Handheld multi-sensor device for detecting vehicle paint quality, recoating, dents, corrosion, and estimating the relative age of damage.

Abstract

Handheld multi-sensor diagnostic device for non-destructive testing of vehicle body surfaces, including: • a handheld device; • an infrared sensor module configured to detect fluctuations in thermal emissivity; • a paint thickness measurement module configured to measure coating thickness; • a surface deformation detection module configured to detect dents and geometric irregularities; • a corrosion detection module configured to identify oxidation features; • an electronic processing unit configured to receive and analyze measurement data from the sensor modules; • a display interface configured to show diagnostic results; wherein the processing unit performs a sensor fusion analysis to produce a consolidated assessment of repainting, dent severity, presence of corrosion, and relative age of damage.

Description

SCOPE OF THE INVENTION

[0001] The present invention relates to a portable handheld diagnostic device designed for the real-time inspection and analytical evaluation of coated vehicle body parts. The system integrates several sensor technologies into a single compact housing to detect repainting, coating irregularities, dents, corrosion, and material wear characteristics.

[0002] The device uses a combination of infrared sensors, layer thickness measurement, geometric deformation detection and corrosion analysis modules to create a comprehensive non-destructive diagnostic assessment of vehicle surfaces.

[0003] The system is particularly suitable for use in vehicle inspection, including the verification of insurance claims, the inspection of used vehicles, the maintenance of vehicle fleets, accident investigation, the verification of vehicle repairs and forensic vehicle assessment.

[0004] The device operates as a compact, self-contained unit capable of performing multi-parameter testing under field conditions without the need for complex laboratory equipment, thus enabling objective and reproducible test results. BACKGROUND

[0005] Conventional vehicle inspection procedures are primarily based on visual observations and manual tactile assessments by technicians or inspectors. While such methods can detect obvious physical damage, they often fail to uncover repairs, subsurface fillers, early-stage corrosion, or repainting that closely resembles the original factory finish.

[0006] In current practice, inspectors often rely on single-function instruments such as paint thickness gauges. While these instruments provide quantitative measurements of coating thickness, they do not offer a comprehensive diagnosis of structural deformations, corrosion, or thermal behavior of the surface.

[0007] Furthermore, filler materials used to repair dents can go undetected if only the thickness is measured. Similarly, corrosion under intact paint layers may not be visible from the outside until the damage is already severe.

[0008] Disputes often arise in insurance claims or vehicle sales when it needs to be determined whether damage is new or pre-existing. Existing inspection methods lack reliable analytical tools to estimate the relative age of damage based on measurable material wear indicators.

[0009] Current diagnostic solutions are fragmented and require multiple instruments and manual evaluation, which can lead to inconsistent reports and an increased risk of fraud.

[0010] Accordingly, there is a need for a compact handheld testing device that can integrate multiple sensor technologies into a single device to perform a comprehensive non-destructive assessment of the condition of vehicle surfaces. SUMMARY OF THE INVENTION

[0011] The present invention relates to a handheld multi-sensor diagnostic device designed for the integrated non-destructive analysis of coated vehicle body parts.

[0012] The device includes an ergonomic handheld housing containing several sensor modules, including an infrared sensor unit, a paint thickness measurement unit, a surface deformation detection module, and a corrosion detection module.

[0013] The measurement signals generated by the sensor modules are transmitted to an embedded electronic processing unit, which performs signal conditioning, data correlation and sensor fusion analysis.

[0014] By integrating thermal, material-related, and geometric measurement data, the device provides a consolidated diagnostic output that can identify repainting, classify dents and surface irregularities, detect corrosion, and estimate the relative age of damage based on material wear patterns.

[0015] The diagnostic results are displayed via an integrated display interface, and the inspection records can optionally be stored internally or transferred to external systems for documentation and reporting.

[0016] The device enables fast, mobile and objective vehicle surface inspection, suitable for technical, commercial and forensic applications. DETAILED DESCRIPTION

[0017] The portable multi-sensor diagnostic device includes several integrated sensor and processing components housed in a compact enclosure designed for stable one-handed operation.

[0018] The housing is preferably made of impact-resistant polymer or composite material that can withstand the demands of workshops, on-site inspections and outdoor use.

[0019] In the lower part of the housing there is a sensor interface window through which the sensor modules can interact directly with the vehicle body surface by means of contact or controlled proximity measurement.

[0020] Internal mounting structures ensure that all sensor modules remain securely aligned to guarantee the consistency and accuracy of measurements. 1. Main Components • Infrared Sensor Module

[0021] The infrared sensor module is configured to detect fluctuations in the thermal emissivity and heat dissipation properties of the surface under investigation.

[0022] The module can include the following: • A pair of infrared transmitters and receivers or • A passive infrared heat sensor array.

[0023] When the module is positioned near the vehicle body surface, it detects differences in the thermal response between factory coatings, repainting, fillers and corroded metal.

[0024] Subsurface fillers and corrosion sites create characteristic heat absorption and reflection properties, which are detected and converted into electrical signals. • Module for measuring paint thickness

[0025] The paint thickness measurement module measures the coating thickness using one or more of the following measurement principles: • Magnetic induction for ferromagnetic substrates • Eddy current measurement for non-ferromagnetic metallic substrates • Ultrasonic measurement for multi-layer coating systems

[0026] The module generates quantitative thickness measurements, which are transmitted to the electronic processing unit. The system compares the measured values ​​with stored reference ranges that correspond to the factory coating standards.

[0027] Significant deviations from the reference ranges indicate repainting, the application of filler, or abnormal coating buildup. • Module for detecting surface deformations

[0028] The surface deformation detection module evaluates geometric irregularities such as dents, scratches, and surface distortions.

[0029] In one embodiment, the module uses: • Laser profilometry or • Structured light projection.

[0030] A projected optical beam or a structured pattern is reflected from the vehicle surface and detected by an optical sensor. The reflected signal is processed to determine curvature deviations, depth variations, and distortion gradients.

[0031] The module generates digital geometric parameters, including buckling depth, curvature deviation, and degree of deformation. Corrosion detection module

[0032] The corrosion detection module identifies oxidation-related changes in surface or substrate materials.

[0033] The module analyzes: • Changes in spectral reflectivity • Variations in infrared sensitivity • Differences in electrical conductivity associated with oxidation

[0034] Corroded metal surfaces exhibit altered optical and electrical behavior compared to intact coated metal surfaces.

[0035] Signals corresponding to the oxidation intensity and the propagation patterns are transmitted to the processing unit for evaluation. • Electronic processing and sensor fusion unit

[0036] All sensor modules are connected to an embedded electronic processing unit, which includes the following: • Microcontroller or System-on-Chip (SoC) • Analog-to-digital converter • Signal conditioning circuits • Embedded firmware for implementing sensor fusion algorithms

[0037] The processing unit performs the following operations: 1. Acquisition of raw signals from all sensor modules 2. Noise filtering and signal normalization 3. Correlation of thermal, thickness-related, geometric and corrosion data 4. Multisensor fusion analysis 5. Diagnostic Classification

[0038] This integrated analysis improves diagnostic accuracy and reduces false alarms. Display and user interface

[0039] The device has a display interface for showing the inspection results.

[0040] The parameters displayed may include: • Measurements of paint thickness • Classification of the severity of bumps • Corrosion detection indicators • Warning messages for identifying repainting • Relative category of damage age

[0041] If the measured values ​​exceed predefined thresholds, visual or audible warning messages can be issued. • Data storage and communication interface (optional)

[0042] In certain embodiments, the device may include the following: • Internal memory for storing inspection records • Storage of scan data with timestamp • Communication interfaces such as USB, Bluetooth or wireless connectivity

[0043] These functions enable the transfer of inspection data to external systems for reporting or documentation. • Power supply system

[0044] The device is powered by a rechargeable lithium-ion battery integrated into the housing.

[0045] A battery management system regulates the charging cycles, voltage stabilization and thermal protection to ensure reliable operation in the field. 2. Functionality

[0046] The handheld device operates according to the following test procedure: 1. The operator positions the device near the vehicle body. 2. Infrared sensors measure thermal emission fluctuations. 3. The paint thickness modulus measures the coating thickness. 4. The surface deformation module scans geometric contour profiles. 5. The corrosion detection module evaluates oxidation indicators. 6. The raw signals from all sensors are transmitted to the processing unit. 7. The processing unit performs filtering, normalization, and sensor fusion. 8. Diagnostic algorithms determine the presence of repainting, the classification of dents, the corrosion condition, and the relative damage condition. 9. The results are displayed via the user interface. 10. The inspection records can optionally be saved or transferred.

Claims

Handheld multi-sensor diagnostic device for non-destructive testing of vehicle body surfaces, comprising: • a handheld housing; • an infrared sensor module configured to detect variations in thermal emissivity; • a paint thickness measurement module configured to measure coating thickness; • a surface deformation detection module configured to detect dents and geometric irregularities; • a corrosion detection module configured to identify oxidation features; • an electronic processing unit configured to receive and analyze measurement data from the sensor modules; • a display interface configured to display diagnostic results;the processing unit performs a sensor fusion analysis to create a consolidated assessment of the repainting, the severity of the dents, the presence of corrosion, and the relative age of the damage. Device according to claim 1, wherein the housing comprises an impact-resistant polymer structure with a sensor window configured for surface contact or proximity measurements. Device according to claim 1, wherein the infrared sensor module comprises an infrared transmitter and receiver pair or a passive infrared sensor array. Device according to claim 1, wherein the paint thickness modulus operates using a magnetic induction measurement. Device according to claim 1, wherein the paint thickness modulus operates using an eddy current measurement. Device according to claim 1, wherein the paint thickness module comprises an ultrasonic measuring system for analyzing multilayer coatings. Device according to claim 1, wherein the module for detecting surface deformations comprises a laser profilometry system or a structured light projection system. Device according to claim 1, wherein the corrosion detection module analyzes spectral reflectivity, infrared sensitivity or changes in electrical conductivity that indicate oxidation. Device according to claim 1, wherein the electronic processing unit performs a correlation of the data from multiple sensors to improve diagnostic reliability. Device according to claim 1, further comprising an internal storage unit configured to store inspection records. Device according to claim 1, further comprising a communication interface comprising USB, Bluetooth or wireless communication. Device according to claim 1, wherein the device comprises a rechargeable lithium-ion battery and a battery management system.