Spirit Aerosystems, Inc.

The Boeing Company

John Faber Sjogren

Henry D Harkins

Theodore J Eilert

Michael R Grosser

John A Ritter

An apparatus and method for detecting an increase in thickness of a strip of material from a desired thickness. The apparatus may comprise a light source, a light detector, an indicator, a first fiber optic cable coupled with the light source, a second fiber optic cable coupled with the light detector, and a housing. The housing may comprise a material slot for passing the strip of material therethrough and fixing optical fibers of the first fiber optic cables to reflect light off of a first and second face of the strip of material into optical fibers of the second fiber optic cable. The amount of light detected by the light detector depends on the proximity of each of the faces of the strip of material to ends of the optical fibers. The thicker the strip of material, the less light received by the light detector, which may actuate the indicator.

Apparatus and method for thickness detection

An apparatus and method for detecting a difference in width of a strip of material from a desired width of material. The apparatus may comprise a light source, a light detector, an alarm, a first fiber optic cable coupled with the light source, a second fiber optic cable coupled with the light detector, and a housing. The housing may comprise a material slot for passing the strip of material therethrough such that edges of the strip of material may at least partially intersect a plurality of light fields directed from the first fiber optic cable to the second fiber optic cable. The amount of light detected by the light detector is dependant on the amount of light blocked by the strip of material. If the amount of light received is outside of a range of tolerance from the desired width of material, the alarm may be actuated.

Apparatus and method for width detection

A system and method for detecting unwanted wrapping of one or more of a plurality of strips of material around a feed roller intended to urge the strips of material forward. During proper operation, the strips of material remain to a first side of the feed roller, but an error may cause the material to pass to a second side of the feed roller. The system for detecting this error may comprise a plurality of send optical fibers configured to send light in a direction toward the second side of the feed roller; a plurality of receive optical fibers configured to receive light reflected off of the feed roller and/or any of the strips of material; and an alarm for notifying a user or an automated system if an amount of light received is not a desired amount of light, indicating reflection off of at least one strip of material.

Fiber optic sensor for tow wrap

A real-time thermal imaging apparatus and method includes multiple digital infrared cameras mounted to an automated composite material layup device to record digital infrared images of the composite material surface on a real-time basis during a composite material layup process. The digital infrared cameras are triggered periodically to produce digital images of the composite material. The digital image data is sent to an image analyzer which detects edges of and anomalies in the composite material and generates alarm and other process control signals. The image analyzer also aggregates the digital images from the multiple cameras and the digital images recorded over a sequence in time to produce a continuous virtual digital image of the composite material surface. The digital image data and associated analysis results are saved and may be displayed on a real-time basis or at a later time.

Real-time infrared thermography inspection and control for automated composite marterial layup

A system and method for processing a preform in a vacuum vessel to produce a structural assembly are provided. The system includes a heated die set defining a cavity in which the preform can be formed, bonded, or otherwise processed. The die set is disposed in a cavity of the vacuum vessel from which gas can be evacuated. Thus, a pressurized fluid can be provided to the preform, e.g., to an interior space of the preform to form or constrain the preform in the die cavity, and the vacuum vessel can be evacuated so that the die set, and typically the preform, are exposed to a pressure that is reduced relative to the ambient pressure. Further, the vacuum vessel can constrain the die set in the closed position during processing.

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Wichita, KS, United States of America

John Faber Sjogren