Inline Quality Control for Thermoplastic Automated Fiber Placement by 3D Profilometry

Abstract

Thermoplastic Automated Fiber Placement (T-AFP) is a promising technology for the manufacturing of complex aerospace parts. In contrast to tapelaying of duromere prepregs TAFP has the potential of in-situ consolidating the laminate as well as the opportunity for a dustfree ssembly based on thermoplastic welding. Subsequent rework is challenging in this single-stage process due to the direct consolidation onto the substrate. In result inline quality control gains even more importance. Starting from AIPS 0302019 at DLRs Center of Lightweight Production Technology in Augsburg we investigated the feasibility of a fully automated inspection system based upon a high-performance light sheet sensor that is capable of detecting most crucial defect types such as gaps and overlaps inline, allowing an early correction by the user or by a control system. We found that especially overlaps between tracks in lower plies have the potential of introducing extreme undulations at higher plies. In order to assure a constant minimum gap between placed tracks in production, measuring overlaps as well as gaps has been our focus. Since steering effects and other influences are complex all received data is associated with machine data and stored in a data management system for further algorithmic and AI-based evaluation.