The challenge for K|Lens
A honeycomb seal is a special type of seal that is used in various technical applications to seal gaps between moving and stationary components. It is characterized by its honeycomb structure, which consists of many small, hexagonal cells.
An important area of application is gas turbines, particularly in aviation. Honeycomb seals are used here to seal the gap between the rotor and stator and thus increase the efficiency of the turbine. Even the smallest deviations have a direct impact on safety, performance and CO2 emissions. Thorough defect testing is therefore essential, but at the same time extremely challenging.
Manual inspection
Inspection is often done manually, with operators examining each individual cell with lights, light probes and magnifying lenses. This process is extremely time-consuming and tiring, resulting in high operator stress. Operators can only perform this task in a very limited time frame due to the high workload.
Time required
As each honeycomb has to be checked individually, a complete inspection of a honeycomb seal can take several hours, depending on its size. As this procedure is often impractical, a 100% inspection of the honeycomb seal cannot be carried out.
Inadequate documentation
Due to the highly demanding inspection, sufficient documentation is not possible during manual inspection. This makes it difficult to trace faulty honeycomb seals.
The solution from K|Lens
Overview of solution approach and technical implementation
To meet the challenges in the inspection of honeycomb seals, we have developed an innovative inspection solution based on a combination of state-of-the-art sensor technologies and intelligent software. At the heart of this solution are the K|Lens Light Field Sensor 1inch and the K|Lens Honeycomb Sensor, which enable a comprehensive and detailed analysis of the honeycomb seals.
The light field sensor enables a 3D evaluation of the honeycomb structure, while the honeycomb sensor can inspect the inside of each cell. The combination of these two sensors enables comprehensive quality control that takes into account both the overall structure and the individual cells of the honeycomb seal.
A specialized AI-supported analysis enables precise and automated detection of defects that are missed by conventional methods. The overall evaluation combines 3D data and AI analysis and ensures a comprehensive and objective quality control that meets the high demands of the aviation industry.
This makes it possible for the first time to convert manual random checks into automated and thus documented inspections for these honeycomb structures.
Specific design of the components / structure / extensions
Highly innovative sensor technology
The combination of the Light Field Sensor 1inch and the Honeycomb Sensor offers an innovative way to create 3D models of honeycomb seals. The Light Field Sensor can be used to create precise three-dimensional representations, while the Honeycomb Sensor enables detailed inspection of each individual cell.
3D analysis
Precise 3D analysis is made possible by special calibration and depth calculation components. These components ensure an accurate 3D reconstruction of the honeycomb seal, which is essential for defect detection.
UI
A customized graphical user interface (GUI) visualizes all specified defects. This enables operators to check the inspection results intuitively and efficiently.
Robust evaluations with multiview AI
Customized data curation and multiview AI training provide a reliable multiview AI model for defect detection. This AI-powered analysis enables accurate and automated detection of defects that are missed by traditional methods.
Comprehensive analysis
The merging of 3D data and AI analysis by the evaluation algorithm enables automatic measurements according to customer specifications. Different inspection criteria are combined into a final analysis via decision trees. This ensures comprehensive and objective quality control that meets the high requirements of the aviation industry.
System used
The honeycombINSPECT system specializes in the examination of honeycomb structures and forms the basis for inspection.
Customer Benefits and ROI
Cost savings and ROI
Reduction in process costs
Automated control is faster and more efficient than manual control by employees and requires fewer personnel. This significantly reduces process costs.
Reduction of rejects and rework
The early correct detection of defects through repeatable and objective processes reduces scrap and rework. This leads to significant cost savings.
Optimization of manufacturing processes
The detailed inspection data enables the optimization of manufacturing processes. This increases efficiency and reduces production costs.
Defense against warranty costs
The automatic creation of a digital twin of each connector enables follow-up inspections even after delivery, reducing traceability and warranty costs.
Improved inspection accuracy and reliability
Detailed inspection
The combination of Light Field Sensor and Honeycomb Sensor enables both overall inspection and detailed cell-by-cell inspection. This ensures comprehensive quality control and minimizes the risk of undetected defects.
Objective inspection
Automated inspection reduces operator error and subjective judgments. This leads to objective and consistent quality control.
AI-supported analysis
AI-assisted analysis enables precise and automated detection of defects that are often overlooked by conventional methods.
Competitive advantage and innovation
Advanced technology
The patented Multiview technology of the K|Lens Light Field Sensor enables a detailed 3D analysis that cannot be realized with conventional systems. The combination of 3D data and AI analysis in a single inspection system further sets the system apart.
Improved product reliability
Automated inspection improves product quality and reduces production downtime. Digital documentation enables improved data-based analysis and process optimization. This results in consistently optimal performance (low power loss), low consumption and therefore low CO2 emissions from the turbines.
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