FIELD

The present invention relates to the field of composite materials manufacturing systems, methods, and apparatuses; even more particularly, to systems, methods, and apparatuses for automated quality checks for manufactured composite materials.

BACKGROUND

Lean manufacturing is a systematic method for waste minimization within a manufacturing system while maintaining high productivity. Lean manufacturing takes into account the waste created through unbalanced manufacturing processes, and seeks to identify and focus on products and services that add value to the process. Successful lean manufacturing requires development of tools that assist in the identification and steady elimination of waste. With the growing demands placed on automation in the manufacturing floor to improve yields, methods to improve communication between the machine and supervising operators are increasingly valuable. Thus, a need exists for an open architecture system that enables quick introduction of new capabilities, increases safety, grows functionality, and reduces defective manufactured articles—without large expense or retrofitting in manufacturing settings.

SUMMARY

The present invention relates to the field of composite materials manufacturing systems, methods, and apparatuses; even more particularly, to systems, methods, and apparatuses for automated quality checks for manufactured composite materials.

According to a first aspect, an automated inspection system for monitoring a manufacturing process comprises: a core platform to operatively connect a plurality of systems or subsystems via one or more interfaces; and a sensor system operatively coupled with the core platform to monitor one or more characteristics of a composite article being manufactured, the core platform configured to: receive a first measurement of the one or more characteristics of a composite article from the sensor system while forming the composite article; receive data regarding a second measurement of the one or more characteristics from the sensor system after curing the composite article; and generate an alert in response to a determination that a defect exists in the composite article based on the first or second measurement.

In certain aspects, the system further comprises a state manager operatively coupled with the core platform to determine a defect associated with the one or more characteristics.

In certain aspects, the state manager is configured to determine whether a first defect exists in the composite article based on the first measurement.

In certain aspects, the state manager is configured to determine whether a second defect exists in the composite article based on the second measurement.

In certain aspects, the state manager is configured to: identify a value corresponding to the one or more characteristics associated with the defect based on the first or second measurement; and calculate a score representing the degree of the defect of the manufactured article based on the identified value.

In certain aspects, the core platform further configured to: receive data regarding a third measurement of the one or more characteristics after performing a trim operation on the composite article; determine whether a third defect exists in the composite article based on the third measurement; and generate an alert in response to a determination that a third defect exists in the composite article.

In certain aspects, the system further comprises a human machine interface operatively coupled with the core platform to provide an interface between an operator and the system.

In certain aspects, the core platform is configured to transmit the alert to the human machine interface, the alert comprising one of an audible or visual alert presented by the human machine interface.

In certain aspects, the system further comprises an actuation system operatively coupled with the core platform to implement the manufacturing process based on instruction from the core platform, wherein the core platform transmits the alert and information regarding the first or second defect to the actuation system to adjust an operating value of a manufacturing process of the system.

In certain aspects, the operating value comprises one of a speed of the manufacturing process, a temperature of the curing stage, and a position of the composite article.

In certain aspects, the sensor system is operatively coupled with one or more of a non-contact ultrasound sensor, a laser sensor, an impedance sensor, an infrared sensor, or a heat sensor.

In certain aspects, the sensor system monitors the one or more characteristics by two or more sensors of the sensor system to determine the first or second defect.

In certain aspects, the characteristic comprises one of a density, a temperature, a chemical composition, and a thickness associated with the composite article.

According to a second aspect, a method of determining the integrity of a composite article comprises: measuring, by a sensor, a first characteristic corresponding to integrity of a composite article while forming the composite article; measuring, by the sensor, a second characteristic corresponding to integrity of the composite article after curing the composite article; identifying, at a core platform, a defect based on the characteristic; and generating an alert in response to a determination that a defect exists in the composite article based on the first or second characteristic.

In certain aspects, the method further comprises: determining, by the core platform, a defect value associated with the first or second characteristic; comparing the defect value to a plurality of defect values; and designating the manufactured article as containing a defect based on the comparison.

In certain aspects, the method further comprises: identifying, by the core platform, a stage at which the defect appears; and adjusting an operating value of a manufacturing process based on the identification.

In certain aspects, the operating value comprises one of a speed of the manufacturing process, a temperature of the curing stage, and a position of the composite article.

In certain aspects, the first or second characteristic comprises one of a density, a temperature, a chemical composition, and a thickness associated with the composite article.

In certain aspects, the method further comprises transmitting the alert to a human machine interface operatively coupled with the core platform.

In certain aspects, the alert comprises video or audio identifying the defect.

