Transcript
SUCCESS STORY
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Inline Quality Assurance in Lightweight Fiber Composite Construction Using Basler pilot GigE Cameras Customer
The modular structure of the system allows for flexible adjustment to changing process conditions. The camera is an important component in the system, as it handles the inspection of the surface structure and identifies production errors. The system’s creators were seeking an easy-to-integrate area scan camera with a standardized GigE interface.
Machine Tool Lab (WZL) at the RWTH Aachen Location: Aachen, Germany Industry: Machine Engineering, R&D Implementation: April 2014
Application: A great many areas of business are interested in cutting energy consumption by reducing weight. Lightweight construction is one solution to this problem. Compared with conventional metal engineering, lightweight construction with textile fiber composite materials opens up new potential for energy efficiency. Fiber composite materials are comprised of an embedding matrix and reinforcing fibers. The combination of these two components lends the material its strong durability despite the reduced weight. Its stability in various directions is determined by the orientation and characteristics of the fibers. Instead of using individual fibers for a workpiece made of fiber reinforced plastics (FRP), pre-fabricated meshes or cores are typically used and bonded with the matrix during the ongoing process and fused into one single piece. Components made from FRP are essential for a sustainable, innovative and yet affordable implementation of lightweight construction concepts. Quality assurance for this high-performance material has to date been performed primarily using manual techniques, which raises reliability and affordability issues in trying to match the market requirements. The objective for quality assurance in the production of FRP is the securing of the entire process chain. This can be performed through automated inspection and the integration of control procedures.
Fiber Measurement System (FMS)
Solution and Benefits
The Machine Tool Lab (WZL) at the RWTH Aachen thus developed the Fiber Measurement System (FMS), a robot-based sensor system to detect and classify production errors in semi-finished textile products involved in FRP production. The sensor information from the FMS is used as part of inline QA within the production process to correct process parameters.
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The Machine Tool Lab (WZL) at the RWTH Aachen developed procedures based on a fusion of sensor data from active and passive optical measurement processes. While special laser-based measurement techniques are used for recording 3D geometry (macroform), the high-resolution area scan camera, Basler pilotpiA2400-17gm, is used for the detection of fiber orientation (microform) in the FRP structures. A diffused lighting unit provides a uniform, low-shadow field of vision for the camera while also minimizing reflections. Depending on the desired measurement cycle speed and the available installation space, image
processing and analysis is performed on real-time compatible FPGA boards or industrial PC systems. The FMS is thus in a position to detect the fiber orientation of semi-finished textile products in three dimensions as well as any protection errors that arise, all in real time. Beyond complete automation, the development of different man/machine or machine/machine concepts allows for efficient and effective tracing of the analyzed sensor information, even in manual processes. The FMS thus establishes an important basis for process optimization in the production of fiber reinforced plastics components and offers the decisive benefit of quality assurance. The system developed in Aachen is already being deployed for various applications. One example of such applications is the 3D digitalization of so-called preforms based on the draping process. Because the draping process involves the reshaping of two-dimensional fiber mats into 3D shapes means, a certain amount of flaws from gases and creases in the textile preform are unavoidable. If these flaws occur in areas relevant to safety, then the structural integrity of the component can no longer be assured. The use of FMS allows for early detection of flaws through the detection of 3D geometry and 3D fiber orientation. A comparison of the target/actual states using reference geometry also allows for flaws in the 3D model to be marked with color.
The extensive use of innovative “inline quality assurance” allows for start-to-finish transparency in the FRP production. Thanks to the quantified evaluation of the FRP process, the continuous monitoring of quality using FMS detects disruptions and parts to be rejected during production. The integration of the control process directly into production also significantly improves the capability and stability of the production process. The FMS is a mature measurement system that is an essential facilitator to achieving maximum optimization of conventional production processes. Sarah Ekanayake, M.Sc. in the Department of Production Measurement Technology in the WZL of the RWTH Aachen is highly satisfied with the selection of camera for the system: “The Basler pilot camera delivers top-quality images and can be configured in a variety of ways.”
Technologies Used Basler piA2400-17gm Dome light Laser for geometrical detection
More information http://www.wzl.rwth-aachen.de/de/mq.htm
Digitalized Preform with Defect Spot Classifications Basler pilot piA2400-17gm camera
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