| The data for the computer generated
drawings of the plies that are displayed correctly in place,
may originate from virtually any CAD application, or from
Anaglyph's
Laminate Tools
software application, for additional features. Laminate
Tools is a powerful design tool for composite material
structures, and includes industry-leading draping simulation
capabilities for ply definition. In this way, ply
information comes directly from design and may not require
any translation or manipulation whatsoever, for use with the
present system.
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The position and direction of the digital
camera in space requires a Coordinate-Measuring Machine
(CMM) system of high-specification. Following trials with
several potential methods and systems, a
commercially-available solution was adopted to provide
coordinates very accurately and at the necessary high rate.
This CMM, as supplied with PlyMatch, can be used totally
independently to ply placement, for unrelated coordinate
measurement tasks, using a wireless probe, thus offering
added value to this investment. |
| The digital camera coordinates and the
live video image from the camera are both fed continuously
to a computer, via suitable interfaces. By using the digital
camera coordinates, the supplied Placement software
application (or the Laminate Tools software application
where available) draws the computer-generated image of the
fabric ply to be stacked next in sequence, in a way that it
matches the image of the "real world" as seen through the
camera. The computer-generated image of the ply is drawn
superimposed onto the live video image from the camera,
giving a virtual-reality compound picture (also known as "augmented
reality"). The operator observes the computer screen and
aligns the actual ply with its image as drawn by the
software. |
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Note that the camera can be moved at all
times, ensuring the best viewpoint for the operator,
matching his/her angle of view, and observing the component
from all directions. As the camera is moved, the
coordinate-measurement system continuously updates the
camera's position to the computer software so that the
computer-drawn image follows the changes in the video image.
If necessary, a complete video recording of the layup
operation may be obtained on hard disk, showing any possible
deviations from nominal ply position, or even fibre
orientation. Also note that the system can potentially be
used to locate any manufacturing or assembly-sequence
feature, such as bolt holes or labels. |
PlyMatch vs. Laser Projection
The advantages of
PlyMatch over laser projection systems are the following:
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portable system
-
mould can be moved at
all times
-
better for small
parts or small plies
-
better for highly
curved parts whose surface is not fully visible from one
direction
-
can look inside
cavities (eg. a conical surface)
-
can be used directly
from the design software (Laminate Tools)
-
any CAD info can be
included in the display (dxf curves)
-
low cost to buy
-
"zero" cost to
maintain
-
can display full
draping information, splits, etc., not just the outline.
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room for
customisation (more sensors, wireless probes, display hardware)
-
process can be
recorded to hard disk for quality control
-
low
cost to buy
-
"zero" cost to maintain.
The PlyMatchâ„¢
System is available in flexible configurations to suit the
requirements of every end-user. As a minimum, it includes:
-
PC with suitable display,
-
Placement software,
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Laminate Tools software extensions for video and probe
interfaces and image blending,
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Digital
camera with boom stand,
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Coordinate
Measuring Machine
with wireless and tool reference probes,
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On-site
training.
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