Sealant Thickness Measurement Using 3D Scanning
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Solution Overview
Problem
Current methods for inspecting sealant thickness on aircraft fasteners are time-consuming, tedious, and lack accuracy, often requiring human operators to use gauges, which can lead to inconsistent measurements and increased manufacturing costs due to the difficulty in accessing and measuring the sealant thickness within composite fuel tanks.
Innovation Solution
A method and apparatus using three-dimensional scanners to generate data on the geometry of fasteners before and after sealant application, calculating the sealant thickness by identifying differences in the data sets, and providing a map to indicate areas needing additional sealant, thereby ensuring the desired thickness is achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human operators use hand-held gauges to measure sealant thickness, then measurement capability is provided, but inspection time and labor are excessive
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated optical measurement system. A scanner captures images of the sealant, and image processing algorithms automatically calculate sealant thickness by analyzing the captured images, eliminating the need for manual gauge measurements and significantly improving inspection speed.
Solution Approach 2:
The patent creates a digital copy of the sealant geometry through image capture and processing. By generating a digital representation of the sealant thickness distribution, the system enables automated analysis and eliminates manual measurement while preserving measurement accuracy through computational methods.
2Measurement precision
If manual inspection methods are used, then measurement capability is provided, but the process is tedious and time-consuming
Solution Approach 1:
The patent replaces tedious manual measurement processes with automated optical scanning and image processing. The system captures images of multiple fasteners simultaneously and uses automated algorithms to calculate sealant thickness, reducing inspection time while maintaining measurement precision.
Solution Approach 2:
The patent enables continuous inspection by automating the measurement process. The scanning system can continuously capture images and process data without interruption, allowing for efficient inspection of large numbers of fasteners without the breaks and repositioning required in manual methods.
3Measurement precision
If hand-held gauges are used for measurement, then sealant thickness can be assessed, but accessibility to interior fasteners is difficult
Solution Approach 1:
The patent replaces manual gauge insertion with a remote scanning system. The scanner can capture images of sealant on fasteners in the interior of composite fuel tanks without requiring physical access to each fastener location, making the measurement process feasible for hard-to-reach areas.
Solution Approach 2:
The patent introduces an optical intermediary (the scanning system) that bridges the gap between the inspector and the inaccessible fasteners. The scanner acts as a mediator that can reach into difficult-to-access areas and transmit measurement data without requiring direct human access to each measurement point.
4Reliability
If extensive inspection of thousands of fasteners is performed, then sealant quality is ensured, but manufacturing costs increase
Solution Approach 1:
The patent replaces costly manual inspection labor with an automated scanning and image processing system. This automation maintains comprehensive quality assurance by inspecting all fasteners while reducing labor costs and improving manufacturing efficiency through faster inspection speeds.
Solution Approach 2:
The patent changes the measurement parameter from requiring physical contact (manual gauge measurement) to optical measurement. This parameter change enables simultaneous inspection of multiple fasteners and allows for automated processing, improving both reliability through comprehensive coverage and productivity through reduced inspection time.
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
This approach reduces inspection time and labor, enhances accuracy, and allows for precise application of additional sealant, potentially reducing aircraft production costs and weight by ensuring consistent sealant thickness across fasteners.
Implementation Method 1
A method and apparatus are provided for inspecting sealant on an object. First data is generated for a first geometry of a first surface of the object prior to sealing the object. Second data is generated for a second geometry of a second surface of the object after the sealant has been applied to the object.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A method and apparatus for inspecting sealant on an object. First data is generated for a first geometry of a first surface of the object prior to sealing the object. Second data is generated for a second geometry of a second surface of the object after the sealant has been applied to the object. A difference is identified between the first data and the second data. The difference indicates a thickness of the sealant on the object.