Honeycomb Cell Inspection via Light Centroid Analysis
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Solution Overview
Problem
Current methods for inspecting honeycomb structures, such as those used in vehicle engines, lack efficiency in determining the pointing angle and vector of cells, which is crucial for assessing evenness and alignment, especially when dealing with complex geometries and varying cell orientations.
Innovation Solution
A system utilizing diffuse light sources that project light through and out of cells, with a digital imaging sensor and processor to determine the centroid of the light on a target, allowing for the calculation of pointing angles and vectors by comparing the light's location with the source, enabling precise inspection of cell groups, even when cells are not parallel to the axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional light transmission methods are used to inspect honeycomb structures, then the inspection process is simple, but the ability to determine pointing angles and vectors for complex geometries and varying cell orientations is insufficient
Solution Approach 1:
The inspection system divides the honeycomb structure into multiple cell groups, with each group inspected by a corresponding light source. This segmentation allows independent measurement of pointing angles and vectors for each cell group, improving precision for complex geometries while keeping each individual measurement simple
Solution Approach 2:
A target is introduced as an intermediary element between the light source and the imaging sensor. The target displays the transmitted light, enabling precise determination of light location and centroid, which is crucial for calculating pointing angles and vectors in complex geometries
2Productivity
If multiple light sources are used to inspect different cell groups simultaneously, then inspection productivity increases, but the system complexity and cost increase
Solution Approach 1:
Multiple light sources are combined with a single imaging sensor to inspect multiple cell groups simultaneously. This merging approach increases productivity by enabling parallel inspection of different cell groups while sharing common components (imaging sensor, processor, target) to control the increase in system complexity
Solution Approach 2:
The imaging sensor serves multiple functions: it captures light from multiple light sources, determines centroids for different cell groups, and provides data for calculating pointing angles and vectors. This multi-functionality increases inspection efficiency while minimizing the need for additional specialized components
3Adaptability or versatility
If diffuse light sources are used to project light through cells, then the inspection covers complex geometries and varying orientations, but the light distribution and measurement accuracy become more challenging
Solution Approach 1:
The system uses diffuse light sources that provide uniform light distribution across each local cell group while maintaining the ability to precisely determine light location through the target. This local quality approach enables inspection of complex geometries with varying orientations while preserving measurement accuracy through localized light projection and centroid determination
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
This method provides accurate and efficient inspection of honeycomb structures by determining the pointing angle and vector of cells, facilitating better alignment and evenness assessment, even in complex geometries, thereby improving the quality control process.
Implementation Method 1
The at least one light source projects light through and out of the at least one corresponding group of the cells
Implementation Method 2
the imaging system is further configured to gather data related to a surface of the target and determine a location of a centroid of the displayed light from the gathered data
Data Source
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AI summary
A system for inspecting a body (102), which includes a first end side (104), a second end side (106), and cells extending through the body from the first end side to the second end side, is provided. The system includes at least one light source (124) configured to project light through and out of at least one corresponding group of the cells, a target (136) configured to display the light projected through and out of the at least one corresponding group of the cells, an imaging system (160) configured to determine at least one location of the displayed light on the target, and a system processor (166) configured to compare the determined at least one location of the displayed light with a location of the at least one light source and calculate, from the comparison thereof, at least one of a pointing angle and a pointing vector for the at least one corresponding group of the cells.