Imaging Fixture for Automated Image Scaling in Composite Inspection
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Solution Overview
Problem
Current methods for detecting wrinkles in composite material components, such as those used in aircraft, are time-intensive and prone to variability due to manual scaling and light correction, leading to inconsistent results.
Innovation Solution
A fixture system that holds an imaging device at a fixed distance from the object and controls incident light, combined with calibration objects to determine an image scaling factor, allowing for automated and repeatable measurement of physical dimensions from images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual scaling and light correction methods are used, then flexibility in operation is maintained, but measurement precision and reliability deteriorate due to variability between inspectors and scan locations
Solution Approach 1:
A fixture is introduced as an intermediary device between the imaging device and the object being imaged. The fixture includes a hollow elongate section that holds the imaging device at a fixed distance from the object and controls incident light, thereby eliminating variability caused by manual positioning and lighting adjustments while maintaining ease of use through simple placement on the object surface
Solution Approach 2:
The system changes the parameter of imaging distance from variable (manual adjustment) to fixed (determined by fixture geometry). The hollow elongate section's length precisely defines the distance between the imaging device and the object, ensuring consistent measurement conditions across all inspections
2Productivity
If manual scaling and light correction are performed, then adaptability to different inspection scenarios is maintained, but productivity deteriorates due to time-intensive processes
Solution Approach 1:
The fixture performs self-service by automatically controlling incident light and maintaining fixed imaging distance without requiring manual intervention for scaling or light correction. The hollow elongate section's structure inherently provides the necessary positioning and lighting control, eliminating time-consuming manual operations while remaining adaptable to different objects through simple placement
3Reliability
If fixed distance imaging is implemented using a fixture, then measurement reliability is improved, but device complexity increases
Solution Approach 1:
The system is segmented into simple, distinct components: a hollow elongate section for positioning, an opening for receiving the imaging device, and a bracing structure. This segmentation allows each component to perform its function simply, maintaining low overall complexity while achieving reliable fixed-distance imaging through the coordinated arrangement of these basic elements
Data Source
AI summary
An example system includes a base, two objects each having a known dimension and positioned on the base spaced apart by a known distance, an imaging device positioned such that the two objects are in a field of view of the imaging device and such that the field of view of the imaging device originates from a point normal to a surface of the base, and a computing device having one or more processors and non-transitory computer readable medium storing instructions executable by the one or more processors to perform functions. The functions include receiving an image from the imaging device capturing the two objects in the field of view, and based on one or more of the known dimension of the two objects and the known distance between the two objects, determining an image scaling factor that associates a number of pixels in the image to a physical distance.