Hyperspectral Probe Inspection for Foreign Object Debris Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for detecting foreign object debris in manufacturing processes, such as in aircraft construction, are time-consuming and prone to human error, with radiographic inspection being lengthy and requiring evacuation due to radiation, while visual inspection is labor-intensive.

Innovation Solution

A system utilizing a hyperspectral imaging device mounted on a movable probe, potentially with a robot, that analyzes hyperspectral image data using AI or machine learning to automatically detect and localize foreign object debris, accompanied by a debris collector for removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If radiographic inspection is used to detect foreign object debris, then detection capability is improved, but inspection time increases significantly and radiation safety issues arise

Engineering Contradiction:

Improvedetection capabilityVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces radiographic inspection (which uses ionizing radiation) with hyperspectral imaging that uses visible and near-infrared light. This substitution maintains detection capability while eliminating radiation hazards and significantly reducing inspection time, as the hyperspectral system can scan aircraft components rapidly without safety evacuations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the detection parameter from radiographic absorption to spectral reflectance characteristics. By analyzing the unique spectral signatures of foreign object debris across multiple wavelengths, the system achieves reliable detection while enabling faster scanning speeds and avoiding radiation-related time losses.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If manual visual inspection is used to detect foreign object debris, then no radiation safety issues arise, but inspection time and labor requirements increase significantly

Engineering Contradiction:

Improveradiation safetyVSAvoidinspection efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The hyperspectral imaging system automatically detects and identifies foreign object debris through algorithmic analysis of spectral data, eliminating the need for manual inspection labor. The system performs self-assessment of debris presence based on spectral pattern recognition, dramatically improving productivity while maintaining safety.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual visual inspection with an automated hyperspectral imaging system that uses optical sensors and computational algorithms. This substitution eliminates human labor requirements and radiation safety concerns while significantly increasing inspection throughput and efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If manual visual inspection is used to detect foreign object debris, then equipment complexity is reduced, but detection accuracy decreases due to human error

Engineering Contradiction:

Improveequipment simplicityVSAvoiddetection accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces human visual inspection with an automated hyperspectral imaging system that uses spectral analysis algorithms. This substitution eliminates human error while maintaining reasonable equipment complexity through the use of standard hyperspectral sensors and computational processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces hyperspectral image processing algorithms as an intermediary between the sensor and the detection decision. These algorithms objectively analyze spectral patterns to identify foreign object debris, providing high detection accuracy while keeping the physical system relatively simple.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables rapid, precise, and reliable detection of foreign object debris with reduced human intervention, improving efficiency and accuracy by differentiating debris from background images through spectral analysis.

Implementation Method 1

The probe includes a hyperspectral imaging device configured to acquire hyperspectral image data of one or more portions of the structure

Methodology Applied

Scientific EffectHyperspectral imaging: Absorption Spectroscopy

Data Source

PatentUS12601692B2Systems and methods for detecting foreign object debris within a structure

Publication Date: 2026.04.14 THE BOEING CO

AI summary

A system and a method for detecting foreign object debris in relation to a structure include a probe configured to move in relation to the structure. The probe includes a hyperspectral imaging device configured to acquire hyperspectral image data of one or more portions of the structure. A control unit is in communication with the hyperspectral imaging device. The control unit is configured to receive the hyperspectral image data from the hyperspectral imaging device, and analyze the hyperspectral image data to detect a presence of the foreign object debris.