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

Schuster, Alfons and Mayer, Monika and Brandt, Lars and Deden, Dominik and Krebs, Florian and Kupke, Michael (2021) Inline Quality Control for Thermoplastic Automated Fiber Placement by 3D Profilometry. In: Proceedings SE Conference 21 Baden / Zürich. SAMPE Europe 2021, 28.-30.9.2021, Baden, Switzerland.

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Official URL: https://downloads.sampe-europe.org/wp-content/uploads/2021/10/TP117-Schuster_SE21_final.pdf

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.

Item URL in elib:https://elib.dlr.de/145315/
Document Type:Conference or Workshop Item (Speech)
Title:Inline Quality Control for Thermoplastic Automated Fiber Placement by 3D Profilometry
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iD
Schuster, AlfonsAlfons.Schuster (at) dlr.dehttps://orcid.org/0000-0002-7444-366X
Mayer, MonikaMonika.Mayer (at) dlr.deUNSPECIFIED
Brandt, LarsLars.Brandt (at) dlr.deUNSPECIFIED
Deden, DominikDominik.Deden (at) dlr.dehttps://orcid.org/0000-0001-8959-8720
Krebs, FlorianFlorian.Krebs (at) dlr.dehttps://orcid.org/0000-0001-6033-801X
Kupke, MichaelMichael.Kupke (at) dlr.deUNSPECIFIED
Date:30 September 2021
Journal or Publication Title:Proceedings SE Conference 21 Baden / Zürich
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Published
Keywords:Thermoplastic Tape Laying, Inline-Quality Control, Profilometry, Light sheet sensor, process control, defect reciognition
Event Title:SAMPE Europe 2021
Event Location:Baden, Switzerland
Event Type:international Conference
Event Dates:28.-30.9.2021
Organizer:SAMPE
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:Components and Systems
DLR - Research area:Aeronautics
DLR - Program:L CS - Components and Systems
DLR - Research theme (Project):L - Production Technologies
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Schuster, Dr.-Ing. Alfons
Deposited On:09 Nov 2021 13:55
Last Modified:09 Nov 2021 13:55

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