IN-PROCESS VISION DETECTION OF FLAW AND FOD CHARACTERISTICS

• US 20090000723A1
• Filed: 03/28/2008
• Published: 01/01/2009
• Est. Priority Date: 11/24/2004
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Hannebaum, Reed, Engelbart, Roger W., Pollock, Tim
• Granted Patent: US 7,712,502 B2
• Time in Patent Office: Days
• US Class Current: 156/64
• CPC Class Codes: B29C 70/38 Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns application heads for tyres B29D30/28
• CPC Class Codes: G01N 2021/8472 Investigation of composite materials
• CPC Class Codes: G01N 21/89 in moving material, e.g. running paper or textiles G01N21/90, G01N21/91, G01N21/94 take precedence

Abstract

An inspection system (9) includes an idler wheel (61) that is coupled to a fabrication system (8) and is in contact with a backing layer (65) of an applied material (64), A rotation sensor (63) monitors the idler wheel (61) and generates a rotational signal. A controller (24) is coupled to the rotation sensor (63) and determines a characteristic of one or more flaws and FOD (19) on a composite structure (12) in response to the rotation signal.

Claims

1-15. -15. (canceled)

16. A fabrication system comprising:

a lamination system comprising a layer applicator applying a plurality of composite material layers to a substrate to form a structure; and

a flaw and foreign object debris (FOD) inspection system proximate said lamination system comprising;

an idler wheel coupled to said lamination system and contacting a backing layer of an applied material;

a rotation sensor monitoring said idler wheel and generating a rotational signal; and

a controller coupled to said rotation sensor and determining at least one characteristic of at least one flaw and FOD on said structure in response to said rotation signal.

17. A fabrication system as in claim 16 wherein said controller alters operation of the fabrication system in response to said at least one characteristic.

18. A fabrication system comprising:

a lamination system comprising a layer applicator applying a plurality of composite material layers to a substrate to form a structure; and

a flaw and foreign object debris (FOD) inspection system proximate said lamination system comprising;

at least one illumination device illuminating a portion of the structure;

at least one detector monitoring said portion and detecting at least one flaw and FOD in said portion during application of said plurality of composite material layers in response to reflection of said light rays off of said portion;

an idler wheel coupled to said lamination system and contacting a backing layer of an applied material;

a rotation sensor monitoring said idler wheel and generating a rotational signal; and

a controller coupled to said rotation sensor and determining at least one characteristic of said at least one flaw and FOD in response to said rotation signal.

19. A fabrication system as in claim 18 wherein said controller alters operation of the fabrication system in response to said at least one characteristic.

20-34. -34. (canceled)

35. A method of fabricating a composite structure comprising:

applying a plurality of composite material layers to a substrate to form the composite structure;

rotating a material collection device via a backing layer of a composite material;

monitoring said material collection device and generating a rotational signal; and

determining at least one characteristic of at least one flaw and FOD on a portion of the composite structure in response to said rotation signal.

36. A method as in claim 35 wherein determining at least one characteristic is performed during application of said plurality of composite material layers.

37. A method as in claim 35 further comprising:

generating light rays;

directing said light rays at said portion of the composite structure;

monitoring said portion; and

detecting said at least one flaw and FOD in said portion during application of said plurality of composite material layers in response to reflection of said light rays off of said portion.

38. A method as in claim 35 further comprising altering operation of a fabrication system in response to said at least one characteristic.

39. A method as in claim 35 delaying further application of said plurality of composite material layers in response to said at least one characteristic.

40. A method as in claim 35 further comprising:

acquiring images via at least one detector, counting images to generate an image count;

counting cessations of said material collection device to generate a cessation count; and

determining said at least one characteristic in response to said image count and said cessation count.