2D Sensor Array for Targeted Structural Inspection

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Solution Overview

Problem

Existing methods for inspecting structures for damage are time-consuming, costly, and inefficient, especially for structures that are high above ground level or irregularly shaped, making targeted evaluation impractical.

Innovation Solution

A system utilizing a two-dimensional array of sensors controlled by an armature, aligned and engaged with a specific portion of a structure's surface, scans the area for damage and then disengages, allowing for non-destructive, targeted, and efficient evaluation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sensors scan the entirety of a structure, then damage detection coverage is improved, but inspection time and cost increase

Engineering Contradiction:

Improvedamage detection coverageVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The structure is divided into multiple discrete portions or regions of interest. Instead of scanning the entire structure uniformly, the sensor array focuses on segmented areas that are more likely to contain damage or require closer inspection, thereby reducing overall inspection time while maintaining detection reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inspection system applies different inspection strategies to different portions of the structure. High-priority areas receive detailed scanning with the sensor array, while lower-priority areas receive minimal or no scanning, optimizing the balance between detection coverage and inspection time.

Inventive Principle:

Principle #3Local quality

2Reliability

If sensors scan the entirety of a structure, then damage detection coverage is improved, but inspection cost increases

Engineering Contradiction:

Improvedamage detection coverageVSAvoidinspection cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs partial scanning of the structure by focusing sensor energy on specific portions rather than scanning the entire structure. This partial action approach reduces the resources required for inspection while maintaining adequate damage detection capability for critical areas.

Inventive Principle:

Principle #16Partial or excessive action

3Adaptability or versatility

If sensor equipment is installed to inspect high or irregular structures, then inspection capability is improved, but system complexity and installation difficulty increase

Engineering Contradiction:

Improveinspection capabilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical sensor mounting systems with a magnetic field-based sensor array that can be remotely activated and deactivated. The sensor array attaches to and detaches from the structure using magnetic fields, eliminating the need for permanent mechanical installations on high or irregular structures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses magnetic fields as an intermediary mechanism to couple the sensor array to the structure during inspection and decouple it afterward. This magnetic intermediary allows the sensors to access difficult-to-reach areas without requiring complex mechanical mounting hardware or permanent installations.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10712286B1Systems and methods for non-destructive evaluation of a structure

Publication Date: 2020.07.14 THE BOEING CO

AI summary

In an example, a method for non-destructive evaluation of a structure is described. The method comprises identifying a portion of a surface of the structure for evaluation. The method further comprises controlling an armature to align a two-dimensional array of sensors with the portion of the surface. The method further comprises causing the two-dimensional array of sensors to engage the portion of the surface. The method further comprises, responsive to determining that the two-dimensional array of sensors has engaged with the portion of the surface, (i) releasing the two-dimensional array of sensors from the armature, and (ii) scanning, the portion of the surface to collect sensor data. The method further comprises, after scanning the portion of the surface, (i) controlling the armature to couple to the two-dimensional array of sensors, and (ii) causing the two-dimensional array of sensors to disengage with the portion of the surface.