Airframe Fastener Inspection With Optical Tracking Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing aircraft airframe inspection methods are inefficient and inaccurate, often requiring manual inspection with inconsistent results, and digital systems lack effective data processing and infrastructure, leading to non-conforming fasteners being missed.
Innovation Solution
A feature inspection system comprising feature inspection devices with scanners, tracking subsystems, and computing devices that autonomously determine fastener positions and orientations, using augmented reality projectors and photogrammetry surveying systems with UAVs for precise, real-time measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual tactile observation is used to inspect fasteners, then inspection can be performed without specialized equipment, but inspection consistency and accuracy deteriorate due to human variation
Solution Approach 1:
The patent replaces manual tactile inspection with automated optical scanning systems that use cameras and image processing to measure fastener dimensions. This substitution eliminates human variability in measurement while maintaining ease of operation through automated data collection and analysis systems.
Solution Approach 2:
The patent creates digital copies of fastener geometries through optical scanning and photogrammetry. These digital models allow repeated measurement without physical contact, ensuring consistent results while maintaining inspection accessibility. The digital twins can be analyzed multiple times by different operators without variation.
2Measurement precision
If digital inspection devices are used to scan fasteners, then measurement precision improves, but data processing difficulty and infrastructure requirements worsen
Solution Approach 1:
The patent divides the inspection system into modular components: scanning devices, tracking subsystems, computing devices, and data processing modules. Each component handles specific tasks independently, reducing overall system complexity while maintaining high measurement precision through specialized hardware and software modules.
Solution Approach 2:
The patent introduces tracking targets and augmented reality projectors as intermediaries between the scanning system and the airframe coordinate system. These intermediaries simplify the complex task of registering scan data with the airframe by providing known reference points that automatically align measurements with the airframe coordinate system.
3Extent of automation
If robotic manipulators and gantry systems are used for inspection, then automation level improves, but infrastructure investment and operational complexity worsen
Solution Approach 1:
The patent employs dynamically adjustable inspection systems where operators can position scanning devices at various locations around the airframe. The system adapts to different inspection needs through flexible positioning rather than requiring fixed robotic manipulators or gantry systems, reducing infrastructure requirements while maintaining automation.
Solution Approach 2:
The patent creates a universal inspection platform that can inspect different airframe features from multiple locations using the same basic scanning hardware. The system performs multiple functions (measurement, positioning, orientation, data logging) through integrated software rather than requiring separate specialized equipment for each function.
4Device complexity
If traditional two-step inspection process is used, then simple equipment requirements are maintained, but inspection efficiency and effectiveness deteriorate
Solution Approach 1:
The patent merges multiple inspection functions into a single integrated system that simultaneously performs measurement, positioning, and orientation determination. The scanning device, tracking subsystem, and computing devices work together to complete the entire inspection process in one operation rather than requiring separate steps, dramatically improving efficiency while maintaining reasonable equipment complexity.
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
The system provides automated, precise, and efficient inspection of aircraft features, reducing human error, minimizing infrastructure requirements, and enabling real-time data logging and predictive analytics for quality control.
Implementation Method 1
The scanner may be a three-dimensional surface inspection sensor, an optical sensor, a camera, or any other suitable scanning component
Implementation Method 2
The tracking subsystem includes a number of cameras and a tracking computer. The tracking subsystem ensures spatial tracking of the feature inspection device (and hence the fasteners) relative to an aircraft coordinate system
Implementation Method 3
The augmented reality projector may display the above information directly on the airframe
Data Source
AI summary
A system for inspecting features of an airframe, the system including a feature inspection device configured to measure an aspect of a first feature and a tracking subsystem configured to determine a position of the feature inspection device when the feature inspection device measures the aspect of the first feature. The system is configured to determine a position of the first feature on the airframe via the feature inspection device and the tracking subsystem, the determination of the position of the first feature being independent from the measurement of the aspect of the first feature.