System and method for monitoring tape ends of a composite layup machine

Patent metadata

Field	Value
Publication number	US-10192298-B2
Application number	US-201514690700-A
Country	US
Kind code	B2
Filing date	Apr 20, 2015
Priority date	Apr 20, 2015
Publication date	Jan 29, 2019
Grant date	Jan 29, 2019

Abstract

A device for identifying an end of a fiber tape rolling over a composite structure is presented. The device includes a light source disposed proximate to the composite structure and configured to project a line of light at a first angle on the fiber tape rolling over the composite structure. Also, the device includes an image capturing unit disposed proximate to the composite structure and configured to capture an image of the line of light on the fiber tape at a second angle. Further, the device includes a controller coupled to the image capturing unit and configured to process the captured image to detect a discontinuity in the line of light on the fiber tape and identify the end of the fiber tape based on the detected discontinuity in the line of light on the fiber tape.

First claim

The invention claimed is:

1. A device for identifying an end of a fiber tape rolling over a composite structure, the device comprising:
a light source disposed proximate to the composite structure and configured to project a line of light at a first angle on the fiber tape rolling over the composite structure;
an image capturing unit disposed proximate to the composite structure and configured to capture an image of the fiber tape having the line of light, wherein the image is captured at a second angle;
a controller coupled to the image capturing unit and configured to:
process the captured image to detect a discontinuity in the line of light on the fiber tape if the line of light fits to a line of a predetermined orientation of the fiber tape over the composite structure; and
identify the end of the fiber tape based on the detected discontinuity in the line of light on the fiber tape; and

a layup head operatively coupled to the image capturing unit and configured to roll the fiber tape over the composite structure, wherein the layup head is further configured to send a first signal to the image capturing unit to indicate the end of the fiber tape, and wherein the image capturing unit is further configured to capture the image of the fiber tape having the line of light when the first signal is received from the layup head.

2. The device of claim 1 , wherein the controller is configured to:
determine that the end of the fiber tape is displaced from a predetermined position on the composite structure; and
send a second signal to the layup head to cease the layup head from rolling the fiber tape over the composite structure.

3. The device of claim 1 , wherein the line of light is substantially perpendicular to the end of the fiber tape.

4. A device for identifying an end of a fiber tape rolling over a composite structure, the device comprising:
a light source disposed proximate to the composite structure and configured to project at least two lines of light at a first angle on the fiber tape rolling over the composite structure;
an image capturing unit disposed proximate to the composite structure and configured to capture an image of the fiber tape having at least two lines of light, wherein the image is captured at a second angle;
a controller coupled to the image capturing unit and configured to:
process the captured image to select a pair of points among a plurality of pairs of points associated with a discontinuity in the at least two lines of light in the captured image;
determine an angle of a line connecting the selected pair of points in the captured image; and
detect the end of the fiber tape when the determined angle of the line is collinear to a predetermined orientation of the fiber tape laying over the composite structure; and

a layup head operatively coupled to the image capturing unit and the light source and configured to lay the fiber tape at the predetermined orientation over the composite structure, wherein the layup head is further configured to send a first signal to the image capturing unit to indicate the end of the fiber tape, and wherein the image capturing unit is further configured to capture the image of the the fiber tape having the at least two lines of light when the first signal is received from the layup head.

5. The device of claim 4 , wherein the end of the fiber tape is detected when the selected pair of points is at a first position in the captured image.

6. The device of claim 4 , wherein the selected pair of points comprises a first point and a second point, wherein the first point is associated with one of the at least two lines of light and the second point is associated with other of the at least two lines of light.

7. The device of claim 4 , wherein the at least two lines of light is substantially perpendicular to the end of the fiber tape.

Assignees

• Gen Electric

Inventors

• Harding Kevin George
• Nafis Christopher Allen
• Tait Robert William

Classifications

• B29L2007/007

  Narrow strips, e.g. ribbons, tapes, bands (belts B29L2029/00; tapes as carrier of sound or information B29L2017/008) · CPC title

• G06T2207/30108

  Industrial image inspection · CPC title

• G06T7/0004 Primary

  Industrial image inspection · CPC title

• B29C70/386 Primary

  Automated tape laying [ATL] · CPC title

• B32B41/00 Primary

  Arrangements for controlling or monitoring lamination processes; Safety arrangements · CPC title