Image-Based Inspection System for Mil-Level Precision
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Solution Overview
Problem
Current manual inspection methods for objects like aviation engine components are time-consuming and expensive due to the need for custom-built hard fixtures, which are costly and inefficient for achieving mil-level precision.
Innovation Solution
An image-based inspection system using a network-connected image capture device and inspection device, which captures high-resolution images of objects and processes them to determine discrepancies through 3D modeling and projection error correction, enabling mil-level precision without the need for custom fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection using hard fixtures is used, then measurement precision can be achieved, but inspection time and cost increase significantly
Solution Approach 1:
The patent replaces the mechanical hard fixture system with an optical/image-based inspection system. Instead of using physical fixtures and manual dial calipers, the system captures images of the object and uses image processing algorithms to extract dimensional measurements, thereby eliminating the time-consuming manual measurement process while maintaining mil-level precision through computational methods
Solution Approach 2:
The patent creates a digital copy (image) of the physical object and performs measurements on this copy rather than the original object. By capturing high-resolution images and processing them computationally, the system obtains dimensional data without physical contact or manual measurement, significantly reducing inspection time while preserving measurement accuracy
2Measurement precision
If custom hard fixtures are built for each object, then precise measurement is possible, but manufacturing cost increases
Solution Approach 1:
The patent implements a universal image-based inspection system that can measure multiple different objects without requiring custom-built fixtures for each. The same hardware setup (camera, lighting, stand) serves all inspection tasks, and the system adapts to different objects through software configuration and image processing, eliminating the need for expensive custom manufacturing while maintaining measurement precision
Solution Approach 2:
The patent replaces the mechanical fixture manufacturing process with a software-based measurement approach. Instead of physically building custom fixtures for each object type, the system uses image capture and computational analysis to achieve precise measurements, thereby eliminating fixture manufacturing costs entirely
3Productivity
If automated image-based inspection is implemented, then inspection speed and efficiency improve, but measurement precision may be compromised
Solution Approach 1:
The patent captures high-resolution digital images of the object that serve as accurate copies, preserving all dimensional information in pixel form. By using high-resolution cameras and proper imaging techniques, the digital copy maintains sufficient detail to extract mil-level precise measurements through image processing, bridging the gap between automated speed and measurement precision
Solution Approach 2:
The patent changes the measurement parameters from physical contact (manual caliper readings) to optical parameters (pixel coordinates, image resolution, focal length). By carefully controlling and calibrating these optical parameters, the system achieves mil-level precision in the automated image-based measurement process, maintaining accuracy while enabling high-speed automated inspection
Data Source
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AI summary
A method (600) for image based inspection of an object includes receiving (602) an image of an object from an image capture device, wherein the image includes a representation of the object with mil-level precision. The method further includes projecting (604) a measurement feature of the object from the image onto a three-dimensional (3D) model of the object based on a final projection matrix; determining (606) a difference between the projected measurement feature and an existing measurement feature on the 3D model; and sending (608) a notification including the difference between the projected measurement feature and the existing measurement feature.