Portable Surface Inspection Lighting for Immediate Defect Detection
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Solution Overview
Problem
Construction and automotive industries face challenges in detecting and rectifying surface imperfections such as high or low points in drywall joints and body panels, which require time-consuming and costly rework due to their difficulty in detection.
Innovation Solution
A mobile surface inspection system with a base, extendable arm, and a light fixture that illuminates surfaces to reveal imperfections, combined with a processor to analyze images and output their positions for remediation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional visual inspection methods are used to detect surface imperfections, then the inspection process is simple and quick, but the detection precision is insufficient and small imperfections are difficult to detect
Solution Approach 1:
The patent introduces an intermediary optical system consisting of a light source, beam expander, and imaging lens that mediates between the surface being inspected and the detector. This optical intermediary amplifies the detection capability by creating an enlarged optical image of the surface, allowing small imperfections to be detected with much higher precision than direct visual inspection, while the system remains relatively simple in structure.
Solution Approach 2:
The patent changes the optical parameters of the inspection system by using a beam expander to increase the diameter of the light beam and an imaging lens to magnify the surface features. This parameter change (magnification) transforms the detection capability, enabling the system to resolve small surface imperfections that would be invisible to the naked eye, thereby improving measurement precision without requiring complex equipment.
2Reliability
If contractors return to job sites to repair imperfections after completion, then thorough inspection can be performed, but time and expense increase significantly
Solution Approach 1:
The patent enables preliminary action by allowing thorough quality inspection to be performed immediately after the surface treatment is completed, before the contractor leaves the job site. The portable inspection system can be deployed on-site to conduct comprehensive detection of surface imperfections while the work is still fresh in memory and materials are readily available, eliminating the need for time-consuming return visits and enabling immediate repair if needed.
3Ease of operation
If portable inspection equipment is used, then mobility and ease of transport are improved, but the illumination intensity and detection capability may be reduced
Solution Approach 1:
The patent applies the nesting principle by placing the beam expander and imaging lens within or alongside the portable light source housing. The optical components are integrated into a compact, nested arrangement that maintains portability while providing sufficient illumination intensity and detection capability. The system can be easily transported to job sites while delivering the optical performance needed for high-precision surface inspection.
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
Facilitates efficient detection and logging of imperfections, reducing the need for rework by allowing immediate correction and improving quality control in construction and automotive processes.
Implementation Method 1
a light fixture that illuminates surfaces to reveal imperfections
Data Source
AI summary
A mobile surface inspection system having a base, at least one extendable arm coupled to the base, a hollow tubular member coupled to the base, and a processor, and a method of using the same. The base has at least one front leg, at least one back leg, and at least one wheel. The extendable arm has four extension members and there is a pivotable joint connected to the fourth extension member. A light fixture is removably connected to the pivotable joint. The processor is configured to receive an image of the surface when illuminated by the light fixture, apply a high-pass filter to the image, identify surface imperfections from the filtered image. and output a position for each of the surface imperfections.