Fastener Concentricity Inspection via X-Ray and Stereo Vision
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Solution Overview
Problem
Current inspection techniques for fasteners in assemblies, such as aircraft, are destructive, time-consuming, costly, and operator-dependent, making it difficult to efficiently verify proper installation, especially in automated processes.
Innovation Solution
A system and method utilizing an x-ray imaging system, camera devices, and processing units to create 3D images of fasteners, allowing for non-destructive, quick, and automated inspection of fastener concentricity, flushness, and detection of foreign object debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual probe inspection is used, then measurement capability is provided, but inspection is destructive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical probe inspection with an automated optical imaging system using digital cameras and image processing algorithms. This substitution eliminates the need for physical contact with fasteners, enabling non-destructive inspection while automatically capturing and analyzing fastener characteristics, thereby reducing inspection time without sacrificing measurement precision.
Solution Approach 2:
The patent creates digital image copies of fasteners using multiple camera views that are processed to generate virtual representations. These digital copies allow for repeated measurement and analysis without physically touching or damaging the actual fasteners, enabling non-destructive inspection while maintaining measurement capability through virtual modeling.
2Productivity
If automated fastener installation is used, then productivity is improved, but in-process inspection capability is lost
Solution Approach 1:
The patent implements inspection capability that can assess fastener installation quality after automated installation, using pre-configured imaging systems and algorithms that automatically evaluate concentricity and other critical parameters. This preliminary assessment capability ensures that automated installation processes maintain quality control without requiring manual intervention or losing inspection functionality.
3Ease of operation
If operator-dependent inspection is used, then flexibility is maintained, but repeatability deteriorates
Solution Approach 1:
The patent implements automated image processing algorithms that consistently apply the same measurement criteria and analysis methods to every fastener inspected. The system provides objective feedback based on predetermined tolerances and acceptance criteria, eliminating operator variability and ensuring high repeatability while maintaining operational flexibility through programmable inspection parameters.
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
Enables efficient, non-destructive, and automated inspection of fasteners, reducing time and costs while improving the accuracy and repeatability of the inspection process.
Implementation Method 1
an x-ray imaging system oriented and configured to produce an x-ray image of the fastener
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Systems and methods inspect a fastener (12) installed at least partially through a hole in a part, by measuring fastener concentricity, measuring fastener flushness with a surface, and/or detecting foreign object debris near the fastener. Systems include an x-ray imaging system (18), a first camera device (20), a second camera device (22), a first support structure (26), and at least one processing unit (24). The first camera device produces a first image of the fastener from a first vantage point, and the second camera device produces a second image of the fastener from a second vantage point, such that a 3D image of the fastener can be created from the first image and the second image. The system inspects the fastener based on the x-ray image and/or the 3D image, to determine concentricity and/or flushness of the fastener. Systems may be automated and mounted on robot arms to be positioned relative to the fasteners being inspected.