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Quality Assured Aircraft Fuselage Production: Data Evaluation of a Quality Control Sensor for Thermoplastic Automated Fiber Placement

Mayer, Monika and Schuster, Alfons and Brandt, Lars and Deden, Dominik and Fischer, Frederic and Schmorell, Demas and Vistein, Michael (2022) Quality Assured Aircraft Fuselage Production: Data Evaluation of a Quality Control Sensor for Thermoplastic Automated Fiber Placement. Deutscher Luft- und Raumfahrtkongress 2022, 27.-29. Sept. 2022, Dresden, Deutschland. doi: 10.25967/570129.

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In-situ thermoplastic automated fiber placement (TP-AFP) is a lean additive manufacturing process without further vacuum bagging and autoclave cycling. Heated by laser and subsequently compacted with a consolidation roller, the tapes are consolidated on the fly. This makes TP-AFP a single stage manufacturing process. For this highly transient process inline quality assurance (QA) is vital. The inline QA sensor is situated about 100 mm behind the consolidation roller and measures height profiles via laser triangulation. The evaluation routine identifies gaps and overlaps between tows and tracks as well as early/late cut at the beginning and end of each track. Processing the profile data includes outlier removal, thresholding, bitwise operations, the Sobel operator, erode and dilate operations and contour finding. We present the data evaluation of a full-scale fuselage skin of a test shell which was produced with a multitow laying head that processes three ½ inch carbon fiber tapes. The primary focus is the detection of gaps and overlaps. A 3D spatial plot will give an overview where the production process has to be revised.

Item URL in elib:https://elib.dlr.de/191823/
Document Type:Conference or Workshop Item (Speech)
Title:Quality Assured Aircraft Fuselage Production: Data Evaluation of a Quality Control Sensor for Thermoplastic Automated Fiber Placement
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Mayer, MonikaUNSPECIFIEDhttps://orcid.org/0000-0002-4448-9501UNSPECIFIED
Schuster, AlfonsUNSPECIFIEDhttps://orcid.org/0000-0002-7444-366XUNSPECIFIED
Brandt, LarsUNSPECIFIEDhttps://orcid.org/0009-0007-8608-0759140954382
Deden, DominikUNSPECIFIEDhttps://orcid.org/0000-0001-8959-8720UNSPECIFIED
Fischer, FredericUNSPECIFIEDhttps://orcid.org/0000-0001-5421-4336UNSPECIFIED
Vistein, MichaelUNSPECIFIEDhttps://orcid.org/0000-0001-6998-0017133661198
Date:11 November 2022
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In ISI Web of Science:No
Keywords:thermoplastic composites, LM-PAEK, laser triangulation sensor, inline quality assurance, process monitoring, tape placement sensor, data evaluation, Sobel operator, thermoplastic Automated Fiber Placement, production technology, MFFD, multifunctional fuselage demonstrator
Event Title:Deutscher Luft- und Raumfahrtkongress 2022
Event Location:Dresden, Deutschland
Event Type:national Conference
Event Dates:27.-29. Sept. 2022
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 - Structural Materials and Design
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Mayer, Monika
Deposited On:09 Dec 2022 10:30
Last Modified:22 Aug 2023 12:58

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