The Boeing Company

Barry Allen Fetzer

Gary E Georgeson

James C Kennedy

Hien T Bui

James J Troy

Michael J Duncan

Scott Wesley Lea

Jeffrey Reyner Kollgaard

Jeffrey G Thompson

William Joseph Tapia

Fred D Young

Clyde T Uyehara

Steven Ray Walton

Navpreet S Grewal

Jill Paisley Bingham

Morteza Safai

John Ralph Hull

Hong Hue Tat

Steven Kenneth Brady

Martin L Freet

Mark A Lee

Jeffry J Garvey

Michael C Hutchinson

Justin D Serrill

Thomas E Riechers

Kate Brown Boudreau

Richard C Krotzer

William Paul Motzer

Christopher David Brown

Patrick Lee Anderson

Kareem Shehab

John Makoto Shinozaki

William R Schell

Samuel R Goertz

Mark L Little

Kevin M Uhl

Peter Kuk-kyung Hwang

Darrell Darwin Jones

Daniel R Smith

Jeong-Beom Ihn

Daniel James Wright

Mark Alan Negley

Dennis P Sarr

Christopher R Brown

Jeremy Evan Justice

Glenn A Geithman

Christopher Ralph Brown

William O Walters

Edward L Puckett

Ronald E VonWahlde

Vicki Wu

Kevin R Bray

David K Brooks

Carrie Ann Decker

Kevin J Mandt

Arthur P Ricker

Terrace G McClure

Baljinder Singh

Phillip D Rudolph

Steven R Walton

Jonathan W Bell

Micheal C Hutchinson

Michael Joseph Duncan

Ronald E Vonwahlde

William J Tapia

Gary Ernest Georgeson

Peter Kuk-Kyung Hwang

Methods and scan systems for analyzing an object. The methods include obtaining a local operation dataset that includes a plurality of operation data points obtained from an object and a corresponding location, within the operation coordinate system, for each operation data point of the plurality of operation data points. The methods also include mapping the plurality of operation data points from the operation coordinate system to a global coordinate system for the object. The mapping includes mapping to generate a global operation dataset that includes the plurality of operation data points and a corresponding global location, within the global coordinate system, for each operation data point. The scan systems include a robot that performs a plurality of operations on an object within an operation coordinate system and a computing device that maps the plurality of operation data points from the operation coordinate system to a global coordinate system.

Methods and scan systems for analyzing an object

A non-destructive test apparatus includes a drive coil and a resonant coil in working relation to the drive coil. The non-destructive test apparatus includes a voltage source coupled to the drive coil. The voltage source is configured to apply an alternating current signal to the drive coil. The non-destructive test apparatus includes a sensor coupled to the resonant coil. The sensor is configured to output sensor data indicative of a voltage induced in the resonant coil by the alternating current signal applied to the drive coil. The non-destructive test apparatus also includes a processor coupled to the sensor to receive the sensor data from the sensor. The processor is configured to determine, based on the voltage, a porosity of an item positioned in working relation to the resonant coil.

Porosity detection for composite materials using inductive resonance

Systems and methods are provided for inspecting aircraft fuselages. Non-Destructive Inspection (NDI) stations inspect sections of a fuselage via pulsed-line assembly techniques. After each pulse, a section of fuselage is moved by less than its length, and one or more NDI stations disposed at different portions of the section to inspect the section of fuselage for out-of-tolerance conditions. A method for inspecting a structure for inconsistencies which includes advancing a structure along a track in a process direction through a Non-Destructive Inspection (NDI) station, indexing the structure to the NDI station and inspecting the structure with the NDI station.

Non-destructive inspection station for aircraft fuselage sections fabricated in an assembly line

A mixed-domain analysis method for evaluation of ultrasonic inspection data is disclosed. A return signal of an ultrasonic waveform applied to an article under inspection is received. The return signal is digitally processed to generate a mixed-domain spectrogram of the return signal. The mixed-domain spectrogram plots ranges of a frequency of the return signal, a time of flight of the return signal, and a power spectral density of the return signal. A data gate having ranges of frequency and time of flight that define an area of interest in the mixed-domain spectrogram is set. At least one of a material characteristic and an anomaly characteristic of the article under inspection is identified based on evaluating one or more time-frequency characteristics of the article under inspection in the area of interest.

Mixed-domain analysis of ultrasonic inspection data

A system for inspecting a structure includes a laser ultrasound device configured to direct laser light onto a surface of the structure that generates ultrasonic waves within the structure and to generate an array of ultrasound data representative of the ultrasonic waves. The system includes a robotic arm configured to move the laser light across the surface. The system includes a multiplex controller configured to trigger generation of the ultrasonic waves within the structure at an inspection location and to receive the array of ultrasound data for the inspection location. The system includes a computer system that includes a motion-control module configured to control movement of the laser light relative to the surface of the structure, a motion-tracking module configured determine when the laser light is at the inspection location, and an inspection module configured to process the array of ultrasound data to inspect the structure at the inspection location.

Ultrasound inspection system and method

Disclosed herein is a non-destructive inspection system. The non-destructive inspection system comprises a motion platform and a tool assembly. The tool assembly is coupled to the motion platform such that the tool assembly is movable relative to the motion platform. The tool assembly comprises an inspection tool assembly that comprises a base structure coupled to the tool assembly and a plurality of probe assemblies coupled to the base structure. Each probe assembly comprises a first linear actuator and a probe, different from the probe of any other one of the plurality of probe assemblies, for inspecting a different structural feature of a structure. Each probe is moveable, along a first axis relative to another one of the probes and substantially perpendicular to the base structure, using the first linear actuator of the corresponding one of the plurality of probe assemblies.

Multi-probe non-destructive inspection system

Methods of performing a plurality of operations within a region of a part utilizing an end effector of a robot and robots that perform the methods are disclosed herein. The methods include collecting a spatial representation of the part and aligning a predetermined raster scan pattern for movement of the end effector relative to the part with the spatial representation of the part. The methods also include defining a plurality of normality vectors for the part at a plurality of predetermined operation locations for operation of the end effector. The methods further include moving the end effector relative to the part and along the predetermined raster scan pattern. The methods also include orienting the end effector such that an operation device of the end effector faces toward each operation location along a corresponding normality vector and executing a corresponding operation of the plurality of operations with the operation device.

Methods of performing a plurality of operations within a region of a part utilizing an end effector of a robot and robots that perform the methods

Multi-centric radius focusing is used to inspect a radiused surface of a radiused part having a varying radius without mechanically adjusting the array sensor. A plurality of focal laws are designed to electronically steer and focus ultrasound at respective focal points corresponding to centers of curvature of a simulated radiused surface having a varying radius. The mechanical probe that carries the array sensor is located to two physical places that are outside of the radiused area and have a spatial relationship that varies less than the radius of the radiused surface varies. As the probe is moved along the radiused part, the probe maintains the array sensor at a constant location relative to the radiused part. As the array sensor scans the radiused part, the array sensor is electronically adjusted to focus at the respective focal points in sequence.

Method for ultrasonic inspection of structure having radiused surface using multi-centric radius focusing

Methods, systems and apparatuses are disclosed for non-destructively a substrate using ultrasound waves, and enhancing resolution of imaging created from ultrasound signals that are back reflected from a substrate surface second, or back surface by maintaining the incident angles of the ultrasonic beams at the substrate second surface such that the ultrasonic beams strike the substrate second surface at an angle that is substantially perpendicular to the complex geometric profile of the substrate second surface by supplying known spatial coordinates to the system to maintain the incident angles of the ultrasonic beams at a predetermined angle relative to the substrate second surface.

Method and system for automated ultrasonic inspection of complex composite structures with non-parallel surfaces

A non-destructive inspection apparatus includes a robotic device, an end effector coupled to the robotic device, and a controller coupled to the robotic device and the end effector. The controller is configured to determine, based on an amount of linear actuator extension of a sensor of the end effector and an amount of rotation of the sensor about a first axis of rotation and a second axis of rotation, a displacement of the sensor relative to a center point of the end effector surface so as to determine location information of the sensor, wherein sensor data for a location on a surface of a test article is sensed and correlated with the determined location information of the sensor. The robotic device controls movement of the end effector and is configured to determine, during the movement of the end effector, positional information for the center point of the end effector surface.

Imaging beam adjustments on a non-destructive inspection sensor situated on a robotic effector to accommodate in situ conditions

Disclosed herein is a non-destructive inspection (NDI) apparatus. The NDI comprises a main body and a modulated-frequency ultrasonic source, coupled to the main body. The modulated-frequency ultrasonic source comprises a low-frequency ultrasonic source, selectively operable to emit a low-frequency ultrasonic beam having a first frequency. The modulated-frequency ultrasonic source also comprises a high-frequency ultrasonic source, selectively operable to emit a high-frequency ultrasonic beam having a second frequency higher than the first frequency. The modulated-frequency ultrasonic source is configured to mix the low-frequency ultrasonic beam and the high-frequency ultrasonic beam at least at a surface of a structure to be inspected.

Apparatus and method for modulated-frequency ultrasonic inspection of structures

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.

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

Disclosed herein is a non-destructive inspection apparatus that utilizes a biased probe housing to maintain ultrasonic coupling with a part. The apparatus includes an attachment body attached to a robotic arm that has a tool center point (TCP). The apparatus also includes a probe assembly coupled to the attachment body such that movement of the TCP results in a corresponding movement of the probe assembly, and a probe housing disposed around the probe assembly and moveably coupled to the attachment body. The apparatus also includes a biasing member disposed between the attachment body and the probe housing that urges the probe housing away from the attachment body. Also disclosed is a method that includes positioning a probe housing and a probe assembly adjacent a part, ultrasonically scanning the part for defects, and biasing the probe housing relative to the attachment body to maintain engagement of the part.

Apparatus and method for non-destructive inspection of variable angle manufacturing components

Apparatus and methods for ultrasonic inspection of elongated composite members in a single scan pass using pulse echo phased arrays operating in a bubbler method. The system concept is fully automated by integrating an inspection NDI probe assembly to a robot and using the robot to move the inspection NDI probe assembly along the part (i.e., outside of an inspection tank); and by integrating tooling fixtures that move out of the way as the inspection NDI probe assembly travels along the length of the part during the inspection. In addition, the system allows for generally elongated composite members having lengthwise variation in shape, curvature and dimensions.

Automated ultrasonic inspection of elongated composite members using single-pass robotic system

Growing community of inventors

Renton, WA, United States of America

Barry Allen Fetzer