Propulsor Blade Imaging Assembly for Automated FOD Detection
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Solution Overview
Problem
Existing systems for inspecting propulsor blades in aircraft propulsion systems are inadequate in identifying foreign object damage (FOD) efficiently and safely, often requiring manual inspection that disrupts operations and poses risks.
Innovation Solution
An imaging assembly with a camera and light sources is integrated into the propulsor section, controlled by a processor to capture and analyze images of rotating propulsor blades, identifying damage through multiple lighting combinations and thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection of propulsor blades is performed, then damage identification can be conducted, but operational disruption and safety risks increase
Solution Approach 1:
The propulsor inspection system performs self-diagnosis by capturing images of its own blades during rotation and automatically analyzing them for damage using image processing algorithms, eliminating the need for external manual inspection and maintaining operational continuity
Solution Approach 2:
The patent replaces manual visual inspection with an automated optical imaging system that uses cameras and image processing algorithms to detect blade damage, substituting human operators with mechanical/optical systems to maintain continuous operation
2Measurement precision
If multiple light sources are used to improve damage detection accuracy, then measurement precision increases, but device complexity increases
Solution Approach 1:
The patent positions multiple light sources at specific locations around the propulsor to provide targeted illumination from different angles, with each light source serving a specific inspection function rather than uniform illumination, thereby improving damage detection accuracy while managing system complexity
Solution Approach 2:
The inspection system uses periodic illumination patterns where light sources are activated in sequences or combinations during different phases of propulsor rotation, allowing multiple lighting conditions to be tested over time without requiring all lights to be active simultaneously, reducing instantaneous complexity
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 automated, efficient, and safe inspection of propulsor blades for FOD, reducing downtime and risk of manual inspection, while enabling remote monitoring and analysis.
Implementation Method 1
The plurality of light sources are disposed in the propulsor section. The controller includes a processor in communication with a non-transitory memory storing instructions, which instructions when executed by the processor, cause the processor to: control the plurality of light sources to direct light to the plurality of propulsor blades
Implementation Method 2
control the camera to capture image data of each propulsor blade of the plurality of propulsor blades as the plurality of propulsor blades rotate about the rotational axis
Data Source
AI summary
An assembly for an aircraft propulsion system includes a propulsor section, an imaging device, a plurality of light sources, and a controller. The propulsor section includes a propulsor. The propulsor includes a plurality of propulsor blades. The imaging device is disposed in the propulsor section. The imaging device includes a camera. The plurality of light sources are disposed in the propulsor section. The controller includes a processor in communication with a non-transitory memory storing instructions, which instructions when executed by the processor, cause the processor to: control the plurality of light sources to direct light to the plurality of propulsor blades, control the camera to capture image data of each propulsor blade of the plurality of propulsor blades, and identify a presence or an absence of damage for each propulsor blade of the plurality of propulsor blades using the image data.