Abrasive Coating Inspection Using Camera Arrangement
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Solution Overview
Problem
Mechanical and electro-mechanical systems, such as gas turbine engines, face performance and efficiency issues due to abrasive surface coatings that are outside predetermined tolerances, leading to gas leaks and inefficiencies.
Innovation Solution
A method involving a camera arrangement and controllers to inspect objects by capturing and combining images of different surface parts, determining parameters of abrasive coatings, and adjusting the coating application process based on these parameters to ensure precise deposition and application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If abrasive surface coating is applied to control clearance, then gas leakage is reduced and system efficiency is improved, but coating thickness and composition may fall outside predetermined tolerances causing performance degradation
Solution Approach 1:
The system performs preliminary inspection of the abrasive coating before final assembly or operation. By capturing images and analyzing coating parameters (thickness, composition, uniformity) in advance, the system can identify coatings that fall outside predetermined tolerances and prevent them from being installed, thereby ensuring only compliant coatings are applied to critical components.
Solution Approach 2:
The patent replaces manual inspection methods with an automated optical inspection system using cameras and image processing algorithms. This substitution enables precise, non-contact measurement of coating parameters, significantly improving measurement accuracy and consistency compared to traditional mechanical or visual inspection methods.
2Measurement precision
If manual inspection of abrasive coating is performed, then coating quality can be assessed, but inspection accuracy and consistency are insufficient to detect subtle deviations from tolerances
Solution Approach 1:
The system replaces subjective manual inspection with automated optical capture and digital image processing. Cameras capture high-resolution images of the coating, and software algorithms automatically analyze coating parameters, eliminating human error and subjectivity while achieving consistent, high-precision measurements across all inspected components.
Solution Approach 2:
The inspection system creates digital copies (images) of the abrasive coating for analysis. These digital replicas allow for repeated, consistent measurement and analysis without physically contacting or potentially damaging the coating, enabling precise measurement while preserving the integrity of the inspected component.
3Reliability
If comprehensive inspection of entire object surface is performed, then coating quality is thoroughly verified, but inspection time and processing complexity increase
Solution Approach 1:
The inspection system divides the object surface into multiple discrete regions or zones that can be imaged and analyzed separately. By segmenting the inspection process into manageable portions, the system can efficiently process large surfaces without requiring excessively long inspection times, while still providing comprehensive coverage through systematic sampling of critical areas.
Data Source
AI summary
A method of inspecting an object, the method comprising: receiving a first image of a first part of a first surface of the object from a camera arrangement; controlling relative movement between the camera arrangement and the object through a predetermined distance; receiving a second image of a second part of the first surface of the object from the camera arrangement, the second part being different to the first part; generating a third image using at least the first image and the second image; and determining a parameter associated with an abrasive surface coating on the object using the third image.