Automated scanning systems for non-destructive inspection of curved cylinder-like workpieces

Patent metadata

Field	Value
Publication number	US-11044011-B2
Application number	US-201916268159-A
Country	US
Kind code	B2
Filing date	Feb 5, 2019
Priority date	May 16, 2014
Publication date	Jun 22, 2021
Grant date	Jun 22, 2021

Abstract

Systems and methods for high-speed non-destructive inspection of a half- or full-barrel-shaped workpiece, such as a barrel-shaped section of an aircraft fuselage. Such workpieces can be scanned externally using a mobile (e.g., translating) arch gantry system comprising a translatable arch frame disposed outside the fuselage section, a carriage that can travel along a curved track carried by the arch frame, a radially inward-extending telescopic arm having a proximal end fixedly coupled to the carriage, and an NDI sensor unit coupled to a distal end of the telescoping arm. The stiffeners of the fuselage sections can be scanned using a mobile scanner platform disposed inside the fuselage section, which platform comprises a radially outward-extending telescopic arm rotatably coupled to a mobile (e.g., holonomic or linear motion) platform and an NDI sensor unit coupled to a distal end of the telescoping arm. The scan data is matched with position data acquired using any one of a plurality of tracking systems to enable the display of NDI features/flaws on a three-dimensional representation of the workpiece.

First claim

The invention claimed is:

1. A method for scanning a stringer in an inside of a workpiece having a curved section that extends longitudinally and circumferentially, the method comprising:
placing a workpiece having a curved section that extends longitudinally and circumferentially so that the workpiece is stationary relative to a floor;
moving a mobile platform to a starting position on the floor and underneath the workpiece;
pivoting an extendible arm that is pivotably coupled to the mobile platform to a target tilt angle dependent on an angular position of a stringer to be inspected;
at the target tilt angle, extending an inner sleeve of the extendible arm until a first NDI sensor unit coupled to a distal end of the inner sleeve engages a first portion of the stringer to be inspected;
activating the first NDI sensor unit to inspect the first portion of the stringer;
processing signals output from the first NDI sensor unit to derive first scan data characterizing a structural state of the first portion of the stringer; and
acquiring first location data representing a first location of the first NDI sensor unit when the first NDI sensor unit engages the first portion of the stringer.

2. The method as recited in claim 1 , further comprising:
moving the mobile platform in a manner that causes the first NDI sensor unit to travel along the stringer until the first NDI sensor unit engages a second portion of the stringer;
activating the first NDI sensor unit to inspect the second portion of the stringer;
processing signals output from the first NDI sensor unit to derive second scan data characterizing a structural state of the second portion of the stringer; and
acquiring second location data representing a second location of the first NDI sensor unit when the first NDI sensor unit engages the second portion of the stringer.

3. The method as recited in claim 2 , further comprising:
moving a curved track along first and second linear tracks to a first longitudinal position, the curved track in the first longitudinal position being disposed radially outward from the curved section of the workpiece;
adjusting a position of a second NDI sensor unit relative to a carriage to which the second NDI sensor unit is adjustably coupled by an extendible arm, the carriage in turn being movable along the curved track;
moving the carriage along the curved track while the curved track is stationary at the first longitudinal position;
activating the second NDI sensor unit to inspect a strip-shaped area of the curved section of the workpiece as the carriage is moved along the curved track; and
processing signals output from the second NDI sensor unit to derive a strip of scan data characterizing a structural state of the strip-shaped area of the curved section of the workpiece.

4. The method as recited in claim 3 , wherein the second NDI sensor unit is activated while the first NDI sensor unit is moving along the stringer.

5. The method as recited in claim 1 , wherein a path followed by the mobile platform during moving is parallel to a projection of an axis of the stringer onto the ground.

6. The method as recited in claim 1 , further comprising adjusting a radial position of the first NDI sensor unit as the first NDI sensor unit travels along the stringer.

7. The method as recited in claim 1 , wherein the mobile platform is a holonomic motion vehicle.

8. The method as recited in claim 1 , wherein the mobile platform moves on tracks.

9. The method as recited in claim 1 , wherein the workpiece is a fuselage section.

10. The method as recited in claim 9 , wherein the stringer is made of composite material.

11. The method as recited in claim 1 , wherein the first scan data is acquired from at least a central cap portion of the stringer and an angled side of the stringer.

12. A system for supporting a mobile platform inside a curved cylinder-like workpiece, comprising:
a first extendible support comprising a first pedestal, a first fixed outer sleeve projecting vertically upward from said first pedestal, a first inner sleeve that is translatable inside said first outer sleeve, and a first bearing mounted to a distal end of said first inner sleeve;
a second extendible support comprising a second pedestal, a second fixed outer sleeve projecting vertically upward from said second pedestal, a second inner sleeve that is translatable inside said second outer sleeve, and a second bearing mounted to a distal end of said second inner sleeve;
a bridge beam spanning a space between said first and second extendible supports, said bridge beam having a first end rotatably coupled to said distal end of said first inner sleeve by said first bearing and a second end rotatably coupled to said distal end of said second inner sleeve by said second bearing;
first and second cross beams attached to and projecting laterally from said bridge beam;
first and second linear rails which are attached to said first and second cross beams in a mutually parallel relationship; and
a mobile platform comprising a frame, a first set of rollers arranged on opposite sides of said first linear rail and a second set of rollers arranged on opposite sides of said second rail.

13. The system as recited in claim 12 , further comprising:
a first actuator which, when activated, exerts a force urging said mobile platform to move;
an extendible arm comprising a first member pivotably mounted to said frame of said mobile platform and a second member which is translatable relative to said first member;
a second actuator which, when activated, exerts a force urging said extendible arm to pivot relative to said frame;
an NDI sensor unit coupled to a distal end of said second member; and
an encoder device capable of outputting signals representing incremental movements of said NDI sensor unit along a substructure.

14. The system as recited in claim 13 , further comprising a third actuator which, when activated, exerts a force urging said second member to translate relative to said first member.

15. The system as recited in claim 13 , further comprising a compliant support structure between said NDI sensor unit and said distal end of said second member.

16. The system as recited in claim 13 , wherein said NDI sensor unit is an ultrasonic transducer array.

17. The system as recited in claim 13 , further comprising a pivot joint by which said extendible arm is pivotably mounted to said frame of said mobile platform, wherein said first and second extendible supports and said bridge beam are configured such that said bridge beam, said first and second cross beams, and said first and second linear tracks are translatable and rotatable between a first location in which said mobile platform is upright and said pivot joint has an elevation and a second location in which said mobile platform is upside down and said pivot joint has the same elevation.

18. A method for scanning a stringer in an inside of a workpiece having a curved section that extends longitudinally and circumferentially using the system as recited in claim 13 , the method comprising:
placing the curved cylinder-like workpiece so that the workpiece overlies the bridge;
moving the mobile platform to a starting position along the bridge and underneath the workpiece;
pivoting the extendible arm to a target tilt angle dependent on an angular position of a stringer to be inspected;
at the target tilt angle, extending the second member of the extendible arm until the NDI sensor unit engages a first portion of the stringer to be inspected;
activat

Assignees

• Boeing Co

Inventors

• Georgeson Gary E
• Fetzer Barry A
• Troy James J
• Lea Scott W

Classifications

• H04W72/23

  in the downlink direction of a wireless link, i.e. towards a terminal · CPC title

• G01N2291/0231

  Composite or layered materials · CPC title

• G01N29/265

  by moving the sensor relative to a stationary material · CPC title

• H04B7/2656 Primary

  for structure of frame, burst · CPC title

• G01N29/0654

  Imaging · CPC title