Magnetically-Responsive Member Foreign Object Detection

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Solution Overview

Problem

Current methods for detecting foreign objects within vehicle structures during manufacturing are time-consuming, labor-intensive, and inefficient, particularly due to the shielding effect of electrically conductive materials like aluminum aircraft skins, which absorb RF signals and hinder RFID-based detection.

Innovation Solution

A system utilizing a magnetically-responsive member coupled with a magnetic field generator and detector to locate foreign objects by generating a low-frequency magnetic field, causing the member to emit a signal with a third harmonic that can penetrate conductive materials, allowing for efficient detection and identification of objects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If RFID devices are used to detect foreign objects, then detection capability is improved, but electrically-conductive sheets absorb RF signals and shield foreign objects from detection

Engineering Contradiction:

Improvedetection capabilityVSAvoidsignal absorption by conductive sheets

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a magnetically-responsive member as an intermediary between the magnetic field generator and detector. This member converts the magnetic field into a detectable signal that can penetrate conductive sheets, solving the shielding problem while maintaining detection capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the RF-based electromagnetic detection system with a magnetic field-based system. By using magnetic fields instead of RF signals, the system avoids absorption by electrically-conductive sheets while achieving foreign object detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If manual searching methods are used to find foreign objects, then implementation simplicity is improved, but time and labor requirements increase significantly

Engineering Contradiction:

Improveimplementation simplicityVSAvoidsearch time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The magnetically-responsive member on the foreign object actively responds to the magnetic field by generating a detectable signal, enabling self-detection without requiring manual intervention or complex search procedures.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system creates a detectable signal 'signature' from the magnetically-responsive member that stands out against background noise, analogous to making the target visible through color or signal differentiation.

Inventive Principle:

Principle #32Color changes

3Ease of operation

If reporting lost tools is used to prevent foreign objects, then procedural simplicity is improved, but detection efficiency and reliability decrease

Engineering Contradiction:

Improveprocedural simplicityVSAvoiddetection efficiency

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The magnetically-responsive member is attached to tools and components before they are used in manufacturing. This preliminary tagging ensures that if any tool or component is left behind, it can be automatically detected by the magnetic field system.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system provides real-time feedback by detecting the presence or absence of magnetically-responsive members in the work area, immediately indicating when a tool or component has been left behind rather than relying on delayed reporting.

Inventive Principle:

Principle #23Feedback

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 differentiates and locates foreign objects within or on a vehicle structure by using a third harmonic signal, minimizing interference from structural components and enhancing detection efficiency.

Implementation Method 1

A magnetic field generator is configured to generate a magnetic field (which may be a low applied magnetic field of 10 Oersteds, for example) in the presence of the structure

Methodology Applied

Scientific EffectMagnetic field generation: Magnetic Field

Implementation Method 2

The magnetically-responsive member may be formed of a mu-metal. In at least one embodiment, the magnetically-responsive member may include a ferromagnetic coil

Methodology Applied

Scientific EffectFerromagnetic response: Ferromagnetism

Implementation Method 3

The sensor is configured to detect the signal output by the magnetically-responsive member

Methodology Applied

Scientific EffectElectromagnetic radiation detection: Electromagnetic Induction

Implementation Method 4

The control unit is configured to locate the object based on detection of a third harmonic of the signal

Methodology Applied

Scientific EffectHarmonic analysis: Resonance

Data Source

PatentUS9772422B2System and method for detecting objects

Publication Date: 2017.09.26 THE BOEING CO

AI summary

A system and method for locating an object within a structure includes a magnetically-responsive member coupled to the object. A magnetic field generator generates a magnetic field in the presence of the structure. The generated magnetic field causes the magnetically-responsive member to output a signal when the magnetically-responsive member is in the presence of the magnetic field. A detector may include a sensor coupled to a control unit. The sensor detects the signal output by the magnetically-responsive member. The control unit locates the object based on detection of a third harmonic of the signal.