Phased Array Infrared Moisture Detection in Composite Panels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current moisture detection techniques are inadequate for accurately measuring and mapping moisture levels in composite sandwich panels with foam or honeycomb cores, leading to delays and increased costs in aircraft production due to aesthetically undesirable bubbling and disruption in the production line.
Innovation Solution
A moisture detection system comprising a phased array and an infrared detector system, controlled by a controller, which emits a pulse of electromagnetic radiation with wavelengths absorbed by water molecules, synchronizing the radiation with a time window to detect infrared radiation and determine moisture levels in composite sandwich panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional moisture detection techniques are used, then the detection process is simple, but the measurement precision is insufficient to accurately detect moisture in composite sandwich panels
Solution Approach 1:
The detection system is divided into multiple independent modules: phased array for electromagnetic radiation emission, infrared detector system for radiation detection, and controller for coordination. Each module performs a specific function, allowing the complex detection task to be broken down into manageable segments that can be optimized independently.
Solution Approach 2:
The phased array and infrared detector system are designed to perform multiple functions: the phased array both emits electromagnetic radiation and receives reflected signals, while the infrared detector system both detects infrared radiation and provides timing synchronization. This multi-functionality reduces the need for separate dedicated components.
2Productivity
If moisture detection is performed late in production, then the detection process is less disruptive, but the loss of time and productivity increases due to rework requirements
Solution Approach 1:
The system enables moisture detection to be performed early in the production process, before final assembly and finishing operations. By detecting moisture presence and extent at an early stage, manufacturers can identify affected panels before they undergo time-consuming finishing operations, allowing for timely rework or replacement without disrupting later production stages.
Solution Approach 2:
The system replaces traditional mechanical or visual inspection methods with non-contact electromagnetic radiation-based detection. The phased array emits electromagnetic radiation that penetrates the composite panel, and the infrared detector system measures the radiation absorbed or reflected by moisture, providing rapid, contactless detection that does not require disassembly or interruption of the production flow.
3Measurement precision
If the phased array emits continuous electromagnetic radiation, then the heating effect is sustained, but the energy consumption increases and the measurement precision decreases
Solution Approach 1:
The phased array emits electromagnetic radiation in periodic pulses rather than continuously. Each pulse heats the panel temporarily, and the infrared detector system measures the infrared radiation emitted during the cooling phase between pulses. This periodic operation allows the panel to return to near-ambient temperature between measurements, enabling repeated detection cycles with minimal energy consumption and high measurement precision.
Solution Approach 2:
The system exploits the phase transition thermal signature of moisture in the composite panel. When the phased array emits electromagnetic radiation, moisture-containing areas heat up differently than dry areas due to the dielectric properties of water. The infrared detector system detects these temperature differences as the panel transitions between heated and cooling states, providing precise moisture detection based on thermal phase behavior.
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 detects and quantifies moisture levels in composite sandwich panels, reducing production delays and costs by accurately identifying moisture presence and extent, enabling timely rework or replacement.
Implementation Method 1
The pulse of the electromagnetic radiation beam has a number of wavelengths that is absorbed by water molecules
Implementation Method 2
The phased array is configured to emit a pulse of an electromagnetic radiation beam... to heat the composite sandwich panel
Implementation Method 3
The infrared detector system is configured to detect an amount of infrared radiation... when the composite sandwich panel is heated by the pulse of the electromagnetic radiation beam
Implementation Method 4
The amount of infrared radiation indicates a level of moisture in the composite sandwich panel
Data Source
AI summary
A method and system for detecting moisture in a composite sandwich panel for an aerospace vehicle. A pulse of an electromagnetic radiation beam is beam steered to the composite sandwich panel. The pulse of the electromagnetic radiation beam has a number of wavelengths that is absorbed by water molecules. The timing of the pulse of the electromagnetic radiation beam is synchronized to heat the composite sandwich panel with a time window in an infrared detector system to detect an amount of infrared radiation. The amount of infrared radiation in the composite sandwich panel is detected within the time window for the infrared detector system when the composite sandwich panel is heated by the pulse of the electromagnetic radiation beam, wherein the amount of infrared radiation indicates a level of moisture in the composite sandwich panel.