Automated Rivet Measurement System Using Optical Image Alignment
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Solution Overview
Problem
Current methods for measuring rivet concentricity in vehicle manufacturing often require destructive testing, which is time-consuming and costly, and non-destructive methods like x-ray systems are undesirable due to high costs, specialized training requirements, and increased effort.
Innovation Solution
An automated rivet measurement system using end effectors, cameras, and a processor to align and analyze images of rivet holes and installed rivets, determining concentricity without drilling out the rivet, thereby eliminating the need for destructive testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive testing is used to measure rivet concentricity, then measurement capability is achieved, but time consumption and cost increase
Solution Approach 1:
The patent replaces the mechanical destructive testing system (drilling out rivets with hand or machine tools) with an automated optical measurement system using cameras and image processing algorithms. This substitution enables non-destructive measurement of rivet concentricity, eliminating the time-consuming drilling operation while maintaining measurement capability through automated image analysis
Solution Approach 2:
The patent creates a digital copy of the rivet and surrounding structure through photogrammetry using multiple camera images. This virtual model allows measurement of rivet concentricity without physically disturbing the rivet, replacing the need to create physical copies or sections through destructive drilling with an accurate digital representation
2Measurement precision
If destructive testing is used to measure rivet concentricity, then measurement capability is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive manual destructive testing operations with an automated optical measurement system. The automated image capture and processing eliminates the need for skilled operators to perform drilling and manual measurements, reducing labor costs and manufacturing expense while maintaining measurement accuracy
Solution Approach 2:
The measurement system is integrated into the existing manufacturing process, where the rivet installation equipment itself provides the measurement capability through integrated cameras and processing systems. This self-service approach eliminates the need for separate inspection operations and additional equipment, reducing overall manufacturing cost
3Measurement precision
If x-ray systems are used for non-destructive testing, then measurement capability is achieved, but system complexity and cost increase
Solution Approach 1:
The patent replaces complex x-ray imaging systems with simpler optical camera systems and photogrammetric processing. This substitution achieves the same measurement objective (rivet concentricity) using conventional optical equipment and software algorithms rather than expensive and complex radiographic equipment, significantly reducing system complexity
Solution Approach 2:
The patent uses multiple camera images to create a photogrammetric model that provides the measurement information needed. This approach using simple optical copies from multiple angles replaces the need for complex x-ray imaging, achieving the measurement goal with less complex equipment through computational geometry
4Adaptability or versatility
If manual measurement methods are used, then flexibility is maintained, but productivity decreases
Solution Approach 1:
The system performs automated image capture and processing without requiring manual intervention for each measurement. The integrated system automatically processes images and calculates concentricity, maintaining flexibility through software-based methods while dramatically increasing productivity compared to manual measurement operations
Solution Approach 2:
The measurement system operates continuously as part of the automated manufacturing process, with images captured and processed in sequence without interruption. This continuous operation maintains measurement flexibility while eliminating the stop-start nature of manual measurements, thereby increasing overall productivity
Data Source
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AI summary
An automated rivet measurement system for an aircraft comprises a number of end effectors, a number of cameras, a processor, and a comparator. The number of end effectors is configured to perform drilling and riveting on a structure. The number of cameras is connected to the number of end effectors. The number of cameras is configured to take a first image (see e.g. view 1100) of a hole (806) in the structure and a second image (see e.g. view 1100) of a rivet (802, 804 and 808) in the hole. The processor is configured to process the first image and the second image to identify a number of reference points (1002) in the first image and the second image. The comparator is configured to determine a rivet concentricity using the hole in the first image and the rivet in the second image, in which the first image and the second image are aligned using the number of reference points.