Slot Inspection Device Using Segmented Imaging
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Solution Overview
Problem
Current methods for inspecting aircraft components, particularly those with hard-to-access surfaces, are difficult, expensive, and time-consuming, as they often require manual insertion of mirrors and binoculars for visual inspection.
Innovation Solution
An inspection device with multiple imaging devices and illumination devices positioned along an insert that spans the entire height of a slot, utilizing optical fibers and cameras to capture and stitch images of the slot's surface, allowing for efficient and comprehensive visualization of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual inspection methods using mirrors and binoculars are used, then inspection can be performed on hard-to-access surfaces, but the process becomes difficult, expensive and time-consuming
Solution Approach 1:
The inspection device divides the inspection task into multiple segments by using several imaging devices positioned at different heights along the insert. Each imaging device captures a specific portion of the slot, and the processor combines these segmented images into a complete inspection view, eliminating the need for manual mirror manipulation.
Solution Approach 2:
The patent replaces the manual mechanical inspection system (mirrors and binoculars) with an automated optical system. Imaging devices with cameras and illumination devices are positioned along the insert to automatically capture images of the slot interior, and a processor automatically stitches these images together, eliminating manual operation entirely.
2Loss of information
If multiple imaging devices are positioned along the insert to capture the entire slot, then comprehensive visualization is achieved, but device complexity increases
Solution Approach 1:
The insert serves multiple functions: it provides structural support for the imaging devices, acts as a light guide to illuminate the slot interior, and positions the imaging devices at optimal locations. This multi-functionality reduces the need for separate components, thereby managing device complexity while achieving comprehensive inspection coverage.
Solution Approach 2:
The processor acts as an intermediary that receives image data from multiple imaging devices and combines them into a single comprehensive image. This intermediary component simplifies the complexity by automatically handling the integration of multiple images, presenting a unified view to the user without requiring manual coordination of multiple devices.
3Illumination intensity
If the insert acts as a light guide to illuminate the slot, then illumination is improved, but the insert material requirements become more stringent
Solution Approach 1:
The patent changes the optical parameters of the insert material by selecting materials with high light transmission properties. The insert is designed to transmit light from the illumination devices through its structure to illuminate the slot interior effectively. This parameter change requires specific material properties but enables superior illumination quality that manual methods cannot achieve.
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
Enables rapid and thorough inspection of aircraft components by generating a single, comprehensive image of the slot's surface, facilitating the detection of defects like corrosion, cracks, or pits, thereby improving inspection efficiency and reducing costs.
Implementation Method 1
Each of the imaging devices may comprise a bundle of optical fibres
Implementation Method 2
The insert may be substantially transparent and acts as a light guide
Implementation Method 3
Each of the imaging devices may comprise a camera disposed adjacent the external surface of the insert
Data Source
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AI summary
There is described an inspection device for inspecting a slot of a gas turbine engine. The inspection device comprises: an insert (8) for insertion into the slot (6); a plurality of imaging devices (at the housings 36, e.g. cameras or optical fibres) coupled to the insert (8); and a processor. The insert is movable along a longitudinal axis of the slot. Each of the plurality of imaging devices is positioned adjacent an external surface of the insert and is configured to capture an image of a portion of the slot adjacent the imaging device. The processor is configured to receive data corresponding to the images captured by the plurality of imaging devices.