Systems and method for identifying foreign objects and debris (FOD) and defects during fabrication of a composite structure

A system for identifying defects and foreign objects and debris during fabrication of a composite structure, the system comprising:

• at least one light source positioned to emit light for illuminating a portion of the composite structure with bright field illumination and another portion of the composite structure with dark field illumination, the bright field illumination being reflected differently by defects in the composite structure than from portions of the composite structure that are defect free, the dark field illumination being reflected differently by foreign objects and debris on the composite structure than from surfaces of the composite structure not having foreign objects and debris thereon;
• at least one camera for receiving images of the illuminated portions of the composite structure;
• wherein the camera and the light source are mounted on a head unit of a fiber placement machine;
• wherein the camera receives real-time images of the illuminated portions of the composite structure as the head unit moves across the composite structure.

A system for identifying defects and foreign objects and debris during fabrication of a composite structure, the system comprising:

• at least one light source positioned to emit light for illuminating a portion of the composite structure with bright field illumination and another portion of the composite structure with dark field illumination, the bright field illumination being reflected differently by defects in the composite structure than from portions of the composite structure that are defect free, the dark field illumination being reflected differently by foreign objects and debris on the composite structure than from surfaces of the composite structure not having foreign objects and debris thereon;
• at least one camera for receiving images of the illuminated portions of the composite structure;
• at least one reflective surface proximate the composite structure such that the camera receives the images of the illuminated portions following reflection of the images from the reflective surface;
• wherein the reflective surface and the light source are proximate a compaction roller of a fiber placement machine.

A system for identifying defects and foreign objects and debris during fabrication of a composite structure, the system comprising:

• at least one light source positioned to emit light for illuminating a portion of the composite structure with bright field illumination and another portion of the composite structure with dark field illumination, the bright field illumination being reflected differently by defects in the composite structure than from portions of the composite structure that are defect free, the dark field illumination being reflected differently by foreign objects and debris on the composite structure than from surfaces of the composite structure not having foreign objects and debris thereon:
• at least one camera for receiving images of the illuminated portions of the composite structure;
• a light reflection element proximate the light source to redirect light from the light source towards the composite structure;
• wherein the light reflection element comprises a plurality of reflective parabolic curved surfaces in a stepped configuration.

A method for identifying defects and foreign objects and debris during fabrication of a composite structure, the method comprising:

• illuminating a portion of the composite structure with bright field illumination that is reflected differently by defects in the composite structure than from portions of the composite structure that are defect free;
• illuminating another portion of the composite structure with dark field illumination that is reflected differently by foreign objects and debris on the composite structure than from surfaces of the composite structure not having foreign objects and debris thereon;
• acquiring an image of the illuminated portions of the composite structure;
• analyzing the image to identify defects in the portion of the composite structure illuminated by the bright field illumination;
• analyzing the image to identify foreign objects and debris on the another portion of the composite structure illuminated by the dark field illumination;
• and
• positioning at least one light source to emit light for illuminating the portion of the composite structure with bright field illumination while also illuminating the another portion of the composite structure with dark field illumination.