Uncertainty Evaluation in Vision-Based Techniques for the Surface Analysis of Composite Material Components

In this paper, a methodology is discussed concerning the measurement of yarn's angle of two different glass-reinforced polypropylene matrix materials, widely used in the production of automotive components. The measurement method is based on a vision system and image processing techniques for edge detection. Measurements of angles enable, if accurate, both useful suggestions for process optimization to be made, and the reliable validation of the simulation results of the thermoplastic process. Therefore, uncertainty evaluation of angle measurement is a mandatory pre-requisite. If the image acquisition and processing is considered, many aspects influence the whole accuracy of the method; the most important have been identified and their effects evaluated with reference to two different materials, which present different optical-type characteristics. The influence of piece geometry has also been taken into account, carrying out measurements on flat sheets and on a semi-spherical object, which is a reference standard shape, to verify the effect of thermoforming and to tune the process parameters. Complete uncertainty in the order of a few degrees has been obtained, which is satisfactory for purposes of simulation validation and consequent process optimization. The uncertainty budget also allowed individuation of the most relevant causes of uncertainty for measurement process improvement.