Radiographic Fastener Inspection for Hidden Defect Detection
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Solution Overview
Problem
Existing methods for inspecting installed mechanical fasteners, such as rivets, in complex systems like aircraft are inefficient and prone to errors due to the inability to detect latent microscopic defects, especially in inaccessible areas.
Innovation Solution
An automated radiographic inspection system using x-ray imaging and computer vision/machine learning to analyze fastener images, identifying defects and generating inspection reports with color-coded bounding boxes for defected and non-defected fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used for installed fasteners, then the inspection process is simple and quick, but the ability to detect latent microscopic defects is poor
Solution Approach 1:
The patent replaces traditional visual inspection methods with radiographic imaging technology. X-ray beams penetrate the fastener and workpiece, capturing internal structures and defects that are invisible to the naked eye. This substitution of mechanical/visual inspection with radiographic imaging enables detection of latent microscopic defects while maintaining operational simplicity.
Solution Approach 2:
The patent introduces a radiographic image sensor as an intermediary between the fastener and the inspection system. The sensor captures radiographic images that reveal internal defect structures, acting as a mediator that translates invisible internal states into visible image data for analysis.
2Productivity
If manual inspection of installed fasteners is performed, then labor costs are high and inspection time is long, but the inspection process is flexible and adaptable
Solution Approach 1:
The patent implements an automated inspection system that performs inspection tasks independently without human intervention. The system automatically positions radiographic sources, captures images, processes data, and generates reports, enabling self-service inspection operations that significantly increase productivity while reducing labor requirements.
Solution Approach 2:
The patent utilizes adjustable radiographic parameters such as beam energy, exposure time, and detector sensitivity to optimize inspection performance. By changing these parameters, the system can adapt to different fastener types, defect severities, and inspection requirements, maintaining flexibility despite automation.
3Reliability
If radiographic imaging is used to inspect fasteners, then defect detection accuracy is improved, but the cost and complexity of the inspection system increases
Solution Approach 1:
The patent replaces complex manual inspection procedures with a standardized radiographic imaging process. The automated capture and processing of radiographic images provides consistent, reliable defect detection that is not dependent on inspector experience or subjective judgment, thereby improving reliability while managing system complexity through automation.
Solution Approach 2:
The patent incorporates feedback mechanisms where the inspection system automatically analyzes radiographic images, compares findings against acceptance criteria, and generates reports. This feedback loop ensures consistent application of inspection standards and improves reliability by eliminating human variability in defect assessment.
4Measurement precision
If detailed analysis of radiographic images is performed, then defect characterization accuracy is improved, but processing time increases
Solution Approach 1:
The patent implements continuous automated processing of radiographic images through the inspection system. Image capture, analysis, and report generation occur continuously without interruption, allowing detailed defect characterization to be performed on all inspected fasteners without significant time delay, thus maintaining both accuracy and efficiency.
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
Provides accurate and efficient detection of fastener defects with reduced processing time, enhancing inspection accuracy and confidence in defect severity assessment.
Implementation Method 1
a radiographic generator, e.g., an x-ray generator, operable for directing scanning beams of electromagnetic radiation toward a workpiece having the installed fastener
Implementation Method 2
a radiographic image sensor configured to collect a radiographic image of the workpiece and the installed fastener
Data Source
AI summary
A system for automated inspection of an installed fastener includes a radiographic generator, a radiographic sensor, and a computer device. The radiographic generator is operable for directing scanning beams of electromagnetic radiation, e.g., x-rays, toward a workpiece having the installed fastener, for instance a rivet. The radiographic sensor collects a radiographic image of a workpiece inclusive of the installed fastener. The computer device processes the image via one or more trained characterization models to localize the installed fastener within the image, and identifies a presence or absence of a defect in the installed fastener. The computer device also characterizes a quality of the installed fastener based on the presence or absence of the defect, and thereafter generates an inspection report indicative of the quality of the fastener. This may include generating an annotated or color-coded image of the installed fastener.