JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 45

fibre placement system, which was developed by the IFW in
a recent research project (figure 2, left). The modules consist
of an infrared camera with an additional data processing unit
for online failure detection and interpretation as well as data
storage. The design is planned to be universally adaptable to
different fibre placement head configurations from different
machine manufacturers.

Fig. 2: IFW fibre placement head including an IR camera (left) and virtual environment for path planning in the SWMS CAESA CAM software (right)

Fig. 3: Thermal image of the fibre placement process for four tows

The approach introduces a direct link between the ThermO-Plan process planning module and the component design
and construction process. Based on the supplied structural
information and design requirements, SWMS derives fully
automated manufacturing specifications for the AFP process.
With this information, the new path planning algorithm can
automatically generate and optimize lay-up courses in an
iterative procedure. In each layer, the courses are optimally
aligned to keep gaps and overlaps within the given tolerances
and to prevent tow waviness of the material. Therefore, it is
important to know the material and process characteristics
and to consider them during the course optimization process. For this purpose, a self-learning algorithm continuously
interprets the collected process information provided by the
process monitoring system and derives experiences. This
new path planning algorithm will be implemented in the
CAESA CAM software from SWMS (figure 2, right).

Online monitoring
In addition to process planning, the project also aims at developing a new process monitoring and evaluation module.
In cooperation with the IFW, AT is developing a thermal
monitoring system for diverse fibre placement systems.
The basic development of the system and its experimental
validation are primary conducted on a robotized automated

During the fibre placement process, the integrated IR camera
delivers process images that are continuously interpreted
by the data processing unit. It delivers defect and quality
information for the fibre placement process in real time. To
ensure part-specific quality assurance, a connection between
the planning and the evaluation module is installed, providing course-specific process limits and threshold values for
this monitoring task. By linking these threshold values to
the process images, image processing algorithms for failure
detection can detect manufacturing issues. Afterwards, the
evaluation module classifies them into different failure categories to allow individual problem-solving strategies.
The basic phenomenon, which the monitoring approach
is based on, is a visible temperature difference. During the
AFP process, the tows are stored cool, either inside the fibre
placement head or in a creel, in order to ensure the desired
material properties. This environment prevents sticking
inside the material supply. To ensure good tack between the
material and its corresponding subsurface, the subsurface
is heated immediately before the compaction point, thus
resulting in a temperature difference between the placed tow
and the subsurface. By compacting the tows on the subsurface, heat flows from the substrate into the freshly laid-up
tow. Here, the temperature depends on the deposition rate,
connection quality and compaction pressure.
Figure 3 shows a thermal image from the IR camera during
the lay-up process with the IFW fibre placement head (figure
2, left). To demonstrate the effect of a varying compaction
pressure, every single roller of the compaction device acts
with a different pressure. As can be seen, the individual
pressures lead to different heat flows depending on the
individual thermal resistance, which results in different
temperatures of certain tows. Whereas tows 1 and 4 are well
compacted, tows 2 and 3 show poorer compaction.
Independently of the compaction pressure, the image processing clearly localizes the tows in the thermal image, i.e.
an edge-detecting algorithm determines the edges of every
single tow. The derived tow position is continuously stored
within the robot's coordinate system. Deviations of the desired lay-up course can be detected online. Therefore, coursespecific threshold values are constantly compared with the
actual tow position, so that the machine operator can interNo104 April - May 2016 /

jec composites magazine 45



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016

Cover
Edito
Point of view: Thailand smiles at composites
Contents
COMPANY & BUSINESS
Agenda of Events
APPLICATIONS
Cycle
Multisectorial
Music
MARKET
Trend
Carbon
SPECIAL JEC AMERICAS 2016
Conferences
Awards
Oil & Gas
Redevelopment
Laboratory
RESEARCH & DEVELOPMENT
Self healing
Fibre placement
Microwave
TECHNOLOGY & INNOVATIONS
LFT
Intermediate products
Multimaterial
Manufacturing
Process
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Cover
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 2
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Edito
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Point of view: Thailand smiles at composites
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 5
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Contents
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 7
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - COMPANY & BUSINESS
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 9
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Ad1
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Ad2
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 11
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Cycle
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 13
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Multisectorial
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 15
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Music
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 17
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Trend
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 19
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 20
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 21
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Carbon
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 23
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 24
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 25
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Conferences
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 27
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 28
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Awards
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 30
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 31
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 32
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 33
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Oil & Gas
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 35
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Redevelopment
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 37
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Laboratory
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 39
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 40
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Self healing
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 42
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 43
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Fibre placement
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 45
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 46
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Microwave
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 48
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 49
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 50
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - LFT
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 52
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Intermediate products
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 54
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Multimaterial
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 56
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 57
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 58
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Manufacturing
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 60
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Process
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 62
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 63
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 64
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - Index
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - In the world
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 67
JEC COMPOSITES MAGAZINE - Issue #104 - April/May 2016 - 68
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