Optical Sensor Burn Test Evaluation

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Solution Overview

Problem

Conventional burn testing techniques for evaluating fire resistance in aerospace products are subjective and labor-intensive, relying on manual measurements and visual observations, which are prone to errors and inconsistencies.

Innovation Solution

The use of an optical sensor system and computer-based data processing to detect infrared reflections of a flame on a test piece, capturing initiation and cessation of fire damage, and determining burn characteristics through automated measurement and analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional manual burn testing techniques are used, then the evaluation process is simple to implement, but the measurement precision and reliability are poor due to subjectivity and human error

Engineering Contradiction:

Improveburn test evaluation accuracyVSAvoidtesting system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual visual observation and mechanical measurement tools with an optical sensing system that uses cameras and image processing algorithms to automatically detect and measure burn characteristics. This substitution of mechanical/manual systems with optical/automated systems directly improves measurement precision while accepting increased device complexity as a necessary trade-off for achieving objective, accurate burn test evaluation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates digital copies (images) of the burn test process using optical sensors and cameras. These visual copies are then processed through image analysis algorithms to extract precise measurement data about burn characteristics. This copying approach enables automated, objective measurement without direct human intervention, improving both precision and reliability

Inventive Principle:

Principle #26Copying

2Productivity

If manual visual observation and measurement are used, then the device complexity is low, but the productivity and consistency of burn testing are reduced due to labor-intensive processes

Engineering Contradiction:

Improveburn test evaluation efficiencyVSAvoidautomated system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements a self-service automated system where the optical sensors, image processing algorithms, and data analysis software work together autonomously to complete the entire burn test evaluation process. The system automatically captures images, processes them through algorithms, extracts measurements, and generates results without requiring manual intervention at each step, thereby significantly improving productivity and consistency

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces labor-intensive manual operations with automated optical sensing and computer-based image processing. This substitution eliminates the need for human evaluators to manually observe, measure, and record burn test data, replacing these mechanical/manual processes with automated systems that operate continuously without fatigue or inconsistency, thereby enhancing productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If automated optical sensing and image processing are used, then the measurement precision and objectivity are improved, but the device complexity and initial cost increase

Engineering Contradiction:

Improveburn test evaluation reliabilityVSAvoidoptical system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces subjective human judgment with objective optical sensing and algorithm-based image processing. The system uses cameras to capture burn characteristics and applies standardized image analysis algorithms to extract measurements, eliminating human bias and variability. This substitution ensures consistent, reliable, and reproducible results across different tests and evaluators, justifying the increased device complexity through superior reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a feedback mechanism where the optical sensing system continuously monitors the burn test process, captures real-time images, and processes them through algorithms that compare measurements against established criteria. This closed-loop feedback system automatically adjusts and refines measurements, ensuring high reliability and consistency in burn test evaluation despite the complexity of the optical system

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

This approach provides objective, quantitative, and accurate evaluation of burn tests, reducing human error and enhancing the reliability of fire resistance assessments in aerospace materials.

Implementation Method 1

detecting an infrared reflection of a flame on a test piece

Methodology Applied

Scientific EffectInfrared radiation detection: Infrared Radiation

Data Source

PatentUS20240426667A1Systems, apparatuses, and methods for evaluating burn tests

Publication Date: 2024.12.26 THE BOEING CO

AI summary

A system and method for evaluating a burn test includes using an optical sensor system to detect an infrared reflection of a flame on a test piece and using a computer to capture initiation of fire damage to the test piece using the infrared reflection and to capture the fire damage though cessation of the fire damage using the infrared reflection.