Real-time Frame Damage Visualization via Optical Sensor Mapping
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Solution Overview
Problem
Conventional methods for monitoring structural integrity in machines are impractical due to limitations in accessing concealed components, inability to account for cumulative wear, and lack of real-time, comprehensive assessments, leading to inadequate diagnostic and prognostic insights.
Innovation Solution
A visualization system that includes sensors to measure field damage data and an analytical model database to generate an events log, which is used to create a visual model of the machine frame, providing real-time, comprehensive, and cumulative assessments of structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual and visual inspections are used to monitor fatigue damage, then structural integrity can be assessed, but concealed components cannot be adequately assessed and substantial downtime is required
Solution Approach 1:
The patent replaces manual visual inspection methods with an automated optical system using cameras and image processing algorithms. The system captures images of structural components and uses computer vision to detect fatigue damage, eliminating the need for manual inspection and reducing machine downtime while maintaining or improving assessment reliability.
Solution Approach 2:
The system enables the machine to self-monitor its structural integrity through automated image capture and analysis. The optical system and processing algorithms work autonomously to detect damage without requiring human intervention, allowing continuous monitoring during normal operation and eliminating productivity loss from manual inspections.
2Measurement precision
If discrete gauges are placed on structures to electronically monitor loads and strains, then actual impacts on machine frame can be assessed, but comprehensive assessment of the entire frame cannot be provided
Solution Approach 1:
The patent transitions from point-based discrete gauge measurements to a field-based optical measurement system. By using cameras to capture images across the entire structural component and applying image processing techniques, the system obtains damage information across all spatial dimensions simultaneously, providing comprehensive assessment rather than localized data at discrete points.
Solution Approach 2:
The system creates visual copies (images) of the entire structural component and processes these copies to extract damage information. Instead of relying on physical gauges at specific locations, the optical system captures complete visual representations of the structure, allowing comprehensive analysis of the entire frame without physical contact or discrete measurement points.
3Reliability
If discrete strain data is collected from sensors, then localized damage can be detected, but real-time comprehensive monitoring of the entire frame cannot be achieved
Solution Approach 1:
The patent implements continuous monitoring by capturing images at multiple time points and processing them sequentially. The system continuously acquires visual data from the structural component and updates damage assessments in real-time, maintaining uninterrupted monitoring capability that provides frequent updates on the entire frame's condition rather than periodic discrete measurements.
Data Source
AI summary
A visualization system for visualizing structural integrity of a frame is provided. The visualization system may include a monitoring device having one or more sensors coupled to the frame, and a workstation in communication with the one or more sensors. The sensors may be configured to measure field damage data. The workstation may include a display device, an analytical model database storing model damage data, and a controller. The controller may be configured to receive the field damage data from the sensors, receive the model damage data from the analytical model database, generate an events log based on the field damage data and the model damage data, map the model damage data to a visual model of the frame based on the events log, and display the visual model of the frame on the display device.