor operatively coupled to the camera and adapted to receive an image from the camera and to analyze the image to determine a presence of a defect within the portion of the workpiece.

Claims

1. A head assembly adapted to perform a manufacturing operation on a workpiece, comprising:

a tool moveable relative to the workpiece and adapted to perform the manufacturing operation on the workpiece; and

an inspection unit operatively positioned proximate the tool and moveable with the tool relative to the workpiece, the inspection unit being adapted to perform a vision inspection of a portion of the workpiece upon which the tool has performed the manufacturing operation simultaneously with the performance of the manufacturing operation on the workpiece.

2. The head assembly of claim 1, wherein the vision inspection includes a defect detection process including at least one of a striping process and an illumination process.

3. The head assembly of claim 1, wherein the tool is adapted to perform an application of a tape onto the workpiece, and wherein the vision inspection includes detecting at least one of a gap between a recently-applied portion of the tape and a previously-applied portion of the tape, a bump, a ripple, an irregularity, a foreign object, and a debris.

4. The head assembly of claim 1, wherein the tool includes:

a spindle adapted to support a supply of a tape of a composite material; and

a feed assembly adapted to feed the tape from the supply onto the workpiece, the feed assembly having a rotatable compaction roller adapted to apply the tape onto the workpiece.

5. The head assembly of claim 1, wherein the inspection unit includes:

a camera adapted to monitor an area at least partially including the portion of the workpiece upon which the tool has performed the manufacturing operation; and

a processor operatively coupled to the camera and adapted to receive an image from the camera and to analyze the image to determine a presence of a defect within the area monitored by the camera.

6. The head assembly of claim 5, wherein the tool includes

a feed assembly adapted to feed a tape from a tape supply onto the workpiece, the feed assembly having a rotatable compaction roller adapted to apply the tape onto the workpiece;

and wherein the inspection unit further includes;

a drive roller engaged with the compaction roller and rotatable by the compaction roller; and

an encoder operatively coupled to the drive roller by a drive member, the encoder adapted to provide a position indication to the processor.

7. The head assembly of claim 5, wherein the inspection unit further includes at least one of:

a laser having a lens assembly adapted to provide at least one laser stripe on the workpiece within the area monitored by the camera; and

an illuminating source adapted to illuminate the workpiece within the area monitored by the camera.

8. A system adapted to perform a manufacturing operation on a workpiece, comprising:

at least one head assembly adapted to perform the manufacturing operation on the workpiece; and

a translation platform coupled to the at least one head assembly, the translation platform being adapted to operatively position the head assembly proximate the workpiece and to systematically move the head assembly along a translation path proximate the workpiece, and wherein the head assembly includes;

a tool moveable relative to the workpiece and adapted to perform the manufacturing operation on the workpiece; and

an inspection unit operatively positioned proximate the tool and moveable with the tool relative to the workpiece, the inspection unit being adapted to perform a vision inspection of a portion of the workpiece upon which the tool has performed the manufacturing operation simultaneously with the performance of the manufacturing operation on the workpiece.

9. The system of claim 8, further comprising a forming tool adapted to support the workpiece during the manufacturing process.

10. The system of claim 8, wherein the translation platform includes a controller adapted to command movement and function of the translation platform and the head assembly to perform at least one of automated and semi-automated manufacturing operations.

11. The system of claim 8, wherein the tool is adapted to perform an application of a tape onto the workpiece, and wherein the vision inspection includes detecting at least one of a gap between a recently-applied portion of the tape and a previously-applied portion of the tape, a bump, a ripple, an irregularity, a foreign object, and a debris.

12. The system of claim 8, wherein the at least one head assembly comprises a plurality of head assemblies, and wherein the system further comprises a central computer operatively coupled to the head assemblies and adapted to receive one or more defect indications and corresponding images from the head assemblies, and archive the one or more defect indications and corresponding images.

13. The system of claim 12, further comprising a projection system operatively coupled to the central computer and adapted to receive position information corresponding to the one or more defect indications, and to project a defect identifier onto the workpiece at a location corresponding to the one or more defect indications.

14. The system of claim 8, wherein the tool includes:

a spindle adapted to support a supply of a tape of a composite material; and

a feed assembly adapted to feed the tape from the supply onto the workpiece, the feed assembly having a rotatable compaction roller adapted to apply the tape onto the workpiece.

15. The system of claim 8, wherein the inspection unit includes:

a camera adapted to monitor an area at least partially including the portion of the workpiece upon which the tool has performed the manufacturing operation; and

a processor operatively coupled to the camera and adapted to receive an image from the camera and to analyze the image to determine a presence of a defect within the area monitored by the camera.

16. The system of claim 15, wherein the tool includes

a feed assembly adapted to feed a tape from a tape supply onto the workpiece, the feed assembly having a rotatable compaction roller adapted to apply the tape onto the workpiece;

and wherein the inspection unit further includes;

a drive roller engaged with the compaction roller and rotatable by the compaction roller; and

an encoder operatively coupled to the drive roller by a drive member, the encoder adapted to provide a position indication to the processor.

17. The system of claim 15, wherein the inspection unit further includes at least one of a laser having a lens assembly adapted to provide at least one laser stripe on the workpiece within the area monitored by the camera, and an illuminating source adapted to illuminate the workpiece within the area monitored by the camera.

18. A method of perform a manufacturing operation on a workpiece, comprising:

performing the manufacturing operation on a portion of the workpiece using a tool moveable relative to the workpiece; and

simultaneously with performing the manufacturing operation, performing a vision inspection of at least part of the portion of the workpiece upon which the tool has performed the manufacturing operation using an inspection unit positioned proximate the tool and moveable with the tool relative to the workpiece.

19. The method of claim 18, wherein performing a vision inspection includes performing a defect detection process including at least one of a striping process and an illumination process.

20. The method of claim 18, wherein performing a vision inspection includes performing a defect detection process using an inspection unit that includes:

a camera adapted to monitor an area at least partially including the portion of the workpiece upon which the tool has performed the manufacturing operation; and

a processor operatively coupled to the camera and adapted to receive an image from the camera and to analyze the image to determine a presence of a defect within the area monitored by the camera.

21. The method of claim 18, wherein performing the manufacturing operation including performing an application of a tape onto the workpiece, and wherein performing a vision inspection includes detecting a defect including at least one of a gap between a recently-applied portion of the tape and a previously-applied portion of the tape, a bump, a ripple, an irregularity, a foreign object, and a debris.

22. The method of claim 18, wherein performing a vision inspection includes detecting a defect including at least one of operating a laser having a lens assembly adapted to provide at least one laser stripe on the workpiece within the area monitored by the camera, and operating an illuminating source adapted to illuminate the workpiece within the area monitored by the camera.