Optical Surface Characterization for Aircraft Radial Gap Measurement
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Solution Overview
Problem
Current methods for measuring the radial gap between male and female ends of aircraft components are slow and imprecise, hindering the production of high-precision shims necessary for optimal fitment.
Innovation Solution
A system utilizing an inner and outer ring structure with ring targets, combined with stereo imaging and processing, to generate three-dimensional coordinate data for precise characterization of surface regions, enabling accurate determination of radial gaps and shim design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If known methods for measuring the radial gap between male and female ends are used, then the measurement process is simple, but the measurement precision and speed are insufficient
Solution Approach 1:
The patent replaces traditional mechanical contact measurement methods with a non-contact optical measurement system. A projector projects structured light patterns onto the component surfaces, and cameras capture the deformed light patterns to calculate three-dimensional coordinates of surface points, enabling precise radial gap measurement without mechanical contact
Solution Approach 2:
The patent creates optical copies (images) of the component surfaces by projecting structured light patterns and capturing them with cameras. These optical copies are then processed to generate three-dimensional coordinate data, allowing precise measurement of surface geometry and radial gaps without physically touching the components
2Productivity
If traditional measurement methods are used, then the equipment is simple, but the productivity and measurement speed are too slow
Solution Approach 1:
The patent enables continuous measurement by capturing multiple stereo image pairs as the measurement system moves along the component surfaces. The projector and cameras continuously project and capture light patterns, generating a complete three-dimensional map of the surfaces in real-time, significantly improving measurement speed while maintaining precision
Solution Approach 2:
The patent transitions from two-dimensional surface measurements to three-dimensional coordinate mapping. By capturing stereo image pairs from multiple angles and processing them to generate three-dimensional coordinates, the system achieves comprehensive surface characterization that enables both high precision and high productivity
3Manufacturing precision
If high-precision surface characterization is achieved, then the shim fitment quality improves, but the measurement and processing time increases
Solution Approach 1:
The patent performs preliminary action by projecting structured light patterns and capturing stereo images before the actual shim manufacturing process. The three-dimensional coordinate data is obtained in advance, allowing the shim manufacturing to proceed immediately with precise dimensional information, reducing overall production time while maintaining high precision
Solution Approach 2:
The patent replaces slow mechanical measurement methods with rapid optical measurement. The projector and camera system captures surface geometry information much faster than mechanical probes, and the image processing algorithm quickly generates three-dimensional coordinate data, significantly reducing surface characterization time while improving precision
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 significantly improves the accuracy and efficiency of surface characterization, allowing for the production of shims that effectively fill the radial gaps between aircraft components, enhancing the fitment precision.
Implementation Method 1
projecting a first reference image onto a first surface region of the structural component
Implementation Method 2
capturing a first stereo image pair comprising a first left image and a first right image that both include the first reference image, the first ring target, the third ring target, and the component target
Data Source
AI summary
A method includes projecting a first reference image onto a first surface region that includes a component target; capturing a first pair of images that both include (i) the first reference image, (ii) a first ring target located at a first position on an inner ring, (iii) a third ring target located at a third position on an outer ring, and (iv) the component target; projecting a second reference image onto a second surface region; capturing a second pair of images that both include (i) the second reference image, (ii) a second ring target located at a second position on the inner ring, and (iii) a fourth ring target located at a fourth position on the outer ring; and based on the first pair of images and the second pair of images, generating coordinate data that defines the first surface region and the second surface region within a coordinate space.