Aircraft Damage Inspection With IR 3D Scanning in Low Light
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Solution Overview
Problem
Current aircraft inspection methods are inefficient and risky, particularly in poor light conditions, as they require manual inspections that can lead to flight delays and potential crew injuries, and are inadequate for assessing damage to the upper parts of aircraft structures.
Innovation Solution
An automated system with a camera module comprising a first infrared camera, a second infrared camera, and a visible light camera, attached to an autonomous vehicle with a vertically extendable arm, which scans the aircraft's exterior surface to determine damage and generate a three-dimensional model, using modulated continuous waves for independent time-of-flight measurements and differential measurement processes to remove ambient background light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is conducted by crewmembers using ladders and measurement tools, then damage dimensions can be obtained, but inspection time increases and crew injury risk increases
Solution Approach 1:
The patent replaces manual mechanical measurement tools and ladder-based inspection with an automated robotic system equipped with cameras and depth sensors. The robot autonomously navigates around the aircraft, captures images of damaged areas, and uses computational algorithms to calculate depth and dimensions, eliminating the need for crewmembers to physically measure damage with manual tools.
Solution Approach 2:
The system creates a digital copy or model of the damaged area by capturing multiple images and generating depth maps. Instead of manually measuring the physical damage, the system reconstructs a virtual representation of the dent or damage, allowing for precise dimensional analysis without physical contact or manual measurement.
2Measurement precision
If manual inspection is conducted by crewmembers, then damage assessment can be performed, but crew injury risk increases
Solution Approach 1:
The patent replaces human crewmembers with an autonomous robotic inspection system that navigates around the aircraft using sensors and pre-planned paths. The robot eliminates crew exposure to safety risks while maintaining measurement accuracy through calibrated cameras and depth sensors that objectively quantify damage dimensions.
Solution Approach 2:
The inspection system is fully autonomous, performing navigation, damage detection, measurement, and reporting without human intervention during the inspection process. The robot serves itself by autonomously moving to inspection points, capturing data, processing images, and generating reports, thereby removing crewmembers from potentially hazardous situations.
3Productivity
If visual inspection is performed in poor light conditions, then inspection can be conducted, but inspection quality deteriorates
Solution Approach 1:
The patent introduces active illumination sources (lights) as intermediaries between the inspection system and the damaged areas. These lights actively illuminate the inspection zones, enabling the cameras and sensors to capture high-quality images and depth data regardless of ambient lighting conditions, thereby maintaining inspection quality during nighttime or low-light operations.
4Area of stationary object
If top of fuselage, wings, and stabilizers are inspected manually, then complete inspection coverage can be achieved, but inspection time increases
Solution Approach 1:
The patent employs a dynamic robotic inspection system that can move freely around the aircraft on the ground, unlike fixed or stationary inspection methods. The robot navigates to various locations including the top of fuselage, wings, and stabilizers, adjusting its position and orientation as needed to capture complete coverage of all aircraft surfaces efficiently.
Solution Approach 2:
The system transitions from two-dimensional visual inspection to three-dimensional measurement by incorporating depth sensors and generating 3D models of damaged areas. This dimensional enhancement allows for comprehensive assessment of damage volume and geometry, providing complete inspection coverage with added measurement capabilities rather than just extended inspection time.
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 damage, providing accurate three-dimensional models and augmented reality images that enhance inspection efficiency and decision-making, reducing manual effort and potential risks while improving inspection coverage of upper aircraft surfaces.
Implementation Method 1
use the first infrared camera and the second infrared camera to compute three-dimensional coordinates of the damage to the exterior surface
Implementation Method 2
use the first infrared camera and the second infrared camera to compute dimensional parameters of damage to the exterior surface
Data Source
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AI summary
A system includes a camera module (110) that includes a first infrared camera (302), a second infrared camera (304), and a visible light camera (306). The system further includes an autonomous vehicle (120) that includes a vertically extendable arm (122) attached to the camera module. The system also includes a processor (532) configured to initiate movement of the autonomous vehicle around an aircraft (130) according to a predetermined path, initiate a scan of an exterior surface (132) of the aircraft using the first infrared camera, the second infrared camera, the visible light camera, or a combination thereof, determine whether a portion (601) 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.