In the aerospace industry, the Automated Fiber Placement process is an established method for producing composite parts. Nowadays the required visual inspection, subsequent to this process, typically takes up to 50% of the total manufacturing time and the inspection quality strongly depends on the inspector. A Deep Learning based classification of manufacturing defects is a possibility to improve the process efficiency and accuracy. However, these techniques require several hundreds or thousands of training data samples. Acquiring this huge amount of data is difficult and time consuming in a real world manufacturing process. Thus, an approach for augmenting a smaller number of defect images for the training of a neural network classifier is presented. Five traditional methods and eight deep learning approaches are theoretically assessed according to the literature. The selected conditional Deep Convolutional Generative Adversarial Network and Geometrical Transformation techniques are investigated in detail, with regard to the diversity and realism of the synthetic images. Between 22 and 166 laser line scan sensor images per defect class from six common fiber placement inspection cases are utilised for tests. The GAN-Train GAN-Test method was applied for the validation. The studies demonstrated that a conditional Deep Convolutional Generative Adversarial Network combined with a previous Geometrical Transformation is well suited to generate a large realistic data set from less than 50 actual input images. The presented network architecture and the associated training weights can serve as a basis for applying the demonstrated approach to other fibre layup inspection images.@en

The aerospace industry has established the Automated Fiber Placement process as a common technique for manufacturing fibre reinforced components. In this process multiple composite tows are placed simultaneously onto a tool. Currently in such processes manual testing requires often up to 50% of the manufacturing duration. Moreover, the accuracy of quality assurance varies significantly with the inspector in charge. Thus, inspection automation provides an effective way to increase efficiency. However, to achieve a proper inspection performance, the segmentation of layup defects need to be examined. In order to improve such defect detection systems, this paper performs a comprehensive ranking of segmentation techniques. Thus, 29 statistical, spectral and structural algorithms from related work were evaluated based on nine substantial criteria as assessed from literature and process requirements. For reasons of determinism and easy technology transferability without the need of much training data, the development of new Machine Learning algorithms is not part of this paper. Afterwards, seven of the most auspicious algorithms were studied experimentally. Therefore, laser line scan sensor depth maps from fibre placement defects were utilised. Furthermore noisy images were generated and applied for testing algorithm robustness. The test data contained five defect categories with 50 samples per class. It was concluded that Adaptive Thresholding and Cell Wise Standard Deviation Thresholding work best yielding detection accuracies mostly > 97 %. Noteworthy is that influenced input data can affect the detection results. Feasible algorithms with sensible parameter settings were able to perform reliable defect segmentation for layed material.@en

Automated Fibre Placement is a common manufacturing technique for composite parts in the aero-space industry. Therefore, a visual part inspection is required which often covers up to 50% of the actual production time. Moreover, the inspection quality of this manual step fluctuates significantly. A camera-based automated inline inspection is capable of increasing the inspection efficiency and accuracy. However, the interpretability of the acquired data strongly depends on the sensor configuration and the inspected material. Thus, this paper introduces methods for modelling and assessing an imaging sensor on the example of a composite material reflecting a spot laser to a camera sensor. In this context, the reflection properties of the material are incorporated into a simulation and validated in comparison to real camera images from the experimental setup. The EMVA 1288 sensor model in combination with the Cramér–Rao lower bound indicates a feasible estimability of the beam propagation, but shows limitations in the predictability of the number of incident photons. The laser spot analysis indicated that the laser spot can deviate from an exact oval shape but its peak value is suitable for robust spot identification in an image. The outlined methodology is also adaptable to other imaging sensors, illumination sources and materials. Thus, the findings can be useful for other fields and manufacturing processes.@en

Automated fibre layup techniques are commonly used composite manufacturing processes in the aviation sector and require a manual visual inspection. Neural Network classification of defects has the potential to automate this visual inspection, however, the machine decision-making processes are hard to verify. Thus, we present an approach for visualising Convolutional Neural Network (CNN) based classifications of manufacturing defects and quantifying its robustness. Our investigations have shown that especially Smoothed Integrated Gradients and DeepSHAP are particularly well suited for the visualisation of CNN classifications. The Smoothed Integrated Gradients technique also reveals advantages in robustness when evaluating degraded input images. @en

In the aerospace industry, automated fibre laying processes are often applied for economical composite part fabrication. Unfortunately, the current mandatory visual quality assurance process takes up to 50% of the entire manufacturing time. An automised classification of manufacturing deviations using Neural Networks potentially improves the inspection's effectiveness. Unfortunately, the automated decision-making procedures of machine learning approaches are challenging to trace. Therefore, we introduce an approach for evaluating the classifiers response for this use case. For this purpose, we present a parallel classification approach of Convolutional Neural Network (CNN) and Support Vector Machine (SVM) with suitable intermediate checking stages between both classification processes. The particular novelty of this study is this intermediate comparison to trace the behaviour of the two classifiers along their image processing chains and to project the results back to the input image. With respect to the SVM, we analyse their extracted input features via t-Distributed Stochastic Neighbor Embedding calculations and parallel coordinates plots. Moreover, the classification score of the SVM as well as the feature vector distances within the SVM are investigated. For the CNN, the outputs of its first joined convolutional layer are correlated with the raw input images of different classes using Structural Similarity Index Measure metrics. Additionally, also the CNN's classification rates are analysed. Accordingly, a suitable uncertainty confidence interval for the CNN is determined on the bases of its neural activations. Finally, the relevance of individual pixels for the CNN decision is determined through Smooth Integrated Gradients and linked to the manually extracted image features for the SVM Classifier. The results of this paper are particularly valuable for developers and users of visual inspection systems in safety-critical domains.@en

Automated fibre layup techniques are widely used in the aviation sector for the efficient production of composite components. However, the required manual inspection can take up to 50 % of the manufacturing time. The automated classification of fibre layup defects with Neural Networks potentially increases the inspection efficiency. However, the machine decision-making processes of such classifiers are difficult to verify. Hence, we present an approach for analysing the classification procedure of fibre layup defects. Therefore, we comprehensively evaluate 20 Explainable Artificial Intelligence methods from the literature. Accordingly, the techniques Smoothed Integrated Gradients, Guided Gradient Class Activation Mapping and DeepSHAP are applied to a Convolutional Neural Network classifier. These methods analyse the neural activations and robustness of a classifier for an unknown and manipulated input data. Our investigations show that especially Smoothed Integrated Gradients and DeepSHAP are well suited for the visualisation of such classifications. Additionally, maximum-sensitivity and infidelity calculations confirm this behaviour. In future, customers and developers could apply the presented methods for the certification of their inspection systems.@en

The demand for efficient composite production processes is growing as the proportion of composites in modern aircraft increases. Particularly, thermoplastic composites are interesting for sustainability and cost efficiency. They can be manufactured using deposition methods, which involve heating by radiation in the visible and near-infrared spectra. A Xenon flashlamp is a commonly used for manufacturing. In-line inspection can be performed using thermographic cameras which measure infrared radiation. For those, the composite's angle-dependent reflection and emission behaviour is interesting. Accordingly, the relationships between angle and temperature dependent visible/near-infrared reflectivity and thermal infrared emissivity is investigated and composite's conductivity properties are derived. The link between the material's optical and electromagnetic properties is estimated through the Brewster angle derived from Fresnel fitting, which allows the prediction of the directional electrical and thermal conductivity by non-contact measurement. The findings from this study will be valuable for users of Xenon heating and thermographic measurement systems.@en

In modern aircraft, structural lightweight composite components are increasingly used. To manufacture these components in a costeffective way, robust production systems for the manufacturing of complex fibre composite components are necessary. A rather novel but already established process for fibre material deposition is the Automated Fibre Placement (AFP) technology, which automatically places several narrow, parallel fibre tows on a mould. Typically, a component consists of several, often hundreds of stacked layers of these fibre material strips. However, when these narrow fibre tows are placed in position, layup defects can occur and reduce the mechanical properties of the component. Hence, in safety critical applications, such as aircraft manufacturing, a visual inspection of every single ply is mandatory. This inspection step is currently carried out by an expert via a visual examination, which requires up to 50 % of the total production time. An automation of this inspection process using suitable algorithms offers great potential for increasing process efficiency. However, with the growing complexity of these respective defect analysis algorithms, their performance potentially increases, but the comprehensibility of the machine decision and the behaviour of the algorithm become more challenging. This is problematic especially in safety critical applications. In addition, the data quality of recorded images is influenced by the very matte, low reflective Carbon Fibre Reinforced Plastic (CFRP) material which raises the uncertainty of an inspection.... @en

Automated fibre layup techniques are often applied for the production of complex structural components. In order to ensure a sufficient component quality, a subsequent visual inspection is necessary, especially in the aerospace industry. The use of automated optical inspection systems can reduce the inspection effort by up to 50 %. Laser line scan sensors, which capture the topology of the surface, are particularly advantageous for this purpose. These sensors project a laser beam at an angle onto the surface and detect its position via a camera. The optical properties of the observed surface potentially have a great influence on the quality of the recorded data. This is especially relevant for dark or highly scattering materials such as Carbon Fiber Reinforced Plastics (CFRP). For this reason, in this study we investigate the optical reflection and transmission properties of the commonly used Hexel HexPly 8552 IM7 prepreg CFRP in detail. Therefore, we utilise a Gonioreflectometer to investigate such optical characteristics of the material with respect to different fibre orientations, illumination directions and detection angles. In this way, specific scattering information of the material in the hemispherical space are recorded. The major novelty of this research are the findings about the scattering behaviour of the fibre composite material which can be used as a more precise input for the methods of image data quality assessment from our previous research and thus is particularly valuable for developers and users of camera based inspection systems for CFRP components.@en

The Automated Fiber Placement process is established in the aerospace industry for the production of composite components. This technique places several narrow material strips in parallel. Within current industrial Automated Fiber Placement processes the visual inspection takes typically up to 50% of overall production time. Furthermore, inspection quality highly depends on the inspector. Therefore, automation of visual inspection offers a great improvement potential. To ensure reliable defect detection the segmentation of individual defects must be investigated. For this reason, this paper focusses on an assessment of defect segmentation algorithms. Therefore, 29 structural, statistical and spectral algorithms from related work were assessed, theoretically, using the 12 most relevant criteria as assessed from literature and process requirements. Then, seven most auspicious algorithms were analysed in detail. For reasons of determinism, Neural Network approaches are not part of this paper. Manually labelled prepreg defect images from a laser line scan sensor were used for tests. The test samples contain five defect types with 50 samples of each. Additionally, layups without defects were analysed. It was concluded that Adaptive Thresholding works best for global defect segmentation. The Cell Wise Standard Deviation Thresholding performs also quite well, but is very sensitive to grid size. Feasible algorithms perform reliable defect segmentation for layed up material.@en