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Integral quality assurance method for a CFRP aircraft fuselage skin: Gap and overlap measurement for thermoplastic AFP

Mayer, Monika and Schuster, Alfons and Brandt, Lars and Deden, Dominik and Fischer, Frederic (2023) Integral quality assurance method for a CFRP aircraft fuselage skin: Gap and overlap measurement for thermoplastic AFP. Springer Nature Switzerland. 32nd International Conference on Flexible Automation and Intelligent Manufacturing, 19.-22.06.2023, Porto, Portugal. doi: 10.1007/978-3-031-38241-3.

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Manufacturing carbon reinforced plastics with Automated Fiber Placement (AFP) is a widely adopted process despite inherently introduced defects of gaps and overlaps during the manufacturing process. Gaps and overlaps are usually cured during the consolidation process if limited to a certain size, otherwise they will lower mechanical properties of the component. Thus, gaps and overlaps have to be detected and measured especially in a thermoplastic process without a final consolidation step. For this purpose, a quality assurance sensor, based on laser triangulation, is integrated into a thermoplastic AFP machine mounted on a robot. For this paper the data recording and evaluation comprises a full-scale thermoplastic fuselage half shell with 8 m length and a diameter of 4 m. A Computer Vision pipeline extracts and quantifies the gap and overlap defects. The paper compares multiple visualization approaches of the results to showcase their advantages for various stages of component design and production. By illustrating the gaps and overlaps in a 3D graphic, precise localization of out of tolerance defects can be determined to adjust process parameters during production. Preconditions for simulation tools can be defined by summarizing all defects in a 2D heatmap, to improve variable stiffness properties for example.

Item URL in elib:https://elib.dlr.de/199294/
Document Type:Conference or Workshop Item (Speech)
Title:Integral quality assurance method for a CFRP aircraft fuselage skin: Gap and overlap measurement for thermoplastic AFP
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Mayer, MonikaUNSPECIFIEDhttps://orcid.org/0000-0002-4448-9501147715593
Schuster, AlfonsUNSPECIFIEDhttps://orcid.org/0000-0002-7444-366XUNSPECIFIED
Brandt, LarsUNSPECIFIEDhttps://orcid.org/0009-0007-8608-0759147715595
Deden, DominikUNSPECIFIEDhttps://orcid.org/0000-0001-8959-8720UNSPECIFIED
Fischer, FredericUNSPECIFIEDhttps://orcid.org/0000-0001-5421-4336UNSPECIFIED
Date:July 2023
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In ISI Web of Science:No
Publisher:Springer Nature Switzerland
Series Name:Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems
Keywords:thermoplastic composites, laser triangulation sensor, inline quality assurance, tape placement sensor, data evaluation
Event Title:32nd International Conference on Flexible Automation and Intelligent Manufacturing
Event Location:Porto, Portugal
Event Type:international Conference
Event Dates:19.-22.06.2023
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:29 Nov 2023 14:55
Last Modified:29 Nov 2023 14:55

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