Crack Estimation Device Using Surface Shape Measurement

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Solution Overview

Problem

Current nondestructive inspection methods, such as ultrasonic flaw detection and X-ray inspection, face challenges in reducing device size, while shape measurement on structure surfaces struggle to accurately measure internal cracks.

Innovation Solution

A crack estimation device that determines a shape model of the target structure, calculates an estimation model based on numerical analysis, and uses measurement data from the structure's surface to estimate crack states within the structure, enabling internal crack detection with a small-sized device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If ultrasonic flaw detection or X-ray inspection is used, then internal crack detection capability is improved, but device size increases

Engineering Contradiction:

Improveinternal crack detection capabilityVSAvoiddevice size

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

The patent introduces an estimation model as an intermediary that connects surface shape measurement data to internal crack state estimation. Instead of directly measuring internal cracks with complex equipment, the system uses a simplified surface measurement approach combined with numerical analysis-based estimation to infer internal crack conditions, thereby reducing device size while maintaining detection capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a virtual copy of the internal crack state through estimation modeling. By numerically analyzing the relationship between surface shape changes and internal crack states, the system generates an estimated model that replicates internal crack information from surface measurements, eliminating the need for direct internal imaging equipment

Inventive Principle:

Principle #26Copying

2Volume of moving object

If shape measurement on structure surface is used, then device size is reduced, but internal crack measurement capability deteriorates

Engineering Contradiction:

Improvedevice sizeVSAvoidinternal crack measurement capability

Core Design Contradiction:

Volume of moving objectVSMeasurement precision

Solution Approach 1:

The patent transitions from direct spatial measurement (trying to see inside the structure) to an indirect dimensional approach. By measuring surface shape changes in multiple locations and using numerical analysis to propagate this information to the internal crack occurrence plane, the system infers internal states from external measurements, effectively adding an analytical dimension to bridge the gap between surface measurement and internal detection

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20230003626A1Crack estimation device, crack estimation method, crack inspection method, and failure diagnosis method

Publication Date: 2023.01.05 MITSUBISHI ELECTRIC CORP

AI summary

This crack estimation device includes: a data determination unit which determines a shape model of a target structure to be inspected, and a crack occurrence plane and an observation plane in the shape model; an estimation data calculation unit which outputs an estimation model for estimating a state of the crack occurrence plane from a state of the observation plane, on the basis of a matrix that associates, with each other, the state of the crack occurrence plane and the state of the observation plane, obtained through numerical analysis of a structural analysis model generated from the shape model; and a crack estimation unit which estimates a state of a crack at the crack occurrence plane on the basis of the estimation model and a measurement value for the target structure actually measured at the observation plane.