Vacuum Assembly Leak Detection Using Sensor Curve Comparison
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Solution Overview
Problem
Existing methods for detecting leaks in vacuum assemblies during the production of fiber composite components are inadequate for large components like rotor blades and wing shells, as they either fail to locate the leak or are excessively time-consuming, leading to compromised component quality and increased costs.
Innovation Solution
A two-stage detection process involving sensors integrated in the vacuum assembly to identify a general leak area and a subsequent detailed investigation using a thermographic camera and evaluation unit to pinpoint the leak's position, allowing for quick and reliable detection even on large components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermographic image sensor is used to detect leaks in vacuum assembly, then leak detection capability is improved, but inspection time increases excessively for large components
Solution Approach 1:
The inspection process is divided into two stages: first using multiple sensors to identify a general leak area, then using a thermographic camera to precisely locate the leak within that area. This segmentation reduces inspection time by focusing detailed thermographic analysis only on suspect regions rather than scanning the entire large component surface.
Solution Approach 2:
The first detection process using multiple sensors performs preliminary identification of leak areas before the detailed thermographic inspection. This preliminary action narrows down the search area, making the subsequent thermographic inspection faster and more efficient for large components.
2Reliability
If acoustic leak device is used to scan assembly, then leak detection is possible, but location precision is insufficient and process is too tedious
Solution Approach 1:
The detection process is segmented into two functions: the acoustic sensor array identifies the general leak area through comparative analysis, while the thermographic camera provides precise location within that area. This division of labor achieves both broad coverage and high precision.
Solution Approach 2:
The first detection process using multiple sensors acts as an intermediary that narrows down the search area before the detailed thermographic inspection. This intermediary step bridges the gap between broad leak detection and precise location identification.
3Reliability
If negative-pressure measurement is used to detect leaks, then leak presence can be inferred, but leak location cannot be determined
Solution Approach 1:
The detection system is segmented into two functional layers: the first detection process using multiple sensors provides spatial information to identify leak areas, while the second thermographic detection process provides precise location data. Together they deliver both detection and localization.
Solution Approach 2:
The solution adds spatial dimensionality by using multiple sensors at different positions to create value-time curves that reveal leak areas, then adds thermal dimensionality with the thermographic camera to precisely locate the leak within that area.
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 efficient and accurate detection of leaks in large fiber composite components, reducing operational delays and costs by identifying the leak area and position with high precision, suitable for components exceeding 100 meters in size.
Implementation Method 1
the fiber material sealed in a vacuum-tight manner is then evacuated, so that due to the pressure gradient between the fiber material and the outside environment, the matrix material can infiltrate the fiber material
Implementation Method 2
the leak area is then recorded with the help of a thermographic camera and the image data are then analyzed with the help of an evaluation unit, wherein the leak is then detected based on temperature differences in the image data
Data Source
AI summary
The present invention comprises a method for detecting a leak in a vacuum assembly comprising the steps:implementation of a first detection process to identify a leak area, involvingthe supply of a vacuum assembly which has a plurality of sensors for detecting a parameter,the determination of values of the parameter over time during the evacuation of a cavity of the vacuum assembly,the creation of a value-time curve for each sensor of the vacuum assembly from the values detected for the respective sensors by means of an evaluation unit,the comparison of the value-time curves created with one another and identification of differences depending on the comparison by means of the evaluation unit, andthe identification of a leak area in the vacuum assembly depending on the differences determined in the value-time curves and the respective position of the sensor in relation to the vacuum assembly; andimplementation of a second detection process following the first detection process to detect the leak within the leak area identified, involvingthe supply of an additional detection device which is designed to identify a leak in a vacuum assembly, andthe detection of a leak within the leak area by means of the detection device.