Non-destructive Composite Evaluation Using Local Positioning System

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Solution Overview

Problem

Current methods for validating composite repairs in aircraft structures are costly, complex, and lack the spatial resolution and three-dimensional imaging capabilities needed for accurate porosity measurements, particularly for complex shapes and highly contoured surfaces.

Innovation Solution

A non-destructive inspection system combining a local positioning system, a six-degree-of-freedom digitizer with an articulated arm, and a non-destructive sensor array for high-resolution, three-dimensional scanning, enabling free-form scanning and imaging of complex structures with improved cost-effectiveness and portability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If handheld ultrasonic transducer systems are used for composite repair validation, then portability is improved, but measurement precision and productivity deteriorate due to slow scanning speed and inability to produce high-resolution porosity images

Engineering Contradiction:

ImproveportabilityVSAvoidporosity measurement resolution

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The system divides the ultrasonic inspection function into multiple independent transducer elements arranged in an array. Each transducer element can be independently controlled to scan different zones, enabling high-resolution porosity measurements while maintaining system portability through modular architecture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system replaces manual handheld operation with an automated scanning mechanism that positions the ultrasonic array. This substitution eliminates the limitations of manual scanning speed and precision while preserving portability through computer-controlled positioning systems

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If phased array ultrasonic systems are used for composite repair validation, then measurement precision is improved, but device complexity and cost increase

Engineering Contradiction:

Improveporosity measurement resolutionVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The ultrasonic array system is designed to perform multiple functions: porosity measurement, defect detection, and repair validation. By consolidating these functions into a single system, the patent reduces overall complexity compared to using multiple specialized devices while maintaining high measurement precision

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses software-controlled adjustment of ultrasonic parameters (frequency, amplitude, phase) to achieve different measurement objectives. This parameter-based control replaces complex hardware modifications, simplifying the system architecture while preserving measurement capabilities

Inventive Principle:

Principle #35Parameter changes

3Productivity

If mobile automated scanners are used for composite repair validation, then productivity is improved, but device complexity, cost, and operational difficulty increase

Engineering Contradiction:

Improvescanning speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system incorporates automated positioning and data processing capabilities that enable it to operate with minimal human intervention. The computer-controlled system automatically navigates, collects data, and processes results, maintaining high productivity while reducing operational complexity and training requirements

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent introduces a computer control system as an intermediary between the operator and the complex scanning hardware. This intermediary layer simplifies user interaction by handling complex positioning and data acquisition tasks automatically, reducing operational difficulty while maintaining high scanning speed

Inventive Principle:

Principle #24Intermediary (Mediator)

4Productivity

If rapid scan tools are used for composite repair validation, then productivity is improved, but adaptability to complex shapes and three-dimensional imaging capability deteriorate

Engineering Contradiction:

Improvescanning speedVSAvoidcapability for complex shapes

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system employs dynamically adjustable transducer positions and orientations within the array, allowing adaptation to complex structural geometries. The computer-controlled positioning system can dynamically reconfigure the scanning pattern to match the specific geometry being inspected, maintaining both speed and adaptability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent incorporates three-dimensional positioning capabilities that add spatial dimensionality to the scanning process. This enables the system to capture depth information and create 3D representations of complex structures, enhancing adaptability while maintaining rapid scanning through automated multi-axis positioning

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

5Productivity

If freehand area scanning tools are used for composite repair validation, then productivity is improved, but measurement precision deteriorates due to insufficient spatial resolution of IMU devices

Engineering Contradiction:

Improvescanning speedVSAvoidspatial resolution

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The system replaces IMU-based position tracking with a computer-controlled positioning system that uses precision mechanical stages or robotic positioning. This substitution provides superior spatial resolution while maintaining the rapid scanning capability through automated control, eliminating the fundamental limitation of consumer-grade IMU devices

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This system provides low-cost, high-resolution, portable, three-dimensional scanning for efficient validation of composite repairs and damage assessment on complex shapes, simplifying the validation process and reducing costs compared to existing methods.

Implementation Method 1

a local positioning system (LPS) configured for determining position and orientation of objects relative to the coordinate system of the structure

Methodology Applied

Scientific EffectLocal positioning system (GPS/LPS):

Implementation Method 2

Currently only scanned pulse echo ultrasound is capable of providing the zoned porosity measurements required for validating composite scarfed and bonded repairs

Methodology Applied

Scientific EffectPulse echo ultrasound: Ultrasound

Implementation Method 3

scanned pulse echo ultrasound

Methodology Applied

Scientific EffectEcho: Echo

Data Source

PatentUS8983794B1Methods and systems for non-destructive composite evaluation and repair verification

Publication Date: 2015.03.17 THE BOEING CO

AI summary

A non-destructive inspection system for a structure is described. The inspection system includes a local positioning system (LPS) configured for determining position and orientation of objects relative to a structure coordinate system, a six degree-of-freedom digitizer operable for at least one of temporary attachment to the structure and placement proximate the structure, a non-destructive sensor array, and a processing device.