Aircraft Damage Scanning With 3D Infrared Assessment
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Solution Overview
Problem
Current aircraft inspection methods are inefficient and risky, particularly in poor light conditions, as they require manual visual checks and physical measurements, leading to potential flight delays and crew safety hazards when assessing structural damage such as dents on aircraft surfaces.
Innovation Solution
An automated system comprising a camera module with infrared and visible light cameras mounted on an autonomous vehicle with a vertically extendable arm, which scans the aircraft's exterior to generate a three-dimensional model of damage, using time-of-flight measurements and augmented reality to provide accurate dimensional data and enhance visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection and physical measurements are used to assess aircraft structure damage, then inspection accuracy can be achieved, but inspection efficiency decreases and crew safety risks increase
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated optical measurement system. The system uses a portable coordinate measuring machine equipped with cameras and lasers to automatically capture and analyze aircraft surface geometry, eliminating the need for manual visual inspection and physical measurements while maintaining high measurement precision.
Solution Approach 2:
The measurement system is designed to be self-operating, automatically navigating around the aircraft, capturing images, and processing measurement data without requiring continuous human intervention. The system autonomously identifies damage areas and generates assessment reports, enabling the inspection process to serve itself.
2Ease of operation
If manual inspection methods are used in poor light conditions, then inspection can be conducted, but inspection quality deteriorates and time consumption increases
Solution Approach 1:
The patent introduces active illumination devices (lasers and lights) as intermediaries between the measurement system and the aircraft surface. These devices provide controlled lighting in poor environmental light conditions, ensuring consistent image quality and measurement accuracy regardless of ambient lighting levels.
Solution Approach 2:
The system adapts its operational parameters based on environmental conditions. When ambient light is insufficient, the system increases illumination intensity and adjusts exposure settings to maintain optimal measurement quality, dynamically changing operational parameters to compensate for poor lighting conditions.
3Measurement precision
If crewmembers manually climb ladders to measure damage dimensions, then detailed measurements can be obtained, but safety risks and time consumption increase
Solution Approach 1:
The patent replaces the mechanical approach of crewmembers physically climbing ladders and using hand-held measurement tools with an automated robotic measurement system. The portable coordinate measuring machine autonomously positions itself and captures three-dimensional measurements, eliminating the need for crewmembers to access hazardous areas while maintaining measurement accuracy.
4Measurement precision
If comprehensive aircraft inspection is performed manually, then thorough damage assessment can be achieved, but inspection time and labor effort increase significantly
Solution Approach 1:
The measurement system operates continuously around the aircraft without interruption, systematically capturing images and measurement data at every position. The automated system maintains continuous scanning and data acquisition throughout the inspection process, eliminating the start-stop nature of manual inspection and reducing total inspection time while ensuring comprehensive coverage.
Solution Approach 2:
The system performs preliminary positioning and planning before the actual measurement process. The portable coordinate measuring machine pre-calibrates its sensors and pre-maps the aircraft geometry, allowing the subsequent measurement phase to proceed efficiently with minimal adjustments, thereby reducing overall inspection duration while maintaining thoroughness.
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
This system enables efficient and safe assessment of aircraft structure damage, reducing manual effort and risk, allowing for real-time data analysis and improved decision-making for flight operations by providing precise dimensional data and enhanced visibility through augmented reality.
Implementation Method 1
each capable of taking independent time-of-flight measurements using the modulated continuous waves
Implementation Method 2
a modulated continuous wave associated with the first infrared camera is phase shifted to prevent interference with a modulated continuous wave of the second infrared camera
Implementation Method 3
a visible light camera... capable of capturing visible light images of the exterior surface
Data Source
AI summary
A system may include a camera module that may include a first infrared camera, a second infrared camera, and a visible light camera. The system may further include an autonomous vehicle that may include a vertically extendable arm attached to the camera module. The system may also include a processor configured to initiate movement of the autonomous vehicle around an aircraft according to a predetermined path, initiate a scan of an exterior surface of the aircraft using the first infrared camera, the second infrared camera, the visible light camera, or a combination thereof, determine whether a portion of the exterior surface of the aircraft is damaged based on the scan, and in response to the portion of the exterior surface of the aircraft being damaged, use the first infrared camera, the second infrared camera, and the visible light camera to generate a three-dimensional model of the portion of the exterior surface of the aircraft.