Resin Detection System for Composite Structure Inspection
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Solution Overview
Problem
Current methods for inspecting composite structures, particularly for detecting resin thickness variations, are limited by the inability of ultrasonic systems to accurately measure regions less than 40 mils, and visual inspections are challenging in internal cavities with curved surfaces, leading to unreliable detection of resin pockets and ridges.
Innovation Solution
An apparatus comprising a housing with a movement system, an infrared measurement system, and a visible light sensor system, which generates infrared measurement information and image data to determine resin thickness and differentiate between resin pockets and ridges on composite structures, even in hard-to-reach internal locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic systems are used to detect resin thickness, then regions greater than 40 mils can be detected, but regions less than 40 mils cannot be accurately measured
Solution Approach 1:
The patent replaces ultrasonic measurement systems with optical measurement systems (laser scanners, structured light projectors, cameras) to measure resin thickness. Optical systems provide non-contact, high-precision measurement capability that can accurately detect thin resin regions less than 40 mils, eliminating the minimum detection threshold limitation of ultrasonic systems while maintaining reliability across all thickness ranges.
Solution Approach 2:
The patent changes the measurement parameter from ultrasonic wave propagation time to optical reflection and light field distortion. By using optical parameters (light intensity, phase, reflection angle) instead of acoustic parameters, the system achieves superior precision for thin resin measurement without the 40-mil detection floor that constrains ultrasonic systems.
2Loss of information
If visual inspection is used to examine composite structures, then resin pockets and ridges can be identified, but inspection in internal cavities with curved surfaces is challenging
Solution Approach 1:
The patent replaces manual visual inspection with automated optical measurement systems including laser scanners, structured light projectors, and cameras. These systems can capture complete 3D surface data of internal cavities and curved surfaces without requiring physical access constraints, eliminating the difficulty of inspecting hard-to-reach areas while maintaining comprehensive defect detection capability.
Solution Approach 2:
The patent transitions from 2D visual inspection to 3D optical scanning and surface mapping. By capturing depth information and creating three-dimensional representations of internal cavities and curved surfaces, the system makes previously inaccessible regions fully observable, allowing resin pockets and ridges to be identified regardless of location complexity.
3Measurement precision
If a single measurement system is used, then device complexity is low, but the ability to characterize resin thickness variations is insufficient
Solution Approach 1:
The patent combines multiple optical measurement technologies (laser scanning, structured light projection, digital imaging) into an integrated inspection system. This merger enables comprehensive resin thickness characterization by fusing data from different optical modalities, achieving high-precision 3D surface mapping and defect detection that no single system could provide alone, while managing complexity through integrated hardware and software architecture.
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 solution enables accurate identification and characterization of resin thickness variations, improving the reliability of composite structure inspections by providing detailed thickness measurements and distinguishing between resin pockets and ridges, thus enhancing the assessment of composite structure performance.
Implementation Method 1
an infrared measurement system associated with an interior of the housing, wherein the infrared measurement system is configured to generate infrared measurement information in response to detecting infrared light reflected from the composite structure
Implementation Method 2
a light source associated with the housing, wherein the light source is configured to emit a beam of light that includes both visible light and infrared light
Data Source
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AI summary
A method and apparatus for inspecting a composite structure. A resin inspection system (126) comprises a housing (300) having an open section (324), a movement system (306) associated with the housing, a light source (310) associated with the housing, an infrared measurement system (302) associated with the interior of the housing, and a visible light sensor system (304). The movement system is configured to move the housing on a surface of a composite structure. The light source is configured to emit light. The infrared measurement system is configured to generate infrared measurement information from infrared light detected by the infrared measurement system through the open section. The visible light sensor system is configured to generate image information about the surface of the composite structure.