Coating Thickness Inspection With Color-Coded Projection Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual measurement of coating thickness on aircraft surfaces is time-consuming and prone to errors, making it difficult to accurately apply coatings within a determined thickness tolerance.
Innovation Solution
An automated non-contact thickness inspection and projection system using a terahertz sensor, camera, and projector, integrated with a robotic arm and autonomous mobile robot, which measures coating thickness and provides visual feedback for adjusting the coating thickness based on acceptable ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods are used to measure coating thickness, then the measurement process is simple and requires minimal equipment, but the measurement time increases and measurement accuracy decreases
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical measurement system using a camera and projector. The system uses optical projection of measurement patterns onto the coating surface and captures images to determine thickness, eliminating the need for physical contact and manual operation while significantly improving both speed and accuracy.
Solution Approach 2:
The system creates an optical copy of the measurement pattern projected onto the coating surface and captures it via camera. By analyzing the distortion of this optical copy compared to the original pattern, the system calculates coating thickness automatically, replacing direct manual measurement with indirect optical measurement.
2Productivity
If manual measurement of multiple individual points is performed, then equipment complexity is low, but productivity and inspection coverage are reduced
Solution Approach 1:
The system transitions from one-dimensional point-by-point manual measurement to two-dimensional area measurement by projecting a pattern across the entire inspection field. The camera captures the full field of view, enabling simultaneous measurement of multiple locations across the coating surface, thereby dramatically increasing productivity.
Solution Approach 2:
The measurement system integrates multiple functions into a single apparatus: the projector displays measurement patterns, the camera captures images, and the processing system analyzes data to determine thickness. This multi-functional integration enables comprehensive inspection while managing system complexity through coordinated operation of components.
3Manufacturing precision
If visual feedback is provided to operators during coating application, then coating thickness precision can be improved, but the complexity of the coating system increases
Solution Approach 1:
The system implements real-time feedback by continuously measuring coating thickness during application and providing visual indicators to the operator. The measurement results are processed and displayed, allowing the operator to adjust coating parameters immediately to maintain thickness within specified tolerances, thereby improving manufacturing precision.
Solution Approach 2:
The system uses color-coded visual feedback where different colors indicate different coating thickness conditions. The projector displays patterns that change color or intensity based on measured thickness values, providing intuitive visual guidance to operators without requiring complex data interpretation, thus balancing precision improvement with operational simplicity.
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 significantly reduces measurement time and increases accuracy, providing real-time visual guidance for operators to adjust coating thickness, thereby improving the efficiency and precision of coating applications.
Implementation Method 1
An automated non-contact thickness inspection and projection system using a terahertz sensor
Data Source
AI summary
In one embodiment, systems and methods include using an inspection and projection system to measure the thickness of a coating and provide visual guidance for secondary operations. The inspection and projection system comprises a robotic arm operable to rotate about a plurality of axes, wherein an end effector is disposed at a distal end of the robotic arm. The inspection and projection system further comprises a linear rail system, wherein the robotic arm is coupled to the linear rail system, and wherein the robotic arm is operable to translate along the linear rail system. The inspection and projection system further comprises a frame, wherein the linear rail system is disposed on top of the frame, and an information handling system coupled to the frame, wherein the information handling system is operable to actuate the robotic arm and the linear rail system.