3D Surface Inspection Using Reference Surfaces for Defect Detection

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Solution Overview

Problem

Existing surface inspection methods for aircraft fuselages are time-consuming, lack repeatability, and often fail to accurately interpret inspection data, leading to delayed detection of non-conformances that increase production costs and delays.

Innovation Solution

A surface inspection system using a 3D scanner to acquire a point cloud of a localized portion of the surface, establishing a reference surface based on non-defective regions, and determining characteristics of suspect regions to assess deviations from contour requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If straight edge and feeler gauges are used for measuring surface contours, then measurement capability is provided, but inspection time is excessive and repeatability is poor

Engineering Contradiction:

Improvesurface contour measurement accuracyVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical measurement tools (straight edge and feeler gauges) with an automated optical 3D scanning system. The scanner captures point cloud data of the surface, which is then processed algorithmically to generate contour measurements, eliminating manual intervention and significantly reducing inspection time while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transforms the inspection approach by changing from direct physical measurement parameters to digital 3D coordinate parameters. The surface geometry is represented as a point cloud with precise x, y, z coordinates, allowing for automated calculation of contour deviations and enabling rapid, repeatable measurements without physical contact with the surface.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If existing 3D scanners are used to measure surface data, then inspection speed is improved, but measurement accuracy and proper interpretation of contour requirements deteriorate

Engineering Contradiction:

Improveinspection speedVSAvoidsurface contour measurement accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent segments the scanned surface data into distinct regions: suspect regions (potential defects) and non-defective regions. This segmentation allows the system to focus computational resources on analyzing only the relevant areas for contour deviations, improving both measurement precision and interpretation accuracy while maintaining high inspection speed through targeted processing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a reference surface as an intermediary construct. This reference surface is generated from the non-defective regions of the scanned data and serves as the basis for comparing and evaluating the suspect regions. The intermediary reference surface enables accurate interpretation of contour requirements by providing a standardized comparison baseline.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If surface inspection is delayed until after gloss paint coating, then visual detection capability is enhanced, but production cost and time increase due to late defect detection

Engineering Contradiction:

Improvevisual detection capabilityVSAvoidproduction time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent performs surface inspection at an early stage in the production process, before the gloss paint coating is applied. By conducting the 3D scan and contour analysis preliminarily, the system detects surface non-conformances early when rework is less costly and time-consuming, eliminating the need to wait for paint application to enhance visual detection.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the need for gloss paint coating (a mechanical/chemical process used to enhance visual detection) with an optical 3D scanning system. The scanner directly measures surface geometry through light reflection and coordinate mapping, providing accurate contour detection without requiring any coating or visual enhancement, thereby enabling early inspection in the production cycle.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20260063562A1System and method of inspecting a surface

Publication Date: 2026.03.05 THE BOEING CO

AI summary

A surface inspection system for inspecting an inspection surface includes a three-dimensional (3D) scanner configured to scan the inspection surface and acquire a point cloud of points representing at least the localized portion. The localized portion includes a non-defective region and a suspect region at least partially surrounded by the non-defective region and potentially containing one or more defects. The surface inspection system includes a processor establishes a reference surface based on the points in the non-defective region and exclusive of the points in the suspect region, and the reference surface extends across the suspect region. The processor determine one or more characteristics of a shape of the point cloud relative to the reference surface within the suspect region.