Coating Defect Detection via Transient Thermal Imaging
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Solution Overview
Problem
Current methods for detecting defects in thermal barrier coatings on turbomachinery components are largely manual, subjective, and lack quantification, leading to inefficient resource allocation and unnecessary recoating expenses due to inaccurate inspections.
Innovation Solution
A system comprising a heating element, an imaging device, and a computing system that traverses relative to the component, applies heat, pulses airflow, and captures transient thermal responses to automatically detect defects in the coating, enhancing defect visibility and quantification through transient thermal gradients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual visual inspection is used to detect coating defects, then inspection cost and time are reduced, but measurement precision and reliability of defect detection deteriorate
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical imaging system that captures images of the coating surface. The system uses a camera to photograph defects and automatically analyzes them through image processing algorithms, eliminating the need for human operators to visually examine each component while significantly improving detection precision and consistency.
Solution Approach 2:
The patent introduces an intermediary image processing system that acts as a mediator between the coating surface and the final defect detection result. The system captures images, processes them through algorithms to enhance contrast and detect defects, and then provides automated defect identification, serving as an intermediary layer that improves both speed and accuracy compared to direct manual inspection.
2Measurement precision
If automated imaging system is used to detect coating defects, then measurement precision and reliability improve, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional inspection system that combines lighting, imaging, and image processing capabilities into a single integrated device. The system can detect various types of coating defects (spits, pits, cracks) using the same hardware platform, eliminating the need for multiple specialized devices and reducing overall system complexity despite the advanced capabilities provided.
3Device complexity
If manual inspection is used, then device complexity is minimized, but loss of time and productivity decrease
Solution Approach 1:
The patent implements a continuous inspection process where the imaging system continuously captures images of the coating surface as components move through the inspection station. The automated image processing occurs in real-time, allowing continuous operation without the interruptions inherent in manual inspection, thereby significantly improving productivity while maintaining simple device architecture.
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 enables faster, more accurate detection of defects as small as 10 mils, reducing wasteful recoating and improving the quality assessment of thermal barrier coatings by providing enhanced contrast and precision in defect identification.
Implementation Method 1
capturing, with an imaging device, a plurality of images of the component as the heating element traverses relative to the component and applies heat thereto, the plurality of captured images indicating a transient thermal response of the component
Implementation Method 2
cause the imaging device to capture a plurality of images of the component as the heating element traverses relative to the component and applies heat thereto, the plurality of captured images indicating a transient thermal response of the component
Data Source
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AI summary
Systems and methods for automatic detection of defects (230) in a coating of a component (200) are provided. In one aspect, a coating inspection system (100) is provided. The coating inspection system (100) includes a heating element (112) operable to impart heat to the component (200) as it traverses relative thereto. An imaging device of the system (100) captures images (260) of the component (200) as the heating element (112) traverses relative to the component (200) and applies heat thereto. The images (260) indicate the transient thermal response of the component (200). The system (100) can generate a single observation image (250) using the captured images (260). The system (100) can detect and analyze defects (230) using the generated single observation image (250).