Composite Surface Abrasive Preparation Quality Measurement

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Solution Overview

Problem

Current methods for verifying the quality of abrasive surface preparation on composite structures, such as carbon fiber epoxy composites, rely on subjective visual inspections, leading to variability and increased reworking due to the lack of quantitative measurement tools.

Innovation Solution

A method and system utilizing an ohm meter to measure electrical resistance and surface resistivity at specific abrasive surface preparation standards, allowing for quantitative assessment of the quality of abrasive surface preparation before post-processing operations like bonding or painting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If qualitative visual inspection is used to verify surface preparation, then the inspection process is simple and quick, but the measurement precision and reliability are poor due to subjectivity and operator variability

Engineering Contradiction:

Improvesurface preparation quality measurementVSAvoidinspection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical/visual inspection system with an electrical measurement system. An ohm meter measures electrical resistance and surface resistivity of the composite surface to objectively quantify surface preparation quality, substituting subjective visual assessment with precise electrical property measurement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the measurement parameter from visual appearance to electrical resistance and surface resistivity. By measuring these electrical parameters at different surface preparation states, the patent creates quantitative target values that objectively indicate surface preparation quality, resolving the subjectivity issue.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If subjective visual inspection is used, then the inspection method is easy to operate, but the reliability and consistency of results deteriorate due to operator variability

Engineering Contradiction:

Improvesurface preparation verification reliabilityVSAvoidinspection operation simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the human operator's visual judgment with an automated electrical measurement system. The ohm meter provides objective, repeatable measurements of surface resistivity and electrical resistance, eliminating operator variability and significantly improving reliability while maintaining operational simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The measurement system is self-calibrating and provides automatic readings without requiring operator interpretation. The device measures electrical properties directly and compares them against pre-established target values, making the inspection process reliable and consistent while remaining easy to operate.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If quantitative measurement methods are implemented, then the measurement precision and objectivity improve, but the device complexity and measurement system sophistication increase

Engineering Contradiction:

Improvesurface preparation quality measurementVSAvoidmeasurement system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses a simple ohm meter to measure electrical resistance and surface resistivity, replacing complex visual inspection protocols with a straightforward electrical measurement approach. This provides precise quantitative data while keeping the measurement device relatively simple and accessible.

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 approach ensures consistent and reliable surface preparation, reducing unnecessary reworking by providing a standardized, objective evaluation of the composite surface's readiness for subsequent processes.

Implementation Method 1

measuring, with the surface analysis tool comprising the ohm meter, one or more abrasive surface preparation locations on the composite surface of a test composite structure, to measure one or more of, electrical resistance and surface resistivity

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Data Source

PatentUS11204334B2Method and system for determining a quality of an abrasive surface preparation of a composite surface using electrical resistance and surface resistivity

Publication Date: 2021.12.21 THE BOEING CO

AI summary

There is provided a method for determining a quality of an abrasive surface preparation of a composite surface, prior to the composite surface undergoing a post-processing operation. The method includes fabricating levels of abrasive surface preparation standards for a reference composite surface; using a surface analysis tool in the form of an ohm meter, to create target values for quantifying the levels; and measuring, with the surface analysis tool, one or more abrasive surface preparation locations on the composite surface of a test composite structure, to measure one or more of, electrical resistance and surface resistivity, of the composite surface, to obtain test result measurement(s). The method further includes comparing the test result measurement(s) to the levels, to obtain test result level(s); determining if the test result level(s) meet the target value(s); and determining whether the composite surface is acceptable to proceed with the post-processing operation.