Remote Nondestructive Inspection for Aircraft Composite Damage
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Solution Overview
Problem
The challenge lies in effectively inspecting and determining the extent of damage in composite structures of commercial aircraft, particularly when visual detection is inadequate and trained nondestructive inspection (NDI) technicians are not available, leading to potential flight cancellations and significant economic impacts.
Innovation Solution
A remote nondestructive inspection system that communicates NDI data to a distant location for analysis, enabling a repair disposition decision to be made, allowing for temporary or permanent repairs to be performed based on the assessment, even when a skilled technician is not immediately available.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual detection is used to assess damage, then the inspection process is simple and quick, but the detection accuracy is insufficient for sub-surface damage in composite structures
Solution Approach 1:
The patent introduces NDI devices as intermediary tools between visual inspection and damage assessment. These devices (such as ultrasonic, thermographic, or acoustic emission equipment) act as mediators that translate invisible sub-surface damage into detectable signals, enabling accurate detection without requiring complex disassembly or destructive testing.
Solution Approach 2:
The patent replaces manual visual inspection with automated NDI systems that use physical fields (acoustic, thermal, electromagnetic) to detect damage. This substitution transforms the inspection process from a purely mechanical/visual task to a field-based detection system, improving accuracy while maintaining operational efficiency.
2Measurement precision
If a trained NDI technician is deployed to inspect damage, then the inspection quality is high, but the response time is delayed due to technician availability constraints
Solution Approach 1:
The patent implements self-service capabilities through automated NDI systems that can perform inspections and preliminary analysis without requiring immediate technician intervention. The system autonomously collects data, processes signals, and generates initial assessments, enabling rapid response while maintaining high inspection quality. Technicians only need to review critical cases rather than perform entire inspections.
Solution Approach 2:
The patent creates digital copies of the inspection process through automated data collection and analysis systems. The NDI system captures damage information, processes it through algorithms, and generates digital reports that replicate the expertise of trained technicians. This allows multiple inspection points to be evaluated simultaneously without requiring physical presence of technicians at each location.
3Reliability
If extensive repair procedures are performed without confirmed damage extent, then structural safety is ensured, but economic losses increase due to unnecessary maintenance and flight cancellations
Solution Approach 1:
The patent performs preliminary damage assessment through NDI inspection before committing to extensive repair procedures. By accurately characterizing the extent and severity of damage in advance, the system enables informed decision-making about whether temporary repairs, permanent repairs, or flight cancellation are necessary. This preliminary action prevents unnecessary groundings and maintains productivity while ensuring safety through accurate assessment.
Data Source
AI summary
Systems and methods are disclosed for providing nondestructive inspection (NDI) services. For example in accordance with an embodiment of the invention, a system for remote inspection includes a nondestructive inspection (NDI) system configured to examine a structure and provide NDI data related to a damage condition of the structure, the NDI system being configured to communicate the NDI data to a remote location; and a remote computer disposed at the remote location, the remote computer being configured to receive the NDI data and provide the received NDI data for a review, the remote computer being configured to communicate an analytical result based on the review to the NDI system, the analytical result including a repair disposition decision corresponding to the damage condition.