Abstract: In accordance with the present invention, there is provided a technique which may be used in conjunction with an automated Z-pin insertion process to automatically monitor the insertion energy applied to the Z-pins during the initial insertion phase of the automated insertion process, and compare it to an empirically derived value for good insertions, thereafter allowing the insertion process to continue to a predetermined additional insertion depth before terminating the process. The insertion energy is calculated by cumulatively summing the insertion force and multiplying it by the insertion time, thus yielding the cumulative energy. At a specified, predetermined insertion depth, the energy accumulation is stopped and the value at the initial insertion depth is stored and compared to an empirically derived value. If the value is less than the empirical value, the insertion energy is too low, thus indicating that either a partial grid insertion is being encountered or defective Z-pins are being inserted.

Abstract: In accordance with the present invention, there is provided a method of inserting at least one Z-pin into a composite laminate for providing Z direction reinforcement thereto. The method comprises the initial step of positioning at least one Z-pin upon the composite laminate. Thereafter, an insertion force is applied to the Z-pin at a first level which is sufficient to commence an insertion process wherein the Z-pin is driven into the composite laminate at a first insertion speed. The insertion force applied to the Z-pin is continuously monitored, with the first insertion speed being reduced to a second insertion speed in response to a monitored increase in the insertion force from a first level to a second level.

Abstract: In accordance with the present invention, there is provided a method of automatically verifying the acceptable insertion of at least one Z-pin into a composite laminate. The method comprises the initial step of positioning at least one Z-pin upon the composite laminate. Thereafter, an insertion force is applied to the Z-pin at a first level which is sufficient to commence an insertion process wherein the Z-pin is driven into the composite laminate at a first insertion speed. The insertion force applied to the Z-pin is continuously monitored, with the first insertion speed being reduced to a second insertion speed in response to a monitored increase in the insertion force from a first level to a second level. The application of the insertion force to the Z-pin is discontinued and the insertion process terminated in response to a monitored increase in the insertion force from the second level to a third level.

Abstract: A Z-form position detector useful for ascertaining the position of Z-forms with respect to underlying composite structure. The device comprises an oscillating laser that generates a line projected onto the Z-form and composite structure at an angle. The line appears discontinuous due to the topography of the Z-form and composite structure. For example, the line is discontinuous at the edges of the Z-form. The device further comprises a sensor sensitive to the frequency of the laser. The sensor scans along the line until a discontinuity (i.e., a break in the line) is detected. Since the discontinuity corresponds to the edge of the Z-form, detection of the discontinuity allows the device to ascertain precise coordinates of a point on the edge of the Z-form. The device thus allows Z-pins to be driven into composite structure automatically for savings on time and cost.

Abstract: A Z-form position detector useful for ascertaining the position of Z-forms with respect to underlying composite structure. The device comprises an oscillating laser that generates a line projected onto the Z-form and composite structure at an angle. The line appears discontinuous due to the topography of the Z-form and composite structure. For example, the line is discontinuous at the edges of the Z-form. The device further comprises a sensor sensitive to the frequency of the laser. The sensor scans along the line until a discontinuity (i.e., a break in the line) is detected. Since the discontinuity corresponds to the edge of the Z-form, detection of the discontinuity allows the device to ascertain precise coordinates of a point on the edge of the Z-form. The device thus allows Z-pins to be driven into composite structure automatically for savings on time and cost.