In-Process Vision Detection of Flaw and FOD Characteristics

• US 20100204929A1
• Filed: 03/22/2010
• Published: 08/12/2010
• 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 8,524,021 B2
• Time in Patent Office: Days
• US Class Current: 702/36
• 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. An inspection system comprising:

an idler wheel coupled to a fabrication 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 a composite structure in response to said rotation signal.

2. An inspection system as in claim 1 wherein an idler wheel is a non-pressure applying wheel.

3. An inspection system as in claim 1 wherein said rotation sensor is at least one of an encoder, an infrared sensor, and a rotary potentiometer.

4. An inspection system as in claim 1 wherein said controller determines longitudinal position of said at least one flaw and FOD in response to said rotation signal.

5. An inspection system as in claim 1 wherein said controller determines lateral position of said at least one flaw and FOD in response to cessation of said idler wheel.

6. An inspection system as in claim 1 further comprising:

an illumination device illuminating a portion of said composite structure; and

a detector detecting said at least one flaw and FOD and generating a flaw and FOD detection signal;

said controller determining said at least one characteristic in response to said rotation signal and said flaw and FOD detection signal.

7. An inspection system as in claim 6 wherein said illumination device is selected from at least one of an incandescent light a light emitting diode, a noble gas arc lamp, a metal arc lamp, a strobe, a fluorescent light an infrared light and a laser.

8. An inspection system as in claim 6 wherein said detector is selected from at least one of a camera, an infrared sensor, a visible light sensor, a visible light sensor with infrared-pass filtration, and a charged-coupled device.

9. An inspection system as in claim 6 wherein said detector detects at least one flaw and at least one FOD simultaneously.

10. An inspection system as in claim 1 wherein said controller in determining said at least one characteristic determines at least one of size, location, type, density-per-unit area, and cumulative defect width-per-unit area.

11. An inspection system for determining characteristics of flaws and FOD during the fabrication of a composite structure comprising:

a material collection device coupled to the fabrication system;

a take-up sensor coupled to the material collection device, monitoring the translation of a backing layer of a composite material, and generating a take-up signal;

a controller coupled to said take-up sensor and determining at least one characteristic of at least one flaw or FOD on the composite structure in response to said take-up signal.

12. An inspection system as in claim 11 wherein said material collection device is selected from at least one of a material collection wheel, a take-up reel, and a collection container.

13. An inspection system as in claim 11 wherein said backing layer is a backing paper.

14. An inspection system as in claim 11 further comprising:

an illumination device illuminating a portion of said composite structure; and

a detector detecting said at least one flaw and FOD and generating a flaw and FOD detection signal;

said controller determining said at least one characteristic in response to said take-up signal and said flaw and FOD detection signal.

15. An inspection system as in claim 11 wherein said controller in determining said at least one characteristic determines at least one of size, location, type, density-per-unit area, and cumulative defect width-per-unit area.

16-34. -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.