Foreign Object Debris Movement Simulation for Targeted Inspection
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Solution Overview
Problem
Current methods for detecting foreign object debris (FOD) in machines are inefficient, requiring significant time and resources, and often involve introducing new risks by using tools that may introduce FOD into the machine.
Innovation Solution
A computer simulation method that predicts the behavior of FOD within a geometric computer model of a machine, using initial conditions and movement schedules to estimate the likelihood of FOD coming to rest at specific locations, allowing for targeted and resource-efficient inspections without introducing new FOD.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods (visual inspections, X-ray inspections, sweepers, vacuums, magnets) are used to detect FOD, then FOD detection capability is achieved, but time consumption and resource requirements increase significantly
Solution Approach 1:
The system performs preliminary simulation of FOD movement trajectories before actual inspection occurs. By pre-calculating where FOD is most likely to come to rest based on machine geometry and movement schedules, the inspection process is optimized to focus only on high-probability locations, dramatically reducing inspection time while maintaining detection capability
Solution Approach 2:
The system creates a geometric computer model (copy) of the machine that replicates its physical geometry and movement characteristics. This virtual model allows for repeated simulation and analysis without affecting the actual machine or requiring physical inspection of every possible FOD location, saving time and resources
2Measurement precision
If tools (sweepers, vacuums, magnets) are introduced to collect FOD, then FOD collection capability is achieved, but risk of introducing new FOD into the machine increases
Solution Approach 1:
The system replaces physical mechanical tools (sweepers, vacuums, magnets) with a computational simulation system. Instead of physically interacting with the machine interior using tools that could drop or shed debris, the system uses computer-based trajectory simulation to predict FOD locations, eliminating the risk of introducing new FOD while maintaining the ability to identify and collect existing FOD
3Measurement precision
If comprehensive inspection of all machine locations is performed to ensure complete FOD detection, then detection completeness is improved, but resource requirements and inspection complexity increase
Solution Approach 1:
The system applies local quality by focusing inspection resources on specific high-probability locations rather than uniformly inspecting all areas. The simulation identifies regions where FOD is most likely to accumulate based on local geometry and movement patterns, allowing inspectors to concentrate efforts on critical zones while reducing overall inspection complexity
Data Source
AI summary
Examples are disclosed that relate to computer-predicting behavior of foreign object debris (FOD) in a machine. In one example, a geometric computer model of the machine is recognized. FOD initial conditions within the geometric computer model of the machine are recognized. A movement schedule for the geometric computer model of the machine is recognized. A movement trajectory of a FOD from a starting position consistent with the FOD initial conditions throughout the geometric computer model of the machine is simulated based at least on the movement schedule for the geometric computer model of the machine. Simulation data detailing a likelihood that the FOD will come to rest at a location within the geometric computer model of the machine based on the simulated movement trajectory is output.