Optical Surface Inspection Apparatus for Confined Space FOD Detection
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Solution Overview
Problem
Manual inspection of surface finish properties and foreign-object debris (FOD) on structures like aircraft is expensive, time-consuming, and challenging due to space constraints, while existing automated solutions are costly and unsuitable for confined spaces.
Innovation Solution
An apparatus comprising a light source and camera, with a microprocessor, that generates a light beam and captures images to identify surface types and detect FOD by casting shadows and reflections, allowing for close proximity to the surface and efficient image processing to determine surface characteristics and foreign objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is used to determine surface-finish properties and identify FOD, then inspection accuracy can be maintained, but inspection cost and time increase significantly
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system consisting of a light source, camera, and microprocessor. The system uses light beams to illuminate the surface and captures images with a camera, eliminating the need for manual visual inspection while maintaining detection capability through automated image processing.
Solution Approach 2:
The inspection system performs self-analysis by automatically processing captured images through a microprocessor to identify surface-finish properties and foreign-object debris. The system compares captured images against stored reference images to automatically determine inspection results without requiring manual intervention for analysis.
2Measurement precision
If manual inspection is performed, then detailed surface examination is possible, but inspection time and labor costs increase
Solution Approach 1:
The patent replaces time-consuming manual surface examination with rapid automated optical inspection. The light source and camera system can capture and analyze multiple surface areas simultaneously, reducing inspection time while maintaining detailed examination capability through high-resolution imaging and automated image processing.
Solution Approach 2:
The system stores reference images of known surface-finish properties and FOD types in advance. During inspection, the microprocessor quickly compares captured images against these pre-stored references, enabling rapid identification and classification of surface characteristics without requiring manual analysis of each feature.
3Productivity
If conventional automated inspection solutions are used, then inspection speed improves, but device cost increases and adaptability to confined spaces decreases
Solution Approach 1:
The inspection system is divided into separate functional modules: a light source for illumination, a camera for image capture, and a microprocessor for analysis. This modular segmentation allows the system to be configured in compact arrangements suitable for confined spaces while maintaining automated inspection capabilities.
Solution Approach 2:
The patent employs a universal inspection platform that can inspect various surface types and detect different kinds of foreign-object debris using the same basic hardware configuration. The system adapts to different inspection scenarios through software processing rather than requiring specialized equipment for each application, reducing overall device complexity and cost.
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
Enables efficient and accurate identification of surface types and detection of FOD in confined spaces, reducing costs and time by automating the inspection process while ensuring precise analysis of surface finish properties and foreign objects.
Implementation Method 1
a light source, configured to generate a light beam
Implementation Method 2
the light source helps to produce shadows and light reflections from textures in the surface and from foreign objects on the surface
Data Source
AI summary
An apparatus for inspecting a surface comprises a light source and a camera. When a light beam is generated by the light source, a centerline of the light beam is coincident with a line of sight of the camera when viewed in a direction, perpendicular to a first plane that contains one of the centerline of the light beam or the line of sight of the camera. The centerline of the light beam is parallel to the line of sight of the camera when viewed in a direction, perpendicular to a second plane that is perpendicular to the first plane and that contains the centerline of the light beam and the line of sight of the camera.