Automated Scanning Systems for Non-Destructive Inspection of Curved Cylinder-Like Workpieces

Patent metadata

Field	Value
Publication number	US-2015329221-A1
Application number	US-201414279355-A
Country	US
Kind code	A1
Filing date	May 16, 2014
Priority date	May 16, 2014
Publication date	Nov 19, 2015
Grant date	—

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

1 . A method for scanning a workpiece having a curved section that extends longitudinally and circumferentially, the method comprising:
(a) moving a curved track to a first longitudinal position relative to the workpiece, the curved track being disposed radially outward from the curved section of the workpiece; (b) moving an NDI sensor unit along the curved track while the curved track is stationary at the first longitudinal position; (c) during step (b), activating the NDI sensor unit to inspect a first strip-shaped area of the curved section of the workpiece; (d) processing signals output from the NDI sensor unit to derive a first strip of scan data characterizing a structural state of the first strip-shaped area of the curved section of the workpiece; (e) during step (b), acquiring location data representing locations of the NDI sensor unit relative to the workpiece; and (f) mapping the first strip of scan data to a three-dimensional model of the workpiece based on the location data acquired in step (e).

2 . The method as recited in claim 1 , further comprising displaying features overlaid on a representation of a portion of the three-dimensional model of the workpiece based on the results of steps (d) and (f).

3 . The method as recited in claim 1 , wherein the workpiece has a shape of a full barrel, further comprising rotating the workpiece about a longitudinal axis and then repeating steps (a) through (f).

4 . The method as recited in claim 1 , further comprising the following steps:
(g) subsequent to step (b), moving the curved track from the first longitudinal position to a second longitudinal position relative to the workpiece; (h) moving the NDI sensor unit along the curved track while the curved track is stationary at the second longitudinal position; (i) during step (h), activating the NDI sensor unit to inspect a second strip-shaped area of the curved section of the workpiece; (j) processing signals output from the NDI sensor unit to derive a second strip of scan data characterizing a structural state of the second strip-shaped area of the curved section of the workpiece; (k) during step (h), acquiring location data representing locations of the NDI sensor unit relative to the workpiece; and (l) mapping the second strip of scan data to the three-dimensional model of the workpiece based on the location data acquired in step (k).

5 . The method as recited in claim 1 , wherein step (g) comprises generating pulses representing incremental longitudinal movements of the curved track along a stationary linear rail and generating pulses representing incremental circumferential movements of the NDI sensor unit along the curved track.

6 . The method as recited in claim 1 , wherein step (g) comprises the following steps performed during step (b) and (d): emitting light directed toward retro-reflective targets affixed to the NDI sensor unit; and capturing returned light reflected by said retro-reflective targets, and step (h) comprises computing location data representing the locations of the NDI sensor unit relative to the workpiece based on the captured returned light.

7 . The method as recited in claim 5 , further comprising:
converting the location data representing the locations of the NDI sensor unit during step (b) into simulated encoder pulses suitable for processing by non-destructive inspection scan software; and correlating the simulated encoder pulses with the first strip of scan data.

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

9 . The method as recited in claim 6 , wherein the fuselage section is made of composite material.

10 . A system for external scanning of a workpiece having a curved outer mold line, the system comprising:
first and second linear tracks which are mutually parallel; a curved track disposed in a plane generally transverse to said first and second linear tracks, said curved track being coupled to and translatable relative to said first and second linear tracks; a carriage coupled to and movable along said curved track; an extendible arm having a proximal end coupled to said carriage; an NDI sensor unit coupled to a distal end of said extendible arm; a location tracking system capable of tracking the location of said NDI sensor unit relative to said workpiece; a data processing system capable of receiving scan data from said NDI sensor unit and location tracking data from said location tracking system and then correlating the scan data with the location tracking data; and a display system capable of displaying the scan data on a three-dimensional representation of the workpiece based on results of the correlating process performed by said data processing system.

11 . The system as recited in claim 10 , wherein said location tracking system comprises a plurality of cameras, a first plurality of retro-reflective markers attached to the workpiece and arranged in a known pattern; a second plurality of retro-reflective markers attached to the NDI sensor unit and arranged in a known pattern, and a motion capture processor.

12 . The system as recited in claim 10 , wherein said extendible arm comprises a first member coupled to said carriage and a second member which is translatable relative to said first member, and said location tracking system comprises:
a first encoder device that outputs signals representing incremental movements of said curved track along said linear tracks; a second encoder device that outputs signals representing incremental movements of said carriage along said curved track; a third encoder device that outputs signals representing a distance that said second member of said extendible arm has traveled relative to said first member; and a computer system programmed to be capable of converting the output signals from said first through third encoder devices into location data representing locations of said NDI sensor unit.

13 . A system for scanning a workpiece having a curved section that extends longitudinally and circumferentially, the system comprising:
a pair of linear tracks parallel to a longitudinal direction; an arch frame that extends circumferentially and is arranged to travel along said linear tracks; a first actuator which, when activated, causes said arch frame to travel along said linear tracks; a curved track supported by said arch frame; a carriage arranged to travel along said curved track; a second actuator which, when activated, causes said carriage to travel along said curved track; an extendible arm comprising a first member mounted to said carriage and a second member which is arranged to translate relative to said first member; a third actuator which, when activated, causes said second member to translate relative to said first member; and an NDI sensor unit mounted to said second member and operable to acquire scan data during its motion.

14 . The system as recited in claim 13 , further comprising:
a first encoder device that outputs signals representing incremental movements of said arch frame along said linear tracks; a second encoder device that outputs signals representing incremental movements of said carriage along said curved track; a third encoder device that outputs signals representing a distance that said second member of said extendible arm has traveled relative to said first member; and a computer system programmed to be capable of performing the following operations: (a) tracking the location of said NDI sensor unit to acquire location data representing locations of said NDI sensor unit based on signals outputted by said first, second and third enco

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

• B64F5/0045 Primary

  Operations & Transport · mapped topic

• G01N2291/0289

  Internal structure, e.g. defects, grain size, texture · CPC title

• H04L41/0695

  the faulty arrangement being the maintenance, administration or management system · CPC title

• H04W48/16

  Discovering, processing access restriction or access information · CPC title