Honeycomb Core Surface Shape Measurement Using Reflective Film
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Solution Overview
Problem
The existing methods for measuring the surface shape precision of honeycomb cores in aerospace manufacturing are inefficient and costly due to their discontinuous nature and the need for specialized profiling models, which limits precision and increases manufacturing costs.
Innovation Solution
A method involving the application of a reflective film using vacuum adsorption and a laser measurement sensor to scan the honeycomb core's surface, allowing for precise measurement of wall heights and surface shape analysis, including three-dimensional data acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a profiling modeling method is used to detect the shape precision of the honeycomb core, then the measurement can be performed, but the manufacturing cost becomes very high and the precision is limited
Solution Approach 1:
The patent uses a reflective film as a temporary copy of the honeycomb core surface for measurement purposes. The film conforms to the complex curved surface and allows laser scanning without requiring permanent physical modeling, thus achieving precise measurement without high manufacturing costs
Solution Approach 2:
The reflective film acts as an intermediary between the laser measurement device and the honeycomb core surface. It enables the laser to reflect properly from the complex curved surface while being easily applied and removed, avoiding the need for expensive specialized profiling models
2Ease of operation
If the discontinuous characteristic of the honeycomb core surface is measured directly, then the measurement process becomes complex, but using a reflective film simplifies the measurement
Solution Approach 1:
The reflective film serves as a mediator that transforms the complex discontinuous honeycomb surface into a continuous reflective surface. The film bridges the gaps between honeycomb cells and provides a uniform surface for laser scanning, greatly simplifying the measurement process
Solution Approach 2:
The patent employs a flexible reflective film that can conform to the complex curved surface of the honeycomb core. The thin film adapts to the discontinuous surface geometry while providing a continuous measurement interface, making the measurement process much easier
3Measurement precision
If a reflective film is applied to the honeycomb core surface, then measurement precision is improved, but the vacuum adsorption process is required which adds process steps
Solution Approach 1:
The patent uses vacuum adsorption (a pneumatic principle) to attach the reflective film to the honeycomb core surface. The vacuum pressure ensures the film conforms tightly to the complex curved surface without requiring mechanical fastening or complex positioning mechanisms, actually simplifying the overall process
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 approach provides high precision, reduces manufacturing costs, enhances measurement efficiency, and adapts to various surface shapes, enabling in-situ measurement of honeycomb cores with improved accuracy and cost-effectiveness.
Implementation Method 1
coating a reflective film on a surface to be measured of a honeycomb core, using a vacuum adsorption method to adhere the reflective film closely to the surface to be measured of a honeycomb core
Implementation Method 2
performing scanning measurement on the reflective film on the surface to be measured of the honeycomb core to obtain the heights of a honeycomb wall of the honeycomb core at different spatial positions
Data Source
AI summary
A method for measuring a surface shape of a honeycomb core includes the following steps: coating a reflective film on the surface of the honeycomb core to be measured, using a vacuum adsorption method to adhere the reflective film closely to the surface of the honeycomb core to be measured, and recessing the reflective film at a honeycomb cell downwards; and performing scanning measurement on the reflective film on the surface of the honeycomb core to be measured to obtain the heights of a honeycomb wall of the honeycomb core at different spatial positions. A device carries out the measurement of the surface shape of a honeycomb core.