Laser Scanner Optical Surface Inspection Using Grazing Light Debris Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Laser scanners used in aircraft component manufacturing face reduced effectiveness due to debris on their optical surfaces, leading to inferior surface ablation and reduced laser power impact, as deflected laser light results in incomplete material etching.
Innovation Solution
An automated inspection system utilizing a directional optical source and optical detector to detect debris on the laser scanner's optical surface by emitting a light beam that intersects with debris, capturing deflected light, and generating feedback for user alerting and cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a light beam is emitted directly across the optical surface to detect debris, then debris detection capability is improved, but the optical surface may be contaminated by the inspection system itself
Solution Approach 1:
The patent introduces a reflective surface positioned below the optical surface as an intermediary element. The inspection light beam reflects off this intermediate surface to illuminate debris on the optical surface indirectly, rather than the beam directly contacting the optical surface. This mediator enables debris detection while preventing contamination of the optical surface.
2Productivity
If the laser scanner operates with debris on the optical surface, then continuous production is maintained, but laser ablation quality deteriorates
Solution Approach 1:
The patent implements preliminary inspection of the optical surface for debris before the laser ablation process begins. By detecting and alerting operators to debris presence in advance, the system enables preventive maintenance actions to be taken before quality degradation occurs, maintaining both continuous production capability and ablation quality.
Solution Approach 2:
The inspection system provides real-time feedback about debris presence on the optical surface to operators. This feedback mechanism enables timely intervention to clean or replace contaminated optical surfaces, preventing degradation of laser ablation quality while allowing continuous operation when conditions are acceptable.
3Manufacturing precision
If the optical surface is inspected frequently to maintain quality, then ablation quality is improved, but inspection time and system complexity increase
Solution Approach 1:
The patent replaces manual visual inspection or complex multi-component inspection systems with a simple optical detection system using a light source and sensor. This substitution enables rapid, automated debris detection that requires minimal operator time and system complexity while maintaining high ablation quality through frequent inspection capability.
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
Ensures a clear optical surface by accurately detecting debris and alerting users, thereby maintaining high-quality laser ablation and scanner performance.
Implementation Method 1
The light beam extending across, and just above, the surface of the optical surface will impact on any debris in its path that is on the optical surface and deflect out.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure provides an inspection system (300) and method for inspecting an optical surface (306) of a laser scanner (230), the system including a directional optical source (302) a beam axis of which extends across but does not intersect the optical surface of the laser scanner so that the light is incident on debris (D) disposed on the optical surface, and an optical detector (310) configured to collect the light to form an image. The method includes moving one of the laser scanner or the inspection system to a position in which a beam axis of the directional optical source extends across but does not intersect the optical surface, between the optical surface of and the optical detector. The method further includes emitting a light beam from the directional optical source, across the optical surface so that light from the light beam is incident on debris disposed on the optical surface. The method further includes collecting the light at the optical detector to form an image that indicates presence of the debris on the optical surface of the laser scanner; and generating feedback to alert a user of the presence of the debris.