Abstract: A method for using light to indicate locations of inconsistencies on a composite structure. The method generally includes electronically accessing positional data defining one or more inconsistency locations on a composite structure. The positional data may be extracted from a part fabrication file containing numerical control (NC) data that may be used by a material placement machine to fabricate the composite structure. A light source directs light at the composite structure to illuminate the inconsistency locations as defined by the positional data. The information needed by the light source may be stored in a lookup table accessed by a processor of a vision detection system. The light allows the inconsistency locations to be noted for later action.

Abstract: An inspection system (9) includes an idler wheel (61) that is coupled to a fabrication system (8) and is in contact with a backing layer (65) of an applied material (64), A rotation sensor (63) monitors the idler wheel (61) and generates a rotational signal. A controller (24) is coupled to the rotation sensor (63) and determines a characteristic of one or more flaws and FOD (19) on a composite structure (12) in response to the rotation signal.

Abstract: An inspection system (9) includes an idler wheel (61) that is coupled to a fabrication system (8) and is in contact with a backing layer (65) of an applied material (64), A rotation sensor (63) monitors the idler wheel (61) and generates a rotational signal. A controller (24) is coupled to the rotation sensor (63) and determines a characteristic of one or more flaws and FOD (19) on a composite structure (12) in response to the rotation signal.

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).

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).

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).

Abstract: A course material that is applied to a substrate during fabrication of a composite item is inspected by a system that includes a vision assembly. The vision assembly includes an area light, a line generator, a sensor, and an image processor. The area light illuminates an area of the course material. The line generator generates a line of illumination across the area. The sensor captures an image of the area. The image processor analyzes the image. The image processor is configured to identify debris on the course material in response to the area light being activated and the image processor is configured to identify placement aberrations in response to the line generator being activated.

Abstract: A method of providing input to an inspection system for inspecting material laid by a composite material placement machine. A placement machine component that drives a first encoder output is used to drive a second encoder output. The second encoder output is used to trigger image acquisition by the inspection system. Existing components can be used to provide encoding capability for a placement machine inspection system. Because encoder output signals for material placement and for material inspection are driven by the same component, material placement locations can be determined more precisely compared with other methods.

Abstract: An inspection system (9) includes an idler wheel (61) that is coupled to a fabrication system (8) and is in contact with a backing layer (65) of an applied material (64). A rotation sensor (63) monitors the idler wheel (61) and generates a rotational signal. A controller (24) is coupled to the rotation sensor (63) and determines a characteristic of one or more flaws and FOD (19) on a composite structure (12) in response to the rotation signal.

Abstract: The invention relates to pseudo porosity standards, and methods for their manufacture and use, which may substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness. The member may be defined by at least one hollow, non-spherical shaft. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. The non-spherical shaft may scatter and attenuate ultrasonic energy. The reference standard may replace more costly, porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Abstract: The embodiments of the disclosure relate to a method of displaying an image of an inconsistency on a part. The part may be scanned. An inconsistency on the part may be located. An image of the inconsistency may be displayed on the part. In other embodiments, parts are provided which had images of the parts' inconsistencies displayed on one or more surfaces of the parts.

Abstract: The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a cored composite laminate having porosity. An ultrasonic inspection reference standard for cored composite laminates having porosity may include a member having at least one thickness, at least one core, and at least one mesh. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh may produce a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. Use of the core may aide in modeling a cored composite laminate. The manufactured reference standard may replace more costly porous, cored, composite laminate reference standards in the aircraft industry and in other non-aircraft applications.

Abstract: A system and method of inspecting material laid by a material placement machine. Light is directed onto the material in a direction essentially normal to the material to illuminate a section of the material. Laser energy is projected onto the section at an angle predetermined to reveal inconsistencies in the section. This system provides improved illumination for material widths exceeding six inches and is scalable for inspecting various material widths.

Abstract: A course material that is applied to a substrate during fabrication of a composite item is inspected by a system that includes a vision assembly. The vision assembly includes an area light, a line generator, a sensor, and an image processor. The area light illuminates an area of the course material. The line generator generates a line of illumination across the area. The sensor captures an image of the area. The image processor analyzes the image. The image processor is configured to identify debris on the course material in response to the area light being activated and the image processor is configured to identify placement aberrations in response to the line generator being activated.

Abstract: The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate, such as a metallic interleaved composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness, at least one metallic shim, and at least one mesh. A plurality of metallic shims and meshes may be disposed in alternating layers within the member. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh may produce a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. Use of the metallic shim may aide in modeling a metallic laminate.

Abstract: Systems and methods for determining an inconsistency characteristic of a composite structure, such as inconsistency density-per-unit area. In one implementation, a method is disclosed for determining an inconsistency characteristic of a composite structure. The method involves determining a first distance from a first reference point of the composite structure to an inconsistency; determining a second distance from a second reference point of the composite structure to the inconsistency; using the first and second distances to establish a reference area of the composite structure; and considering each inconsistency detected within the reference area and producing therefrom an inconsistency characteristic representative of the composite structure.

Abstract: A system for non-destructive inspection using laser profiling and an associated method are provided. The system includes a support surface, and at least one laser carried by the support surface and directed towards the workpiece at an oblique angle such that at least a portion of the workpiece is illuminated by the laser. The system also includes a camera carried by the support surface and capable of capturing reflections from the workpiece, as well as a translation device capable of traveling proximate to the workpiece. The support surface is coupled to the translation device such that the laser and the camera are capable of traveling along the workpiece. The system further includes a data acquisition system capable of communicating with the camera such that the data acquisition system creates an image indicative of at least a portion of the workpiece based on the reflections from the workpiece.

Abstract: Systems and methods for identifying foreign objects and debris (FOD) and defects during fabrication of a composite structure. The system includes at least one light source positioned to emit light that illuminates a portion of the composite structure with bright field illumination and that also illuminates another portion of the composite structure with dark field illumination. The bright field illumination is reflected differently by defects in the composite structure than from portions of the composite structure that are defect free. The dark field illumination is reflected differently by FOD on the composition structure than from surfaces of the composite structure that are FOD free. The system also includes at least one camera for receiving images of the illuminated portions of the composite structure. The images received by the camera may be processed by a processor which then outputs a response identifying defects and foreign objects and debris based on the images.

Abstract: A method for using light to indicate locations of flaws and defects on a composite structure generally includes electronically accessing positional data defining one or more defect locations on a composite structure. The positional data can be extracted from a part fabrication file in which resides numerical control (NC) data that can be used by a material placement machine to fabricate the composite structure. The method also includes automatically causing at least one light source to direct light at the composite structure to indicate the defect locations as defined by the positional data. Accordingly, the light allows the defect locations to be readily ascertained for later action, such as manual defect repair and/or FOD removal by an operator.

Abstract: A system and method for identifying defects in a composite structure is provided. The system includes a camera for receiving images of the composite structure, a processor for manipulating the images and outputting a response based on the images, and a light source for illuminating the composite structure. Advantageously, the light source is positioned at an oblique angle relative to the composite structure and comprises an infrared component that is differently reflected by defects in the composite structure than from portions of the composite structure that are defect free. Based on the response provided by the processor, defects that meet predetermined criteria can be identified.