Dynamic 3D Engine Imaging for Rotating Component Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional 3D scanning techniques for inspecting complex devices like jet engines require the component to be static, limiting inspection efficiency and consistency due to the need for manual intervention and operator skill, and are constrained by the form factor and field of view of insertion imaging systems.
Innovation Solution
A 3D imaging tool that projects multicolor light patterns onto moving components, captures images with an optical sensor, and constructs a 3D point cloud using a processor to combine data from rotating components, enabling consistent and efficient inspections without manual stopping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional 3D scanning techniques are used, then measurement precision can be achieved, but the component must be static which reduces productivity
Solution Approach 1:
The system transitions from static to dynamic 3D scanning by capturing images of rotating components. The processor determines angular displacement between frames and compensates for rotation when constructing the 3D point cloud, enabling accurate 3D scanning of moving components without requiring them to be stationary.
Solution Approach 2:
The patent replaces the mechanical requirement of stopping and positioning components with an optical and computational system. Instead of mechanically halting rotation for scanning, the system uses optical sensors to capture images during rotation and computationally corrects for the motion based on angular displacement calculations.
2Measurement precision
If manual intervention is used in 3D scanning, then operator skill can improve measurement precision, but it increases loss of time and reduces productivity
Solution Approach 1:
The system performs self-correction for component rotation by automatically determining angular displacement from captured images and adjusting the 3D point cloud construction accordingly. The processor autonomously compensates for motion artifacts without requiring manual intervention or operator skill in timing and positioning.
Solution Approach 2:
The system changes the approach from manual control of scanning parameters to automated parameter calculation. The processor automatically determines angular displacement, rotation speed, and timing parameters based on the captured image data, eliminating the need for manual parameter adjustment while maintaining precision.
3Ease of operation
If insertion imaging systems are used, then access to interior areas is improved, but form factor and field of view are limited
Solution Approach 1:
The system transitions from 2D image capture to 3D point cloud construction by combining multiple 2D images taken at different angular positions. The processor uses angular displacement information to spatially register images from different angles and reconstruct a comprehensive 3D representation, effectively expanding the field of view beyond what a single insertion probe can capture.
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 reduces inspection time and increases data capture consistency by allowing 3D scanning of moving components, providing accurate 3D point clouds aligned with CAD models, and detecting anomalies in real-time.
Implementation Method 1
an optical sensor coupled to an insertion tool configured to be inserted into an engine assembly
Implementation Method 2
a light source configured to output a light projection onto a component of the engine assembly within a field of view of the optical sensor
Data Source
AI summary
Systems and methods for engine imaging are provided. An imaging system includes an optical sensor coupled to an insertion tool and a light source configured to output alight projection onto a component of the engine assembly. The system includes a processor configured to: receive data comprising a plurality of frames from the optical sensor captured while the component of the engine assembly is rotating, determine an angular displacement of the component between frames, and form a 3D point cloud of the component based on combining the data in the frames based on the angular displacement of the component between the frames.