Handheld Optical Measurement Device for Aerostructure Discontinuity Inspection
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Solution Overview
Problem
Existing technologies lack the accuracy, repeatability, and speed to effectively measure surface discontinuities in high-performance structures like aerostructures, particularly due to issues with matte temporary protective coatings and glare, requiring time-consuming removal and reapplication of coatings for precise measurements.
Innovation Solution
A handheld device equipped with light sources, a digital camera, a thickness sensor, and an electronic processing component that allows for three-dimensional topography measurements, capable of measuring discontinuity depth from the bottom to the top of the metal surface without removing the protective coating, using a conforming membrane or gel to uniform reflectivity and color differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple images are captured and compared to estimate discontinuity depth, then discontinuity depth can be determined, but measurement accuracy deteriorates due to reflectivity differences and glare from matte temporary protective coating
Solution Approach 1:
A conforming membrane is introduced as an intermediary layer between the imaging system and the discontinuity surface. This membrane conforms to the surface topology including discontinuities and provides uniform optical properties, eliminating the harmful reflectivity differences and glare caused by the matte temporary protective coating while allowing accurate depth measurement through optical comparison of images captured from different angles.
2Measurement precision
If matte temporary protective coating is removed and reapplied for accurate measurement, then measurement accuracy improves, but productivity deteriorates due to time-consuming removal and reapplication process
Solution Approach 1:
The conforming membrane serves as a temporary intermediary that replaces the need to remove and reapply the matte temporary protective coating. It provides the necessary uniform optical surface for accurate measurement while leaving the original coating intact, thereby eliminating the time-consuming removal and reapplication process and significantly improving inspection productivity.
Solution Approach 2:
A flexible conforming membrane is used that can adapt to the surface topology including discontinuities. This thin film provides a uniform optical interface without requiring removal of the protective coating, enabling rapid inspection while maintaining measurement accuracy.
3Ease of operation
If conventional imaging techniques are used, then inspection process is simple, but measurement repeatability deteriorates due to varying reflectivity and lighting conditions
Solution Approach 1:
The conforming membrane acts as a standardized intermediary that eliminates variations in reflectivity and lighting conditions. By providing a uniform optical interface that conforms to the surface, it ensures consistent image capture across multiple inspections, dramatically improving measurement repeatability while maintaining operational simplicity.
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
The device provides higher resolution, greater accuracy, and increased repeatability for measuring surface discontinuities, enabling quick and efficient evaluation of discontinuities in production and maintenance environments, with the ability to determine the true depth and criticality of discontinuities, and automatically assess repair needs.
Implementation Method 1
The conforming membrane may have two sides and be configured to be applied over the discontinuity and to conform to the discontinuity and make more uniform a reflectivity difference and a color difference between the discontinuity and an adjacent portion of the structure
Implementation Method 2
The pressurization mechanism may be configured to create a pressure differential between the two sides of the conforming membrane so as to urge the conforming membrane into closer contact with the surface discontinuity
Implementation Method 3
The light sources may be configured to illuminate the discontinuity from one or more angles, and the digital camera may be configured to capture one or more images of the discontinuity illuminated by the light sources
Data Source
AI summary
A handheld device for making 3D topography measurements of surface discontinuities in high performance structures, such as aerostructures (e.g., aluminum fuselages). Lights illuminate the discontinuity from multiple angles, and a camera captures images of the discontinuity. A thickness sensor generates thickness data regarding a thickness of the base material and the top protective coating. A position sensor generates position data regarding a location of the discontinuity on the structure. A processor generates geometry data regarding a geometry of the discontinuity based on the images, performs an analysis of the geometry, thickness, and position data, and communicates a result of the analysis on a display. A conforming membrane and/or a gel and an opaque lubricant may be applied over and conform to the discontinuity in order to make more uniform a reflectivity difference and a color difference between the discontinuity and an adjacent portion of the structure.