3D Scan-Based Structural Life Assessment for In-Service Surfaces
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Solution Overview
Problem
The current structural inspection and maintenance process for aircraft components is time-consuming and inefficient, as it relies on manual measurements and limited reuse of complex analysis, which hinders the determination of serviceability and remaining life.
Innovation Solution
A system that uses three-dimensional scan data to generate in-service CAD data, allowing for the determination of serviceability and remaining life by comparing scanned surfaces to nominal CAD data, with options to modify nominal volumes by adding or removing trim volumes, and performing strength analysis such as finite element analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurements and hand inspection methods are used, then measurement accuracy can be maintained, but inspection time and complexity increase significantly
Solution Approach 1:
The patent replaces manual mechanical measurement tools (calipers, micrometers, hull gauges) with an automated 3D scanning system that captures complete surface geometry data. The scanning device optically scans the component and generates 3D scan data, which is then processed by a server to create in-service CAD data for comparison with nominal designs, eliminating time-consuming manual measurement while maintaining accuracy through automated surface deviation analysis.
Solution Approach 2:
The patent transforms the inspection approach by changing from discrete point measurements to comprehensive 3D surface parameter analysis. The system captures complete surface geometry and compares it against nominal CAD models to identify deviations, enabling simultaneous assessment of multiple parameters (shape, position, dimensions) across the entire component surface rather than isolated measurement points.
2Reliability
If complex structural analysis is performed manually by engineers, then analysis accuracy can be ensured, but the analysis process becomes time-consuming and reusable analysis is minimized
Solution Approach 1:
The patent implements an automated analysis system where the server performs structural integrity assessment, strength analysis, and serviceability determination autonomously. The system automatically processes 3D scan data, generates in-service CAD data, compares it with nominal designs, and produces analysis results without requiring manual engineer intervention for each component, thereby increasing productivity while maintaining consistent analysis quality through standardized algorithms.
Solution Approach 2:
The patent performs preliminary automated analysis by comparing in-service CAD data against nominal design data and predetermined serviceability criteria before human review. The system pre-identifies potential issues, calculates deviations, and prepares analysis results in advance, allowing engineers to focus on complex cases rather than performing complete analysis manually for every component.
3Measurement precision
If complete structural analysis is performed on every component, then serviceability determination accuracy is improved, but inspection cycle time extends due to repeated complex analysis
Solution Approach 1:
The patent applies partial analysis by focusing computational resources on components or regions with detected deviations rather than performing complete analysis on every component. The system identifies areas where in-service geometry differs from nominal design and concentrates analysis efforts on those specific regions, reducing overall inspection time while maintaining accuracy for critical areas through targeted assessment.
Data Source
AI summary
According to an embodiment, three-dimensional (3D) scan data representative of an in-service structure that is captured by a scanning device is accessed by a processor circuit. Based on the 3D scan data, in-service computer-aided design (CAD) data representative of an in-service surface corresponding to the in-service structure is generated by the processor circuit. Based on the in-service CAD data representative of the in-service surface, at least one of a serviceability level or remaining life estimate of the in-service structure is determined.