Thermal Image-based Monitoring for the Automated Fiber Placement Process

Schmidt, Carsten; Denkena, Berend; Völtzer, Klaas; Hocke, Tristan

doi:10.1016/j.procir.2016.06.058

Cited by 33 publications

(20 citation statements)

References 2 publications

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“…An integrated edge detector in the 3D printer head detects the gaps online between the fiber tapes. As a second option, the gaps could be detected directly with a thermal camera integrated in the AFP head [10]. The gaps would then be filled with continuous fiber-reinforced thermoplastic composites.…”

Section: Resultsmentioning

confidence: 99%

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A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

Rakhshbahar

Sinapius

2018

J. Compos. Sci.

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Automated processing techniques such as automated fiber placement (AFP) or automated tape laying (ATL) are well known nowadays. However, there is still a lot of potential for these methods to achieve better results, especially for large and complex composite structures. In this experimental work, the gap effect with the Automated Fiber Placement is shown and a solution to overcome this drawback is presented. The gaps are particularly apparent on complex and/or double-curved surfaces and reduce the mechanical properties of the composite structure. In order to cover the unavoidable weak area of this effect, a plurality of fiber composite layers are laid on top of one another in order to increase the mechanical properties of components. This in turn makes the components heavier and more expensive to produce. In this new method, the gaps are detected by profile sensor after placement of the tape on the mold. The gaps are filled with the aid of a 3D printer with carbon continuous-fiber reinforced plastics. By combining the 3D printing and AFP technology, composite parts can be manufactured in a more homogeneous manner. Subsequently, the components are produced faster, cheaper and even lighter because of the avoidance of the additional layers.

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Section: Resultsmentioning

confidence: 99%

“…Only advanced AFP heads can detect and partially correct defects online with the help of various sensors and actuators [9]. The information is acquired by various optical or thermal methods [10]. The error is adjusted in the tolerance range.…”

Section: Geodetically Laid Tapementioning

confidence: 99%

A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

Rakhshbahar

Sinapius

2018

J. Compos. Sci.

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“…Several experimental and numerical modeling studies were conducted to understand, describe and predict the process temperature during the AFP and ATW processes. An in-situ thermographic analysis was carried out in [7,9,15,30] by utilizing an AFP process. Significant temperature gradients were found for the deposited regions having overlapped tows, gaps and twists.…”

Section: Introductionmentioning

confidence: 99%

On the temperature evolution during continuous laser-assisted tape winding of multiple C/PEEK layers: The effect of roller deformation

et al. 2020

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Laser-assisted tape winding (LATW) is a highly automated process for manufacturing tubular-like fiber-reinforced thermoplastic composites such as flywheels and pipes. One of the crucial parameters in the LATW process is the temperature of the nip point at which the incoming prepreg tape is bonded with the substrate by a compaction roller. Therefore, the temperature evolution of the nip point plays a significant role to have a proper consolidation at the tape-substrate interface. The nip point temperature is highly affected by the time-dependent geometry of the substrate and roller during continuous LATW of thick composite rings. In this paper, a critical assessment of the substrate and tape surface temperature evolution is investigated experimentally by means of a thermal camera during the LATW process of a 26-layers thick carbon/PEEK composites. A three-dimensional (3D) optical model is coupled with a thermal model in which the substrate computational domain is updated with respect to the deposited tapes. A good agreement is found between the measured and predicted tape and substrate temperatures. The total absorbed heat and heated length of the substrate and tape are described based on the roller deformation. An increase in tape and substrate nip point temperatures is found with an increase in roller deformation during consecutive winding. It is also found that the consolidation pressure and contact length at the roller-substrate interface increases during the winding process. Accordingly, the heat transfer coefficient at the roller-substrate interface is studied using the developed process model.

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“…This method did not include specifics for holistic data analysis [5]. Thermography for process monitoring has also been developed by Denkena, Schmidt and others to observe any foreign object debris, laps, gaps, and tow misplacement using computer vision techniques on the collected frames, along with a priori knowledge about the planned path of the AFP head [6,7]. However, these tools do not utilize the physics of thermal heat flow to analyze the thermal signal.…”

Section: Introductionmentioning

confidence: 99%

In-situ thermography of automated fiber placement parts

Gregory¹,

Juarez²

2018

AIP Conference Proceedings

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Abstract. Automated fiber placement (AFP) provides precision and repeatable manufacturing of both simple and complex geometry composite parts. However, AFP also introduces the possibility for unique flaws such as overlapping tows, gaps between tows, tow twists, lack of layer adhesion and foreign object debris. These types of flaws can all result in a significant loss of performance in the final part. The current inspection method for these flaws is a costly and time intensive visual inspection of each ply layer. This work describes some initial efforts to incorporate thermal inspection on the AFP head and analysis of the data to identify the previously mentioned flaws. Previous bench-top laboratory experiments demonstrated that laps, gaps, and twists were identified from a thermal image. The AFP head uses an onboard lamp to preheat the surface of the part during layup to increase ply consolidation. The preheated surface is used as a thermal source to observe the state of the new material after compaction. We will present data collected with the Integrated Structural Assembly of Advanced Composites (ISAAC) AFP machine at Langley Research Center showing that changes to the temperature profile is sufficient for identifying all types of flaws.

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Thermal Image-based Monitoring for the Automated Fiber Placement Process

Cited by 33 publications

References 2 publications

A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

A Novel Approach: Combination of Automated Fiber Placement (AFP) and Additive Layer Manufacturing (ALM)

On the temperature evolution during continuous laser-assisted tape winding of multiple C/PEEK layers: The effect of roller deformation

In-situ thermography of automated fiber placement parts

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