Automated Engine Inspection Surface Approximation
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Solution Overview
Problem
Conventional engine inspection methods require skilled operators to manually select reference points for measuring defects, leading to variability and increased safety margins due to human interpretation, which can result in inaccurate and non-repeatable measurements, especially on complex curved surfaces.
Innovation Solution
The system uses automated surface approximation methods to reconstruct an undamaged surface as a nonplanar reference surface, employing CAD geometry, interpolation, or extrapolation from surrounding areas, and standardized measurement techniques to reduce operator dependency and ensure accurate, repeatable defect measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual reference point selection is used for defect measurement, then operator flexibility is maintained, but measurement precision and repeatability deteriorate due to human interpretation variability
Solution Approach 1:
The system performs automated surface approximation and defect measurement without requiring manual reference point selection. The computer automatically identifies the reference surface and calculates defect characteristics, eliminating human interpretation variability while maintaining operational simplicity through automated processing.
Solution Approach 2:
The manual mechanical process of selecting reference points and measuring defects is replaced with an automated computer-based system that uses image processing algorithms. This substitution eliminates human variability while maintaining the essential measurement function.
2Measurement precision
If automated surface approximation is implemented, then measurement repeatability improves, but device complexity increases due to additional processing requirements
Solution Approach 1:
The existing defect inspection system is enhanced with automated surface approximation capabilities, allowing the same device to perform both traditional manual inspection and automated measurement. This multi-functionality approach adds capability without requiring completely separate systems.
Solution Approach 2:
A computer acts as an intermediary between the image capture system and the measurement output. The computer processes images, performs surface approximation, and calculates defect characteristics, serving as a mediator that adds automated functionality while integrating with existing inspection workflows.
3Measurement precision
If nonplanar reference surfaces are used for curved components, then measurement accuracy on complex surfaces improves, but calculation complexity increases
Solution Approach 1:
The system applies surface approximation locally to the specific region being inspected rather than requiring global complex calculations. By focusing on local surface characteristics and using appropriate approximation methods for each region, the system achieves high accuracy on curved surfaces without excessive computational burden.
Solution Approach 2:
The system transforms the complex problem of measuring defects on nonplanar surfaces by changing the reference framework. Instead of measuring relative to the complex curved surface directly, the system approximates a reference surface and measures deviations from this simplified model, reducing calculation complexity while maintaining accuracy.
Data Source
AI summary
A system may include a sensor comprising a sensor configured to capture data from a part of an engine. The system being configured to form a three-dimensional (3D) surface model of the part of the engine based on signals received from the sensor system, determine a nonplanar reference surface based on the 3D surface model of the part, and measure a characteristic of a damaged portion of the part of the engine based on the 3D surface model and the nonplanar reference surface.