Coated Substrate Abnormality Detection System
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Solution Overview
Problem
Conventional methods for detecting abnormalities in coated substrates, such as corrosion, delamination, and material fatigue, are inadequate as they rely on visual inspection, x-ray, eddy current, and infrared techniques, which are limited in sensitivity and require multiple tools, making them inefficient for real-time detection and single-hand operation.
Innovation Solution
A detection system comprising a light source array with intensity modulation and spectral matching to the coating, an optical imaging system for real-time image processing, and an on-board embedded system for spatial and temporal correction, along with a wearable head-up display for remote viewing, enabling single-hand operation and improved fidelity in measuring structural features and abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional detection methods (visual inspection, x-ray, eddy current, infrared) are used, then abnormalities can be detected, but the detection sensitivity is insufficient and multiple tools are required
Solution Approach 1:
The patent combines multiple detection capabilities (optical imaging, light source array with intensity modulation, spectral matching) into a single integrated system. The device merges the functions of illumination, imaging, and analysis into one handheld unit, eliminating the need for separate visual inspection tools, x-ray equipment, eddy current devices, and infrared cameras while achieving superior detection sensitivity through the combined optical effects
2Productivity
If conventional detection methods are used, then abnormalities can be detected, but real-time detection and single-hand operation are not achievable
Solution Approach 1:
The system employs dynamic intensity modulation of the light source array, allowing real-time adjustment of illumination levels to optimize detection across different conditions. The handheld device is designed with ergonomic controls that enable single-hand operation while maintaining real-time imaging and analysis capabilities through integrated processing
Solution Approach 2:
The device incorporates on-board processing and analysis capabilities that automatically process images and detect abnormalities in real-time without requiring external computers or complex post-processing equipment. The system performs self-diagnosis and immediate reporting, enabling operators to conduct inspections independently with a single handheld unit
3Measurement precision
If light source intensity is increased to improve detection, then measurement fidelity improves, but spatial and temporal variations in intensity create measurement errors
Solution Approach 1:
The system incorporates feedback mechanisms that continuously monitor the actual light intensity at the sample surface and automatically adjust the light source modulation to compensate for spatial and temporal variations. Real-time feedback from the optical imaging system allows the control algorithm to correct intensity non-uniformities and maintain consistent measurement fidelity across the entire field of view
Solution Approach 2:
The patent employs spectral matching between the light source and the coating material, selecting specific wavelengths where the coating has optimal transmission properties. By changing the spectral parameters of the illumination and matching them to the coating's optical characteristics, the system achieves high measurement fidelity while minimizing the impact of intensity variations through wavelength-specific optimization
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 effectively detects hidden damage and structural features, improves measurement fidelity, and allows for real-time processing and reporting, enhancing the detection of abnormalities before they compromise the substrate's integrity, while enabling single-hand operation and remote monitoring.
Implementation Method 1
a light source array of a plurality of light sources configurable to be (i) intensity modulated, (ii) matched in bandwidth to a spectral transmission band of the coating, and (iii) arranged to direct light upon the coated substrate
Implementation Method 2
an optical imaging system matched to a wavelength range of the light source array and positioned to collect and measure reflected and scattered light from the coated substrate
Implementation Method 3
an optical imaging system matched to a wavelength range of the light source array and positioned to collect and measure reflected and scattered light from the coated substrate
Data Source
AI summary
Provided is a detection system for detecting abnormalities in a coated substrate having a coating and a substrate, and including a detection device that includes a housing configured to block external sources of light from impinging on the coated substrate, a light source array including a plurality of light sources and configured to be arranged to direct light upon the coated substrate, an optical imaging system configured to capture a video data stream and still images of the coating and an underlying surface of the substrate including structure features comprising any abnormalities in the coated substrate, an on-board embedded system to control the light source array and the optical imaging system and perform real-time processing to correct spatial and temporal variations in intensity of the plurality of light sources of the light source array, and spatial and temporal variations in sensitivity and optical Narcissus effect of the optical imaging system.