FRP Drilling Damage Measurement Using Scanned Hole Image Analysis
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Solution Overview
Problem
Current methods for characterizing drilling damage in fiber reinforced plastic composites are expensive, time-consuming, and lack automation, particularly in quantifying burr and delamination damages, which are critical for improving the service life of workpieces under fatigue loads.
Innovation Solution
A system and method involving a scanner and computing device to measure and calculate delamination size and factor by analyzing scanned images of drilled holes, using a black substrate to isolate damage peaks and employing AutoCAD image processing techniques for accurate measurement of chip and burr regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive equipment like electron microscopes or acoustic microscopes is used to characterize drilling damage, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses optical copying techniques to create images of drilling damage on the workpiece surface. Instead of using complex electron microscopes or acoustic microscopes, the invention employs simple optical cameras and image processing to capture and analyze damage patterns, achieving adequate measurement precision with much simpler equipment
Solution Approach 2:
The patent replaces complex mechanical and physical measurement systems (electron microscopes, acoustic microscopes) with optical imaging and computational analysis. By substituting physical measurement mechanisms with optical-field-based imaging and software-based damage quantification, the system achieves comparable measurement precision with significantly reduced device complexity
2Measurement precision
If manual procedures are used to characterize drilling damage, then measurement precision can be maintained, but productivity decreases
Solution Approach 1:
The patent implements automated image processing algorithms that automatically detect, measure, and quantify drilling damage without requiring manual intervention. The system self-services by capturing images, processing them through computational algorithms, and generating damage characterization results automatically, thereby maintaining measurement precision while dramatically increasing productivity
Solution Approach 2:
The patent enables continuous automated characterization of drilling damage by implementing a workflow where images are continuously captured and processed. Multiple workpieces can be characterized in sequence without interruption, maintaining consistent measurement precision while achieving high throughput and productivity
3Measurement precision
If quantization of burr and delamination damages is implemented, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex physical measurement devices with optical imaging and computational quantification methods. By using image processing algorithms to automatically measure and quantify burr and delamination damages, the system achieves precise damage quantization without requiring complex measurement hardware
Solution Approach 2:
The patent uses optical copying to create digital representations of drilling damage, which can then be precisely measured and quantified using software algorithms. This approach enables accurate quantization of damage dimensions while keeping the physical measurement system simple
4Productivity
If automated image processing is used to characterize drilling damage, then productivity is improved, but measurement precision may decrease
Solution Approach 1:
The patent implements self-service automated image processing with algorithms that automatically detect edges, measure dimensions, and quantify damage. The system includes self-correction mechanisms that validate measurements and ensure precision is maintained while achieving high productivity through full automation
Data Source
AI summary
A system and a method for measuring drilling damage in fiber reinforced plastic (FRP) composites is described. Multiple holes are drilled in the FRP composite using a drill having nominal diameter, and the FRP composite is separated into multiple drilled blocks. Each block, covered with the black substrate, is scanned on a scanner to generate a scanned image depicting a hole region, a background, and delamination damage peaks. For each scanned image, a maximum delamination damage peak and a maximum diameter of a first circle concentric with the drilled hole and passing through tip of the maximum delamination peak, are measured. Further, a delamination size and a delamination factor are calculated based on the maximum diameter of the first circle and the nominal diameter of the drill.