In-process vision detection of flaws and FOD by back field illumination
First Claim
Patent Images
1. A method of detecting flaws or FOD in a composite structure during the fabrication process of that structure comprising:
- illuminating a portion of the composite structure across its entire width with a light source mounted to be in proximity with said composite structure and directing light rays at an acute angle relative to said portion of said composite structure of approximately greater than or equal to 2° and
approximately less than or equal to 15°
, said light source being positioned to emit light that illuminates a portion of the composite structure with bright field illumination and simultaneously illuminates another portion of the composite structure with dark field illumination;
monitoring said portion;
detecting flaws or FOD in said portion during fabrication of the structure in response to reflection of said light rays off of said portion by detecting the contrast between a shadow and the composite structure which allows for the detection of flaws and FOD simultaneously in said portion; and
indicating said flaws or FOD in said portion to a user via a display.
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Abstract
A flaw and foreign object debris (FOD) detection system (11) for use during fabrication of a structure (12) includes an illumination device (13). The illumination device (13) is configured to be in proximity with a fabrication system (10) and illuminates a portion (18) of the structure (12). The illumination device (13) directs light rays (16) at acute angles relative to the portion (18). A detector (14) monitors the portion (18) and detects FOD in the portion (18) during fabrication of the structure (12) in response to the reflection of the light rays (16) off of the portion (18).
129 Citations
16 Claims
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1. A method of detecting flaws or FOD in a composite structure during the fabrication process of that structure comprising:
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illuminating a portion of the composite structure across its entire width with a light source mounted to be in proximity with said composite structure and directing light rays at an acute angle relative to said portion of said composite structure of approximately greater than or equal to 2° and
approximately less than or equal to 15°
, said light source being positioned to emit light that illuminates a portion of the composite structure with bright field illumination and simultaneously illuminates another portion of the composite structure with dark field illumination;monitoring said portion; detecting flaws or FOD in said portion during fabrication of the structure in response to reflection of said light rays off of said portion by detecting the contrast between a shadow and the composite structure which allows for the detection of flaws and FOD simultaneously in said portion; and indicating said flaws or FOD in said portion to a user via a display. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of detecting flaws or FOD in a composite structure during fabrication of that structure comprising:
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illuminating a portion of the composite structure across its entire width with a light source mounted to be in proximity with said composite structure and directing light rays at an acute angle relative to said portion of said composite structure of approximately greater than or equal to 2° and
approximately less than or equal to 15°
, said light source being positioned to emit light that illuminates a portion of the composite structure with bright field illumination and simultaneously illuminates another portion of the composite structure with dark field illumination,monitoring said portion; detecting flaws or FOD in said portion during fabrication of the structure in response to reflection of said light rays off of said portion by detecting the contrast between a shadow and the composite structure which allows for the detection of flaws and FOD simultaneously in said portion; generating status signals indicative of said flaws or FOD in said portion; storing said status signals for future analysis or processing; and indicating said flaws or FOD in said portion to a user via a display. - View Dependent Claims (11, 12, 13, 14, 15)
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16. A method of simultaneously detecting flaws or FOD in a composite structure during a fabrication process using a single illumination level comprising:
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illuminating a portion of the composite structure across its entire width with a light source mounted to be in proximity with said composite structure and to illuminate said portion of said structure; generating light rays and directing said light rays at an active angle relative to said portion of said composite structure of approximately greater than or equal to 2° and
approximately less than or equal to 15°
, said light source being positioned to emit light tat illuminates a portion of the composite structure with bright field illumination and simultaneously illuminates another portion of the composite structure with dark field illumination;detecting flaws and FOD simultaneously in said portion in response to reflection of said light rays of said portion by detecting the contrast between a shadow and the composite structure which allows for the detection of flaws and FOD simultaneously in said portion; and indicating said flaws or FOD in said portion to a user via a display.
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Specification