Composite Surface Artifact Detection via Optical Thickness Analysis
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Solution Overview
Problem
Traditional methods for detecting artifacts in the surface of composite components made from fibre-reinforced composite materials are time-consuming, expensive, and require skilled operatives, limiting their effectiveness in ensuring the structural integrity of components like vehicle parts.
Innovation Solution
A method involving the direction of incident light onto the composite component's surface, recording radiated light, and determining surface thickness to detect artifacts based on wavelength differences, using a system with a lamp, image recording device, and processor to identify inconsistencies in the matrix material's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inspection techniques (thermography, CT-scanning, ultrasonic scanning) are used to detect artifacts in composite components, then detection reliability is improved, but inspection time and cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical inspection systems (CT scanners, ultrasonic equipment) with an optical measurement system that uses light interaction to detect artifacts. The system directs light at the component surface and analyzes reflected light properties to identify subsurface anomalies, substituting mechanical probing with optical sensing to achieve rapid inspection without sacrificing detection capability
Solution Approach 2:
The system changes the measurement parameter from mechanical/thermal/electromagnetic properties to optical properties (light reflection, intensity, wavelength). By measuring how light interacts with the composite material surface and subsurface structures, the system can detect artifacts through optical signature analysis, enabling fast inspection with simple equipment
2Measurement precision
If traditional inspection techniques are used to detect artifacts, then detection accuracy is improved, but operational complexity and skill requirements increase
Solution Approach 1:
The optical inspection system performs self-measurement by directly capturing light interaction data from the component surface. The system automatically processes the optical signals and generates artifact detection results without requiring human interpretation of complex images or data, making the inspection process as simple as pointing the device at the component and reading the results
Solution Approach 2:
The system creates an optical copy or representation of the subsurface structure by analyzing light reflection patterns. Instead of requiring operators to interpret complex CT scans or ultrasonic images, the system generates simplified optical signatures that directly indicate artifact presence, reducing the need for highly skilled interpretation
3Reliability
If comprehensive artifact detection is performed using traditional methods, then component reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs inexpensive optical components (lights, cameras, sensors) instead of expensive, sophisticated inspection equipment. The system uses readily available optical devices that can be easily replaced or upgraded, providing comprehensive artifact detection capability at a fraction of the cost of traditional CT or ultrasonic inspection systems
Solution Approach 2:
By replacing expensive mechanical inspection equipment with optical measurement systems, the patent significantly reduces capital investment and operational costs. The optical system requires no complex mechanics, minimal calibration, and can be integrated directly into production lines, making comprehensive inspection economically viable
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 approach allows for rapid and cost-effective detection of artifacts, improving the inspection process by identifying inconsistencies in the matrix material's thickness, thereby enhancing the structural integrity and reliability of composite components.
Implementation Method 1
directing incident light on to the surface of the composite component, the incident light having a first wavelength; recording radiated light originating from positions on the surface, the radiated light being generated in response to the incident light being directed on to the surface and the radiated light having respective second wavelengths for each position
Data Source
AI summary
A method for detecting artifacts in a surface of a composite component, the composite component comprising reinforcement material, matrix material interspersed with the reinforcement material and matrix material forming the surface of the composite component, the method comprising: directing incident light on to the surface of the composite component, the incident light having a first wavelength; recording radiated light originating from positions on the surface, the radiated light being generated in response to the incident light being directed on to the surface and the radiated light having respective second wavelengths for each position; determining a surface thickness for each position on the surface based on the second wavelength of the radiated light for that position; and detecting one or more artifacts in the matrix material forming the surface based on the surface thickness of at least one position on the surface matching at least one artifact criteria.