Defect detection systems and methods
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Solution Overview
Problem
Conventional methods for detecting and removing conductive debris from non-conductive composite structures are time-consuming, labor-intensive, and prone to human error, leading to undesirable product defects and increased costs.
Innovation Solution
A defect detection system comprising a movement assembly and a sensor assembly with radar devices that direct electromagnetic energy into non-conductive structures to detect conductive debris, allowing for efficient identification and marking of defective areas for subsequent removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection and manual removal methods are used to detect and remove conductive debris, then human error can be avoided through careful inspection, but the process becomes prohibitively expensive and time-consuming
Solution Approach 1:
The patent replaces manual visual inspection with an automated electromagnetic sensing system that uses conductive debris sensors to detect debris through the composite structure. This substitution of mechanical/manual inspection with electromagnetic field-based detection eliminates human labor while maintaining high detection precision and enabling continuous automated inspection.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary between the inspection system and the conductive debris. The sensor assembly generates electromagnetic fields that interact with conductive debris, allowing indirect detection without direct visual contact. This intermediary approach enables automated detection while preserving the integrity of the composite structure.
2Device complexity
If manual inspection methods are used, then equipment costs can be kept low, but labor intensity and processing time increase significantly
Solution Approach 1:
The patent replaces complex manual inspection procedures with a relatively simple automated sensor-based system. The sensor assembly, movement assembly, and controller work together to provide automated detection without requiring complex mechanical intervention, thereby improving productivity while keeping device complexity manageable.
Solution Approach 2:
The system enables self-service inspection where the automated sensor assembly continuously monitors the composite structure for conductive debris without human intervention. The controller automatically processes sensor data and identifies debris locations, eliminating the need for manual labor while maintaining systematic inspection protocols.
3Reliability
If conventional debris detection methods are used, then detection capabilities are limited by human error, but automated systems increase cost and complexity
Solution Approach 1:
The patent replaces human-based detection with electromagnetic sensor-based detection, eliminating human error while maintaining reasonable system complexity. The sensor assembly uses electromagnetic fields to detect conductive debris, providing reliable automated detection without requiring overly complex mechanical or electronic systems.
Solution Approach 2:
The sensor assembly is designed to perform multiple functions: generating electromagnetic fields, detecting conductive debris, and providing data to the controller. This multi-functionality reduces the need for separate specialized components, thereby maintaining detection reliability while controlling overall system 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
The system enables cost-effective and versatile detection and removal of conductive debris, enhancing product quality and reliability by reducing contamination and processing inefficiencies compared to conventional methods.
Implementation Method 1
Electromagnetic energy is directed into the substantially non-conductive structure from at least one radar device of the sensor assembly to detect conductive debris within the substantially non-conductive structure
Data Source
AI summary
A defect detection system comprises a movement assembly and a sensor assembly. The movement assembly is configured and positioned to hold and move a substantially non-conductive structure. The sensor assembly comprises at least one radar device configured and positioned to detect conductive debris in the substantially non-conductive structure as portions of the substantially non-conductive structure move therepast. A defect detection method and a processing a composite structure are also described.