Weld Defect Image Qualification With Iterative Operator Feedback

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Solution Overview

Problem

Existing quality control methods for welding blades in aircraft turbomachines require significant operator intervention due to complex image interpretation, leading to lengthy and error-prone processes, especially since each weld is unique and cannot be standardized.

Innovation Solution

A method involving an iterative algorithm development and training process that includes image marking, operator feedback, and recursive improvement to enhance the algorithm's reliability and efficiency in detecting weld defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If operator intervention is used for quality control of welded blades, then detection accuracy is improved, but processing time increases and error risk increases

Engineering Contradiction:
Improvedetection accuracyVSAvoidprocessing time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The system implements feedback by having operators review and correct algorithmic markings, with corrected results fed back to retrain and improve the algorithm. This creates a closed-loop system where operator expertise continuously enhances automated performance, resolving the contradiction between initial detection accuracy and processing time.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The algorithm performs self-improvement by automatically learning from operator corrections through retraining. The system serves itself by converting operator feedback into enhanced detection capabilities, reducing the need for continuous manual intervention while maintaining high accuracy.

Inventive Principle:
Principle #25Self-service

2Reliability

If operator intervention is used for quality control of welded blades, then detection accuracy is improved, but error risk increases

Engineering Contradiction:
Improvedetection accuracyVSAvoiderror risk
Core Design Contradiction:
ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The feedback mechanism allows operators to correct algorithmic errors, and these corrections are used to retrain the system. This continuous improvement loop systematically reduces error risk by learning from past mistakes while maintaining high detection accuracy through operator expertise.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The algorithm acts as an intermediary between the complex imaging data and the operator, handling initial analysis and filtering obvious cases. This reduces the cognitive load on operators and minimizes human error while preserving accuracy for complex cases that require human judgment.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Productivity

If automated algorithm is used for quality control, then processing speed is improved, but detection reliability deteriorates

Engineering Contradiction:
Improveprocessing speedVSAvoiddetection reliability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The system applies partial automation where the algorithm handles initial screening and obvious cases, while operators focus on reviewing borderline cases and providing corrections. This partial automation approach maintains high processing speed for clear cases while ensuring reliability through human oversight for complex cases.

Inventive Principle:
Principle #16Partial or excessive action

Solution Approach 2:

The algorithm continuously self-improves by learning from operator corrections, progressively enhancing its own reliability. This self-service capability allows the system to maintain high processing speed while automatically improving detection reliability over time without requiring increasing levels of human intervention.

Inventive Principle:
Principle #25Self-service

4Device complexity

If traditional quality control method is used, then simplicity is maintained, but productivity decreases

Engineering Contradiction:
Improvemethod simplicityVSAvoidinspection efficiency
Core Design Contradiction:
Device complexityVSProductivity

Solution Approach 1:

The algorithm performs self-training and self-improvement automatically, requiring minimal human effort for system maintenance. This self-service capability maintains operational simplicity while dramatically improving productivity, as the system continuously enhances its own performance without complex manual reconfiguration.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The feedback loop integrates operator corrections seamlessly into the workflow, maintaining simplicity by using the existing human-in-the-loop approach while dramatically improving productivity through automated pre-screening and continuous algorithmic improvement.

Inventive Principle:
Principle #23Feedback

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 method significantly reduces operator intervention time and error risk by progressively refining the algorithm's performance, allowing it to reliably and efficiently detect weld defects in turbomachine blades.

Implementation Method 1

obtain X-ray images of the manufactured parts

Methodology Applied
Scientific EffectX-ray transmission and absorption: X-Ray

Data Source

PatentEP3762796B1Method to support quality control of manufactured objects
Publication Date: 2025.07.30 SAFRAN AERO BOOSTERS SA
  • EP3762796B1 patent drawingFigure 1

AI summary

The present invention relates to a method for assisting with quality control on manufactured components on the basis of images (11, 12, 13, 14) of these components, comprising a step of qualifying (62, 63, 64) these components by way of an operator (41, 43) and/or of an algorithm (21, 21A, 22), this algorithm being developed in versions on the basis of training (51, 53) performed by applying a marking (31, 33) to a portion of these images. This method is particularly suitable for detecting faults in the welding of vanes of an aircraft turbomachine.