Automated Surface Inspection Sensor Using Multi-Modal Optical Scanning
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Solution Overview
Problem
Current methods for inspecting surface and structural defects are labor-intensive, prone to errors, and require large maintenance man-hours, making them inefficient for accurate defect detection and mapping.
Innovation Solution
An automated inspection system utilizing multiple sensing/imaging modalities, including ring illumination angular scanning, coherent speckle scanning, multi-spectral imaging, and polarization detection, combined with wireless triangulation and optical/ultrasonic distance measurements, to create a digital map of defects on a 3D structure model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated inspection system with multiple sensing modalities is implemented, then measurement precision and productivity are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensing modalities (ring illumination angular scanning, coherent speckle scanning, multi-spectral imaging, and polarization detection) into a single integrated inspection system. This merging of different detection methods allows the system to achieve high measurement precision for various defect types while managing device complexity through unified system architecture.
Solution Approach 2:
The inspection system is designed with multi-functional capabilities to detect different types of defects (coating defects, substrate defects, structural defects) using multiple sensing modalities. Each modality serves multiple detection purposes, and the system can adaptively select appropriate sensing methods based on the inspection requirements, thereby improving measurement precision across diverse defect types.
2Reliability
If multiple sensing modalities are used, then reliability of defect detection is improved, but device complexity increases
Solution Approach 1:
The patent integrates four distinct sensing modalities (ring illumination angular scanning, coherent speckle scanning, multi-spectral imaging, and polarization detection) into a unified inspection system. This combination enhances detection reliability by cross-validating defect detections across multiple sensing methods while managing system complexity through integrated hardware and software architecture.
Solution Approach 2:
The system incorporates data fusion and correlation analysis across multiple sensing modalities, where detection results from one modality provide feedback to enhance the reliability of detections from other modalities. This feedback mechanism allows the system to confirm defect detections through multiple independent sensing pathways, thereby improving overall reliability.
3Productivity
If manual visual inspection is used, then device complexity is low, but productivity and measurement precision deteriorate
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system that uses ring illumination angular scanning, coherent speckle scanning, multi-spectral imaging, and polarization detection. This substitution eliminates human labor requirements, dramatically improves inspection productivity and measurement precision, while the modular system design helps manage the inherent complexity of the automated apparatus.
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 system significantly reduces inspection time, enhances accuracy in defect detection, and provides a precise digital map of defects, enabling efficient maintenance and quality control.
Implementation Method 1
ring illumination angular scanning (i) reveals defects were either part of, or the entire coating is removed, because reflectivity will have a different angular directionality
Implementation Method 2
coherent speckle scanning (ii) measures micro-pits, voids, small/pinhole defects, cracks, and discontinuities on the surface of a coating and structure
Implementation Method 3
Multi-spectral (UV, visible and IR) imaging (iii) is used for multi-material assessment to distinguish between defects at different material layers
Implementation Method 4
differential polarization detection reveals defects by detecting a variation in the surface finish such as the coating and the structure body
Implementation Method 5
position registration is achieved by wireless (WiFi) triangulation, optical and ultrasonic distance measurements
Implementation Method 6
position registration is achieved by wireless (WiFi) triangulation, optical and ultrasonic distance measurements
Data Source
AI summary
Various surface and structural defects are currently inspected visually. This method is labor intensive, requiring large maintenance man hours, and is prone to errors. To streamline this process, herein is described an automated inspection system and apparatus based on several optical technologies that drastically reduces inspection time, provides accurate detection of defects, and provides a digital map of the location of defects. The technology uses a sensor that includes a plurality of light sources for emitting light on the structural surface, and a camera for detecting a shadow or an image shift of the structural surface feature. Furthermore, the technology utilizes an image processing and correction apparatus for performing a pattern image and structural surface defect map detection and generate a distortion corrected defect map for a surface scan area on the structure that is incident on the sensor.