3D Thermographic Defect Localization With IMU-Guided Scanning
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Solution Overview
Problem
Existing non-destructive component testing methods struggle to reliably assign deep-lying component features or defects to a three-dimensional component geometry and lack user-friendly applicability across various applications.
Innovation Solution
A device and method utilizing an excitation source, infrared detector array, surface scanner, inertial measuring unit, and evaluation device for thermographic testing, which includes a geometry detection system and user authentication, enabling precise reconstruction of defects through a regularization method and Green's function-based heat conduction equation, with optional user verification and external data integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If active thermography is used for non-destructive component testing, then deep-lying component features can be detected, but reliable assignment to three-dimensional component geometry is difficult
Solution Approach 1:
The patent combines the infrared detector array for thermal imaging with a geometry detection system (such as laser scanner or structured light system) into an integrated device. This merging allows simultaneous acquisition of thermal data and geometric data, enabling accurate assignment of detected defects to their corresponding three-dimensional locations on the component surface through coordinate transformation algorithms.
Solution Approach 2:
The patent introduces coordinate transformation algorithms as an intermediary process that bridges the thermal image data and the three-dimensional geometry data. The geometry detection system captures surface topography, and through mathematical transformation, this geometric information serves as a mediator to map thermal defect signatures onto the accurate three-dimensional component model, resolving the localization accuracy issue.
2Adaptability or versatility
If hand-guided or robot-guided test systems are used, then mobility is improved, but user-friendliness and measurement precision deteriorate
Solution Approach 1:
The patent incorporates an inertial measuring unit (IMU) that provides real-time feedback on the device's spatial position and orientation during handheld operation. This feedback mechanism allows the system to dynamically compensate for movements and vibrations, maintaining measurement precision even when the device is mobile and hand-guided, thus reconciling mobility with accuracy.
Solution Approach 2:
The patent replaces complex mechanical positioning systems (robot-guided mechanisms) with an inertial measuring unit that uses sensors (accelerometers, gyroscopes, magnetometers) to detect and track device position and orientation. This substitution maintains measurement precision while significantly improving device mobility and user-friendliness, allowing operators to freely move the device without complex mechanical constraints.
3Reliability
If conventional thermography methods are used, then testing can be performed, but reliability of defect assignment to component features is low
Solution Approach 1:
The patent transitions from two-dimensional thermal imaging to three-dimensional defect localization by integrating geometry detection and applying coordinate transformations. This dimensional enhancement allows defects to be assigned to specific three-dimensional locations and orientations on the component, significantly improving assignment reliability by providing spatial context that conventional 2D thermography lacks.
Solution Approach 2:
The patent performs preliminary scanning of the component geometry using the geometry detection system before conducting the thermographic inspection. This preliminary action creates a reference three-dimensional model of the component surface, which is then used during evaluation to accurately interpret and assign thermal defect signatures to their correct spatial locations, improving overall reliability.
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
Enhances the reliability and flexibility of non-destructive component testing by accurately assigning defects to 3D geometry and improving user-friendliness, allowing for broader application in various scenarios.
Implementation Method 1
This is based on the thermal excitation of the test body by means of absorption of optical radiation
Implementation Method 2
The heat radiation of the test body can be detected contactlessly by infrared sensors
Implementation Method 3
the device comprises an inertial measuring unit for detecting movements of the device
Data Source
AI summary
The disclosure relates to a device and a method for thermographic component test with an excitation source for generating an unsteady heat flow in a test object, with an infrared detector array for detecting heat radiation emitted from a surface of the test object, a surface scanner, a control device and an evaluation device, wherein the device comprises an inertial measuring unit for detecting movements of the device.