3D Surface Inspection with Reference Surface for Contour Defects

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Solution Overview

Problem

Existing surface inspection methods for aircraft fuselages are time-consuming, lack repeatability, and often fail to accurately interpret data, leading to delayed detection of non-conformances that increase production costs and delays.

Innovation Solution

A surface inspection system using a 3D scanner to acquire a point cloud of a localized portion of the surface, establishing a reference surface based on non-defective regions, and determining characteristics of suspect regions relative to this reference, including location, height, and slope gradients, to ensure accurate and timely detection of defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If straight edge and feeler gauges are used for measuring surface contours, then measurement capability is provided, but inspection time is excessive and repeatability is poor

Engineering Contradiction:

Improvesurface contour measurementVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces mechanical measurement tools (straight edge and feeler gauges) with a 3D scanning system that uses optical fields to capture surface geometry. The 3D scanner acquires point cloud data representing the inspection surface, eliminating the need for manual mechanical measurements and thereby reducing inspection time while maintaining measurement capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transforms the measurement approach by changing from direct physical contact measurement to non-contact optical measurement. The 3D scanning system captures surface geometry as point cloud data, which is then processed to extract surface contour information, fundamentally changing the measurement parameters from mechanical displacement to optical field interaction

Inventive Principle:

Principle #35Parameter changes

2Productivity

If 3D scanners are used to measure and analyze surface data, then inspection speed is improved, but measurement accuracy deteriorates due to biased measurements and improper data interpretation

Engineering Contradiction:

Improveinspection speedVSAvoidsurface contour measurement accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent applies preliminary action by establishing a reference surface from the point cloud data before performing the actual surface contour analysis. The processor establishes a reference surface that represents the ideal or nominal geometry, which is then used as a basis for comparing and evaluating the actual measured surface, ensuring accurate interpretation of the 3D scan data

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediary reference surface between the raw 3D scan data and the final surface contour evaluation. This reference surface acts as a mediator that translates the complex point cloud data into meaningful surface contour information, enabling accurate measurement interpretation while maintaining high inspection speed

Inventive Principle:

Principle #24Intermediary (Mediator)

3Difficulty of detecting and measuring

If surface inspection is delayed until after gloss paint coating, then visual detection of non-conformances is enhanced, but production cost and time increase due to late defect detection

Engineering Contradiction:

Improvevisual detection capabilityVSAvoidproduction cycle time

Core Design Contradiction:

Difficulty of detecting and measuringVSLoss of time

Solution Approach 1:

The patent performs surface inspection at an earlier stage in the production cycle, before the gloss paint coating is applied. By conducting the 3D scan-based inspection earlier, the system enables early detection of surface non-conformances, allowing for timely corrective actions and reducing rework costs, while the enhanced visual detection capability is achieved through the sensitivity of the 3D scanning system rather than relying on gloss paint

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4703677A1System and method of inspecting a surface

Publication Date: 2026.03.04 THE BOEING CO

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AI summary

A surface inspection system (100) for inspecting an inspection surface (306) includes a three-dimensional (3D) scanner configured to scan the inspection surface (306) and acquire a point cloud (150) of points (152) representing at least the localized portion (308). The localized portion (308) includes a non-defective region (154) and a suspect region (158) at least partially surrounded by the non-defective region (154) and potentially containing one or more defects. The surface inspection system (100) includes a processor (172) establishes a reference surface (164) based on the points (152) in the non-defective region (154) and exclusive of the points (152) in the suspect region (158), and the reference surface (164) extends across the suspect region (158). The processor (172) determine one or more characteristics of a shape of the point cloud (150) relative to the reference surface (164) within the suspect region (158).