Advances in a Next Generation Measurement & Inspection System for Automated Fibre Placement

Achieving the high production rates promised by automated fibre placement (AFP) is often hindered by lengthy and variable manual intervention, predominantly 100% visual inspection of every deposited ply; introducing machine stoppages, the risk of quality escapes, and the cost overhead of employing a manual inspection system with low fidelity measurement aids. An in-situ inspection system embedded in the manufacturing process is a vital enabler to achieve world class manufacturing performance. This paper describes a new and innovative measurement solution based on an optical, interferometric imaging technique called optical coherence tomography (OCT). The system’s characteristics facilitate the design of a compact probe which can be easily integrated onto the AFP head and allow measurements very close to the compaction roller nip point. The high fidelity system shows little sensitivity to differences in material reflectivity and sensor to part incident angle. This paper will cover the initial implementation and system demonstration in a TRL 6 production mature environment using a Viper AFP machine from Fives-Cincinnati. Results will demonstrate the ability of this novel inspection system to accurately detect and measure defects to verify part inspection compliance.
6th Annual Composites and Advanced Materials Expo, CAMX 2019, September 23 - 26, 2019, Anaheim, California