Automated path planning and thermographic monitoring for automated fibre placement

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Therm-O-Plan utilizes path planning capabilities within the process monitoring system of fibre placement processes. A new methodology for knowledge-based path planning is being developed to reduce planning efforts, even for complex carbon parts. In addition, the path planning process is linked to a newly developed online thermal monitoring system for diverse fibre placement systems.

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... Within the research project Therm-O-Plan, a thermal inprocess monitoring system is developed [11]. The approach includes an infrared camera that records the occurring temperature distribution of laid-up cold tows and heated tooling surface. ...
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Automated Fiber Placement is an important manufacturing process when it comes to aerospace part generation. To minimize the machine downtime, an online monitoring system is necessary to prevent time consuming visual inspection. Therefore, a new thermal in-process monitoring system is integrated. Herewith spotted temperature difference enable the localization of placed tows and detection of defects. The thermal contrast between subsurface and tows depends on different process parameters such as lay-up speed, tooling temperature and compaction pressure. This influence is analyzed and discussed within lay-up studies to gain further knowledge about the different effects to increase the reliability of in-process monitoring as well as AFP processes.
... During the standard AFP process, the infrared camera is used for online quality inspection, which is investigated in the research project "Therm-O-Plan" [3,4]. The camera measures surface temperature induced by the heat input of the radiators to detect defects and foreign objects during layup. ...
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To solve the problem of load transmission into thin walled CFRP Structures, a new joining technology is being developed (Multi Layer Insert – MLI). It consists of multiple thin metal foils to distribute load optimally into every single CFRP layer. The placement process for the metal layers is integrated into an Automated Fiber Placement system. In this paper, a process sequence of MLI placement is presented containing the following steps: stockpiling of metal layers, separation, handling, positioning, lay up and fixation of metal layers during fiber placement. Moreover, the monitoring and control concept is discussed.
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