Handheld Infrared Camera for Coated Surface Inspection
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Solution Overview
Problem
Existing infrared detection systems for analyzing coated surfaces are limited by their reliance on broad spectrum light, which causes heating and reduces image quality due to ambient light and radiation interference, and are often complex, unsafe for the human eye, and not portable.
Innovation Solution
A portable, handheld infrared detection camera system that uses near-infrared wavelengths to detect anomalies beneath coated surfaces, featuring a mid-wave infrared camera, a custom infrared lens, a sapphire window, and a compact infrared illumination assembly, which reduces ambient light interference and allows for real-time, nondestructive imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If broad spectrum light is used for infrared detection, then the detection capability is improved, but heating is caused and image quality deteriorates due to substrate radiation interference
Solution Approach 1:
The patent changes the wavelength parameter from broad spectrum to specific near-infrared wavelengths (700-2500 nm), which allows detection of subsurface anomalies while minimizing heating effects and reducing interference from ambient light and substrate radiation
Solution Approach 2:
The patent extracts only the useful near-infrared portion of the spectrum for detection, separating it from the harmful broad spectrum components that cause heating and interference, thereby achieving detection without the adverse effects
2Reliability
If broad spectrum light is used, then detection is enabled, but ambient light and radiation interference increase, reducing image quality
Solution Approach 1:
The patent narrows the detection wavelength range to near-infrared (700-2500 nm), which is less susceptible to ambient light interference compared to visible spectrum, thereby improving image quality while maintaining detection capability
Solution Approach 2:
The patent uses near-infrared illumination as an intermediary that penetrates the coating and interacts with subsurface features, providing a detection mechanism that is less affected by ambient light and radiation interference
3Reliability
If prior art infrared systems are used, then detection is possible, but device complexity increases requiring multiple sensors and processing equipment
Solution Approach 1:
The patent combines the illumination source, camera sensor, and processing capabilities into a single integrated handheld device, eliminating the need for separate sensors, microphones, booms, and audio processing equipment required by prior art systems
Solution Approach 2:
The patent creates a multi-functional handheld device that performs illumination, imaging, and data processing functions, replacing complex multi-component systems with a single versatile tool that can detect various subsurface anomalies
4Reliability
If prior art devices are used, then analysis is performed, but safety for human eye is compromised making them dangerous to use
Solution Approach 1:
The patent operates in the near-infrared wavelength range (700-2500 nm) which is safe for human eyes, replacing prior art devices that used visible or ultraviolet light that could be harmful to the human eye while maintaining effective detection capability
5Ease of operation
If devices are held at a distance from the surface, then operation is easier, but interference from stray light and thermal radiation increases
Solution Approach 1:
The patent uses near-infrared illumination that is less susceptible to stray light and thermal radiation interference compared to visible light, allowing the device to be held at a convenient distance while maintaining image quality and reducing interference from the environment
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
The system effectively detects stress fractures, imperfections, and corrosion beneath coated surfaces without causing heating or damage, providing high-quality, real-time images that are safe for the human eye and can be used in various applications, including aircraft inspection.
Implementation Method 1
The infrared illumination assembly includes at least one light emitting illumination source and at least one reflector. The light emitting illumination source preferably emits near infrared radiation
Implementation Method 2
The imaging array is preferably a camera which has a wavelength in the range into the near infrared, up to about 1500 nm
Implementation Method 3
The window is placed inside the housing above the viewing port, is preferably made of sapphire and has a thickness of 3 mm
Data Source
AI summary
An infrared detection camera for the inspection of coated substrates. A corrosion sensing instrument is handheld, portable, battery powered, compact and lightweight. The camera performs nondestructive, real time imaging of corrosion and defects beneath painted metal or plastics or composite surfaces. The device includes a user-friendly computer interface for real time imaging and image storage capability and is typically used for detecting early stage corrosion beneath painted aircraft aluminum surfaces. The handheld device has a front “open air” imaging port which is designed to be placed in soft contact against the painted surface to be inspected by the instrument. The device includes an infrared camera and infrared lighting to capture an image of the surface. The captured image is transferred to a computer and analyzed to locate imperfections below a coating on a surface.