Automated Laser Projection for Part Inconsistency Detection
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Solution Overview
Problem
Existing nondestructive evaluation methods for post-manufacture parts are often costly, time-consuming, inefficient, prone to errors, and lack repeatability, requiring cumbersome processes for identifying and repairing inconsistencies.
Innovation Solution
A method involving scanning parts for inconsistencies using non-destructive inspection devices, determining reference points, and displaying the inconsistency image on the part using a laser projection device, allowing for precise location and reworking of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional paper plot methods are used to identify and trace inconsistencies, then the process is simple to administer, but it is time-consuming, costly, and prone to human error
Solution Approach 1:
The patent replaces manual mechanical processes (paper plotting, physical alignment, manual tracing) with an automated optical-digital system. The NDI device captures images digitally, software automatically processes and overlays inconsistency markers, and the system projects results directly onto the part, eliminating the need for physical paper manipulation and manual tracing operations.
Solution Approach 2:
The patent creates a digital copy of the part image through NDI scanning, then overlays inconsistency markers on this digital copy. This digital representation serves as a virtual replica that can be manipulated, analyzed, and displayed without affecting the physical part, enabling automated processing while maintaining accuracy.
2Device complexity
If manual alignment and tracing methods are used, then the equipment is simple, but the process lacks repeatability and consistency
Solution Approach 1:
The patent replaces manual alignment operations with automated image processing. Software algorithms automatically align the NDI image with the part geometry and consistently place inconsistency markers based on coordinate data, eliminating the variability inherent in manual alignment and tracing by different operators.
Solution Approach 2:
The system provides visual feedback by overlaying inconsistency markers directly on the digital image and projecting them onto the physical part. This feedback mechanism allows operators to immediately verify the location and nature of inconsistencies, ensuring consistent identification and reducing errors through visual confirmation.
3Ease of manufacture
If full-scale paper plots are printed and manually aligned, then no special equipment is needed, but the process is inefficient and costly
Solution Approach 1:
The patent replaces the mechanical process of printing, handling, and aligning large-format paper plots with a digital imaging and display system. The NDI device captures images digitally, software processes and displays results on screens or through projection, eliminating the need for physical printing and manual paper manipulation while significantly improving efficiency.
Solution Approach 2:
The patent transitions from two-dimensional paper plots to multi-dimensional digital representation and display. The system can display enlarged views, provide three-dimensional context through projection, and offer interactive manipulation of the image data, adding functional dimensions that go beyond simple flat paper visualization.
4Adaptability or versatility
If manual tracing on Mylar sheets is used, then the process is adaptable to different part sizes, but it is difficult to administer and inconsistent
Solution Approach 1:
The patent replaces the manual process of creating and handling Mylar sheets with automated digital image processing. The system captures images at appropriate scales, software automatically adjusts and processes the images, and results are displayed digitally or projected, eliminating the need for manual Mylar preparation and handling while maintaining adaptability to different part sizes.
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 enables efficient, consistent, and automated identification and repair of inconsistencies, reducing human error and time, while improving the accuracy and efficiency of the inspection process.
Implementation Method 1
an image-projecting device capable of projecting an image indicative of the flaw onto the workpiece
Implementation Method 2
a plurality of encoders for determining a location and/or orientation of the image-projecting device
Data Source
Figure 1
Figure 2
AI summary
The embodiments of the disclosure relate to a method of displaying an image of an inconsistency on a part. The part may be scanned. An inconsistency on the part may be located. An image of the inconsistency may be displayed on the part. In other embodiments, parts are provided which had images of the parts' inconsistencies displayed on one or more surfaces of the parts.