| 主权项 |
1. A system for detecting the presence and location of flaws in a composite layup material deposited on a mold by an automated fiber placement head, utilizing a three-dimensional point cloud representing a top surface of the composite layup material, comprising:
a processing device; a laser line scanning device in communication with the processing device; and a non-transitory computer readable memory device in communication with the processing device, the non-transitory computer readable memory device storing instructions that when executed by the processing device result in:
receiving, by the non-transitory computer readable memory device, programmed three-dimensional features of the top surface of the composite layup material, the top surface comprising a region of one or more courses of composite layup material;determining, by a scanning of the top surface conducted by the laser line scanning device, the three-dimensional point cloud representing the top surface of the composite layup material;receiving, from the laser line scanning device and by the processing device, information describing the three-dimensional point cloud representing the top surface of the composite layup material;determining, by the processing device and based on an analysis of the three-dimensional point cloud representing the top surface of the composite layup material, the analysis comprising an execution of a manufacturing flaw detection algorithm, a location of at least one manufacturing flaw on the top surface of the composite layup material;determining, by the processing device and based on an analysis of the three-dimensional point cloud representing the top surface of the composite layup material, the analysis comprising an execution of a feature detection algorithm, information descriptive of a location and a characteristic of one or more as-made features on the top surface of the composite layup material;comparing, by the processing device, the information descriptive of the location and the characteristic of the one of more as-made features on the top surface of the composite layup material with the programmed three-dimensional features of the top surface of the composite layup material;identifying by the processing device and based on the comparison and an execution of at least one as-made flaw detection algorithm, a presence and location of one or more as-made flaws on the top surface of the composite layup material;recording, by the non-transitory computer readable memory device, the presence and location of the one or more manufacturing flaws and the one or more as-made flaws on the top surface of the composite layup material; andcausing, by the processing device and based on at least one of the locations of the one or more flaws on the top surface of the composite layup material, a repositioning of the automated fiber placement head,wherein the determining of the one or more as-made features of the top surface of the composite layup material comprises detecting a left tape edge location, a right tape edge location, a tape add location, a tape drop location, and a tape splice location,wherein the feature detection algorithm comprises a first module programmed to detect at least one of the left tape edge and the right tape edge, a second module programmed to detect at least one of the tape add location and the tape drop location, and a third module programmed to detect the tape splice location, andwherein the first module is programmed to detect the left tape edge, the three-dimensional point cloud comprises a set of data representing a plurality of scan lines oriented parallel to an x-axis, and wherein execution of the first module by the processing device results in:
determining a subset of the three-dimensional point cloud representing the top surface of the composite layup material;determining positive slope peak locations along each scan line of the plurality of scan lines within the subset;locating proximate positive slope peak locations in proximate scan lines, thereby defining one or more positive slope peak point groups;calculating a mathematical fit correlation for each positive slope peak point group; andin the case that the mathematical fit correlation for a positive slope peak point group is above a predefined threshold, identifying the x-coordinate of the positive slope peak point group as the left tape edge. |
