Verification of tow cut for automatic fiber placement

For use with an automatic fiber placement machine, a method of monitoring the operation of cutters used to automatically cut fiber tows to length, comprising:

• recording an image of at least a portion of a row of tows placed by the machine;
• recording the point in time when each of cutters is actuated to cut the tows to length during placement of the tows;
• using the recorded image to detect whether an inconsistency exists in the placement of a tow;
• and,
• determining whether a cutter is responsible for the detected inconsistency by correlating the recorded point in time with the detected inconsistency.

A system for monitoring the operation of cutters used to cut tows to length in a fiber placement machine, comprising:

• image recording means for recording images of tows placed by the machine;
• means for detecting inconsistencies in the placement of tows using the recorded images;
• and,
• means for correlating inconsistencies with the operation of the cutters.

A system for monitoring the operation of cutters used to cut tows to length in an automated fiber placement machine, comprising:

• a device for detecting the actuation of each of the cutters and for generating timing signals respectively representing the actuation of the cutters;
• a controller for receiving and encoding the timing signals;
• a time delay device for delaying the delivery of the timing signals from the detection device to the controller;
• an illumination system for illuminating tows that have been placed;
• a recording system for recording images of the illuminated tows;
• a programmed computer, including an image analysis program for analyzing the recorded images and for detecting inconsistencies in the placed tows, the programmed computer being operable for correlating detected inconsistencies in paced tows with the operation of the cutters used to cut the tows having the inconsistencies;
• and
• a display for visually displaying placed tows having inconsistencies with a correlated indication of cutter operating status.

A method of monitoring the operation of cutters used to cut fiber tows to length in an automatic fiber placement machine, comprising:

• illuminating rows of tows placed by the machine;
• recording images of the illuminated tows;
• detecting when each of the cutters is actuated to cut a tow;
• generating timing signals respectively representing the points in time when the cutters are actuated;
• detecting inconsistencies in the placement of tows using the recorded images, including measuring features in the recorded images that may represent an inconsistency, and comparing the results of the feature measurement with a set of reference standards;
• correlating the detected inconsistencies with the actuation of the cutters using the generated timing signals;
• visually displaying the recorded image;
• and, visually displaying the operational status of each of the cutters respectively adjacent the tows in the displayed image.