Dynamic Backlighting for Transparency Inspection
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Solution Overview
Problem
Current methods for inspecting transparencies, such as aircraft windshields, are inadequate due to lack of resolution, reliance on favorable atmospheric conditions, and inability to detect small optical defects, particularly in complex curved surfaces with high strength requirements.
Innovation Solution
An inspection system utilizing multiple rounded arrays of elongated light elements that radially translate to backlight the transparency, combined with an image recording device and processor to analyze images for optical defects, allowing for efficient detection of small defects in complex curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual inspection using sky as background is used, then inspection can be performed with simple equipment, but inspection time increases significantly and requires favorable atmospheric conditions
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system using a camera and structured light arrays. The mechanical system of human inspectors viewing against sky background is substituted with an automated imaging system that projects light patterns and captures images for computer analysis, eliminating dependency on atmospheric conditions and reducing inspection time.
Solution Approach 2:
The system performs preliminary actions by pre-positioning multiple rounded arrays of elongated light elements behind the transparency and pre-configuring the camera system before inspection begins. The light arrays are arranged in specific patterns and the system is calibrated in advance, allowing immediate inspection without waiting for favorable atmospheric conditions.
2Extent of automation
If automotive industry camera-driven methods are used, then automated inspection is achieved, but resolution is insufficient for detecting small defects in aerospace transparencies
Solution Approach 1:
The patent divides the inspection system into multiple segmented components: multiple rounded arrays of elongated light elements positioned at different locations, each array contributing to illuminating specific regions. The camera captures images that are then segmented and analyzed by computer algorithms to detect defects in different zones, allowing high-resolution inspection across the entire transparency surface.
Solution Approach 2:
The system applies local quality by using elongated light elements arranged in rounded arrays that provide localized high-intensity illumination at specific regions of the transparency. Each light array is positioned to optimize illumination for its corresponding field of view, enabling the camera to capture high-resolution images with enhanced contrast for detecting small defects in specific areas.
3Device complexity
If static backlighting is used, then system construction is simple, but small optical defects cannot be detected effectively
Solution Approach 1:
The patent implements dynamics by making the light arrays movable rather than static. The elongated light elements in the rounded arrays can be positioned and repositioned to dynamically adjust the illumination pattern. This dynamic capability allows the system to optimize light projection angles and positions to enhance the visibility of small optical defects while maintaining relatively simple system construction.
Solution Approach 2:
The system employs periodic action by sequentially activating different rounded arrays of light elements or by moving light arrays through periodic motion patterns. This periodic illumination allows the camera to capture multiple images under varying light conditions, enhancing the detection of small defects through image processing and comparison.
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 enables rapid detection of optical defects, including small particulates and distortions, in a variety of transparency configurations, reducing inspection time and improving accuracy compared to existing methods.
Implementation Method 1
a first rounded array of first elongated light elements, and a second rounded array of second elongated light elements configured to backlight the transparency
Implementation Method 2
a light-element-moving system configured to radially translate at least the first elongated light elements
Implementation Method 3
an image recording device positionable on a side of the transparency opposite the first and second rounded arrays and configured to record images of the transparency during radial translation of at least the first elongated light elements
Implementation Method 4
a processor configured to analyze the images recorded during radial translation of at least the first elongated light elements, and detect optical defects in the transparency based on analysis of the images
Data Source
AI summary
An inspection system for detecting optical defects in a transparency includes a first rounded array of first elongated light elements, and a second rounded array of second elongated light elements. The second rounded array is positionable radially outboard of the first rounded array. The inspection system further includes a light-element-moving system configured to radially translate at least the first elongated light elements. The inspection system also includes an image recording device positionable on a side of the transparency opposite the first and second rounded arrays and configured to record images of the transparency during radial translation of at least the first elongated light elements during backlighting of the transparency. The inspection system includes a processor configured to analyze the images recorded during radial translation of at least the first elongated light elements, and detect optical defects in the transparency based on analysis of the images.