Non-Contact Coating Thickness Inspection With Visual Projection Guidance
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Solution Overview
Problem
Manual measurement of coating thickness on aircraft surfaces is time-consuming and prone to errors, making it challenging to ensure accurate application within specified thickness tolerances.
Innovation Solution
An automated non-contact thickness inspection and projection system using color-coded patterns, which includes a terahertz sensor, camera, and projector integrated with a robotic arm and information handling system, to measure coating thickness and provide visual feedback for adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement of coating thickness is used, then measurement can be performed with simple equipment, but measurement time increases and 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 and image capture to determine coating thickness, eliminating the need for manual mechanical gauges and significantly reducing measurement time while improving accuracy through automated image processing.
Solution Approach 2:
The patent creates an optical copy of the measurement data by projecting patterns onto the coating surface and capturing reflected images. Instead of direct physical contact measurement, the system uses optical imaging to create a visual representation of the coating thickness that can be analyzed automatically, enabling rapid non-contact measurement.
2Productivity
If automated non-contact measurement system is implemented, then measurement speed and accuracy improve, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated system: the projector serves both as a measurement tool and a visual feedback device, while the camera captures both the projected pattern and the coating surface information. This multi-functionality reduces the need for separate equipment and simplifies the overall measurement process despite the advanced capabilities.
Solution Approach 2:
The system performs self-calibration and self-measurement by using the projected pattern itself as the reference standard. The known geometry of the projected pattern allows the system to automatically calculate coating thickness without requiring external calibration artifacts or manual setup, enabling rapid deployment and reducing operational complexity.
3Ease of operation
If visual feedback projection is added to the measurement system, then guidance for secondary operations improves, but device complexity and cost increase
Solution Approach 1:
The patent merges the measurement function and the visual feedback function into a single integrated system using the same projector and camera hardware. The projector that displays measurement patterns also provides real-time visual feedback on coating thickness, eliminating the need for separate display devices and simplifying the user interface.
Solution Approach 2:
The system uses color-coded visual feedback where different colors represent different coating thickness ranges. This intuitive color representation provides immediate visual guidance to operators about whether the coating meets specifications, making the system easier to operate without requiring complex data interpretation or additional instrumentation.
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 visual guidance for secondary operations to ensure coating thickness meets acceptable ranges, thereby improving efficiency and quality in coating applications.
Implementation Method 1
The sensor may include a terahertz sensor operable to transmit and receive signals
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.