Acoustic Impact Detection for Composite Structures
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Solution Overview
Problem
Current methods lack the ability to automatically and efficiently detect and locate structural impacts on aeronautical parts made of composite materials during manufacturing or assembly, leading to potential undetected damage and resulting in costly delays and penalties.
Innovation Solution
A device comprising at least three acoustic sensors and command and control means that detect and locate impacts on a structure by processing acoustic waves, with optional optical pointers for visual designation, allowing for real-time detection and identification without operator intervention, and eliminating spurious signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If systematic final inspection with inspection means is performed to detect damage, then detection reliability is improved, but productivity decreases due to time-consuming inspection processes
Solution Approach 1:
The acoustic detection device performs continuous monitoring during the assembly process itself, detecting impacts as they occur rather than performing inspection after assembly is complete. This preliminary detection approach allows damage to be identified in real-time during manufacturing, eliminating the need for separate final inspection steps and enabling immediate intervention before delivery.
Solution Approach 2:
The invention replaces mechanical inspection methods (visual inspection, tap testing, ultrasonic inspection) with an acoustic detection system that uses microphones and signal processing to automatically detect impact events. This substitution automates the detection process, reducing manual labor time while maintaining high detection reliability through electronic signal analysis.
2Reliability
If constant visual surveillance by operators is implemented to detect incidents, then detection capability is improved, but device complexity and operational difficulty increase
Solution Approach 1:
The acoustic detection device operates autonomously without requiring operator intervention for detection or monitoring. The system automatically captures acoustic signals, processes them through the analysis device, identifies impact events, and generates alerts. This self-service capability eliminates the need for constant human visual surveillance while providing more consistent and reliable detection.
Solution Approach 2:
The invention introduces an acoustic intermediary (sound waves) to detect impacts, replacing direct human visual observation. The acoustic sensors and signal processing system act as intermediaries that automatically detect and analyze impact events, providing objective detection without the complexity of coordinating multiple operators for visual surveillance.
3Reliability
If late intervention is performed after damage is discovered subsequently, then detection is eventually achieved, but loss of time increases causing delivery delays
Solution Approach 1:
The acoustic detection device operates continuously throughout the assembly process, providing uninterrupted monitoring for impact events. This continuous detection capability ensures that any impact occurs is immediately detected and recorded, eliminating detection gaps that occur with periodic or post-assembly inspection methods.
Solution Approach 2:
The system detects and records impact events as they occur during assembly, performing the detection action before the assembly process completes. This preliminary detection allows damage to be identified while the structure is still in the assembly area, enabling immediate intervention and repair scheduling before the component moves to final assembly or delivery, thereby minimizing time loss.
4Productivity
If automated acoustic detection is implemented to detect impacts, then productivity is improved through automation, but measurement precision may worsen due to spurious signals
Solution Approach 1:
The signal processing device analyzes acoustic signals in real-time and provides feedback to distinguish genuine impact events from spurious signals. The system uses signal characteristics (amplitude, frequency, temporal patterns) to differentiate between actual impacts on the structure and background noise or false signals, maintaining high measurement precision while operating automatically.
Solution Approach 2:
The invention changes the detection parameter from visual observation to acoustic signal analysis, using multiple parameters (signal amplitude, frequency spectrum, temporal characteristics) to characterize impact events. By analyzing multiple acoustic parameters simultaneously, the system achieves robust impact detection that can distinguish real events from spurious signals, maintaining precision while enabling automated operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables early intervention and cost-effective repairs by automatically detecting and locating impacts in real-time, reducing the likelihood of late interventions and minimizing unnecessary investigations.
Implementation Method 1
at least three acoustic sensors arranged non-aligned inside the measurement volume and such that an acoustic wave emitted at any point of the measurement volume can be received by direct propagation by each of the sensors
Data Source
AI summary
A device which detects and locates an impact on a structure. The device includes at least three acoustic sensors so that an acoustic wave emitted at any point of a measurement space can be received through direct propagation by each of the sensors. The device also includes command controller configured to process the signals corresponding to the acoustic waves received by the acoustic sensors, to detect the occurrence of an impact, and to locate a point of the structure that is the source of an acoustic wave. At least one optical pointer is actuated by the command controller so as to designate an impact point located on the structure by illuminating a corresponding site of the structure.