Inline Quality Control of Filament Wound Composite Overwrapped Pressure Vessels

The growing demand for efficient hydrogen storage solutions highlights the need for reliable and safe composite overwrapped pressure vessels (COPVs). This study investigates the application of an inline monitoring system combining laser-based measurements and photogrammetric line photography to assess COPV quality during fabrication, including quantitative evaluation of liner concentricity and high-resolution line scanning of the composite surface to detect and measure fiber orientations. Fiber detection and angle measurement using the Hough Transform provide detailed assessment of local winding orientation, while global Fourier Transform analysis supports comparative evaluation across vessels or segments, allowing identification of dominant fiber directions and detection of micro-scale deviations. The integrated approach enables early detection of geometric inconsistencies and localized winding irregularities, providing robust performance-based criteria for accept-reject decisions, while filtering out minor noise and ensuring reliable quantitative evaluation. This framework enhances inline quality control, optimizes material usage, and supports the safe deployment of COPVs in hydrogen storage systems, contributing to efficient and reliable energy storage solutions.