Fiber handling system with fuzz detection

Abstract

An unwinding system includes a detector assembly configured to detect a position of a fiber unwound from a bobbin and the presence of fuzz. The system further includes a controller configured to adjust at least one of a lateral position or a rotational speed of the bobbin based on at least one of the position of the fiber tow or the presence of fuzz.

What is claimed is: 
     
         1 . An unwinding system for unwinding a fiber from a bobbin, the unwinding system comprising:
 a detector assembly configured to detect both a position of a fiber tow including a multifilament ceramic fiber suitable for forming a ceramic matrix composite and a presence of fuzz on or adjacent to the fiber tow; and   a controller configured to adjust at least one of a lateral position or a rotational speed of the bobbin based on at least one of the position of the fiber tow or the presence of fuzz.   
     
     
         2 . The unwinding system according to  claim 1 , wherein the detector assembly includes an imaging sensor and a light source. 
     
     
         3 . The unwinding system according to  claim 2 , wherein the fiber tow is disposed between the light source and the imaging sensor. 
     
     
         4 . The unwinding system according to  claim 2 , wherein the controller is configured to operate the detector assembly in a tow position detection phase and a fuzz detection phase. 
     
     
         5 . The unwinding system according to  claim 4 , wherein the controller is configured to switch between the tow position detection phase and the fuzz detection phase on a periodic basis. 
     
     
         6 . The unwinding system according to  claim 4 , wherein during the fuzz detection phase, the controller is configured to count a number of fuzz elements. 
     
     
         7 . The unwinding system according to  claim 4 , wherein the controller is configured to adjust at least one operational parameter of the imaging sensor or the light source. 
     
     
         8 . The unwinding system according to  claim 4 , wherein the controller is further configured to adjust at least one of a pixel value or an exposure of the imaging sensor. 
     
     
         9 . The unwinding system according to  claim 4 , wherein the controller is further configured to adjust an intensity of the light source. 
     
     
         10 . The unwinding system according to  claim 4 , wherein the controller includes:
 a first controller positioned on the detector assembly, the first controller configured to at least one of: operate the detector assembly in a tow position detection phase and a fuzz detection phase, switch between the tow position detection phase and the fuzz detection phase on a periodic basis, adjust at least one of a pixel value or an exposure of the imaging sensor, or adjust an intensity of the light source; and   a second controller associated with a motor and configured to control the motor to adjust at least one of the lateral position of the bobbin or the rotational speed of the bobbin.   
     
     
         11 . A method for unwinding a fiber from a bobbin, the method comprising:
 unwinding a fiber from a bobbin defining a first axis, the fiber extending from the bobbin along a second axis different from the first axis;   passing the fiber through a detector assembly disposed along the second axis and configured to detect a position of the fiber tow and a presence of fuzz;   providing a value relating to the position of the fiber tow and the presence of fuzz to a controller; and   adjusting at least one of a lateral position or a rotational speed of the bobbin based on at least one of the position of the fiber tow or the presence of fuzz value.   
     
     
         12 . The method according to  claim 11 , further comprising:
 illuminating the fiber by a light source of the detector assembly; and   imaging the fiber at an imaging sensor of the detector assembly.   
     
     
         13 . The method according to  claim 12 , further comprising operating the detector assembly in a tow position detection phase and a fuzz detection phase. 
     
     
         14 . The method according to  claim 13 , further comprising switching the detector assembly between the tow position detection phase and the fuzz detection phase on a periodic basis. 
     
     
         15 . The method according to  claim 14 , further comprising:
 counting a number of fuzz elements during the fuzz detection phase.   
     
     
         16 . The method according to  claim 15 , further comprising:
 adjusting at least one operational parameter of the imaging sensor or the light source.   
     
     
         17 . The method according to  claim 16 , wherein adjusting at least one operational parameter includes adjusting at least one of a pixel value or an exposure of the imaging sensor. 
     
     
         18 . The method according to  claim 16 , wherein adjusting at least one operational parameter includes adjusting an intensity of the light source. 
     
     
         19 . A method for unwinding a fiber from a bobbin, the method comprising:
 unwinding a fiber from a bobbin defining a first axis, the fiber extending from the bobbin along a second axis different from the first axis;   passing the fiber through a detector assembly disposed along the second axis;   operating the detector assembly in a tow position detection phase to determine position of the fiber;   adjusting at least one of a lateral position or a rotational speed of the bobbin based on the position of the fiber;   operating the detector assembly in a fuzz detection phase to determine a presence of fuzz value;   adjusting at least one of the lateral position or the rotational speed of the bobbin based on the presence of fuzz value; and   switching operation of the detector assembly between the tow position detection phase and the fuzz detection phase.   
     
     
         20 . An apparatus for treating a fiber to be formed into a ceramic matrix composite, the apparatus comprising:
 a vacuum chamber having positioned therein:
 a bobbin; and 
 a detector assembly having a radiation source and a sensor assembly and configured to receive a fiber unwound from the bobbin between the radiation source and the sensor assembly, the detector assembly configured to detect both a position of the fiber and a presence of fuzz on or adjacent to the fiber; 
   one or more motors configured to adjust a lateral position of the bobbin within the vacuum chamber or a rotational speed of the bobbin; and   a controller configured to adjust at least one of the lateral position of the bobbin or a rotational speed of the bobbin based on at least one of the detected position of the fiber or the detected presence of fuzz.