The Boeing Company

Bobby Joe Marsh

Kinson D VanScotter

Michael Anthony Lazar

Steven H Nichols

Gary E Georgeson

Michael Anthony Fleming

Joshua Kye Terry

Karen Malen-Hogle

Leonard S Bodziony

Richard Michael Coleman

Michael P Thompson

Barry Theophile Cooke

Michael Marcus Vander Wel

Thomas J Vanderwiel

Orval Marion Nobles

Kinson D Vanscotter

Michael W Thompson

Kinson Van Scotter

Brian E Campbell

Andrew S Olson

Douglas V Dorsey

Jeffrey R Thompson

Steven Nichols

Richard M Coleman

Karen M Malen-Hogle

Methods and devices related to preventing accidental operation of a switch are disclosed. An example device includes a main body, and a latch element rotatably connected to the main body and is configured to move relative to the main body between an unlatched position and a latched position. In the latched position, the main body and the latch element encapsulate the switch. Also, in the latched position, the main body and the latch element form a cavity configured to accommodate wiring to the switch. Further, the main body is configured with a cutout to reveal a status of the switch. The switch has Lock Out Tag Out (LOTO) index pin compatibility.

Encapsulating protective cover for a switch

Systems and methods for infrared thermographic inspection of large-scale composite structures such as sections of an aircraft fuselage. Optical metrology is used to precisely locate the infrared images relative to a three-dimensional coordinate system of the composite structure. The optical metrology may comprise laser tracking or photogrammetry or both. In some embodiments, the optical metrology comprises laser tracking merged with photogrammetry. Once the infrared images have been precisely located relative to the coordinate system of the composite structure, structural data about the composite structure (e.g., thickness data) can be retrieved from a database containing a three-dimensional model of the composite structure. In the case of thermographic porosity measurements, the infrared imaging data can be correlated with thickness data to determine the porosity of the composite structure in the inspection area.

Rapid automated infrared thermography for inspecting large composite structures

A method including placing first and second measurement devices proximate first and second aircraft doors, respectively, and determining a first position of the second measurement device relative to a second position of the first measurement device. The method includes placing first and second pluralities of reflective devices inside the aircraft proximate the first and second doors, respectively. The method includes measuring first and second distances from the first and second measurement devices to the first and second pluralities of reflective devices, respectively, and measuring second distances from the second measurement device to the second plurality of reflective devices. Based on a determined position of the second measurement device and further based on the first distances and second distances, third distances are determined between each of the first and second pluralities of reflective devices. The third distances provide a measurement baseline for points on a fuselage and wings.

Aircraft enhanced reference system and method

Methods provide for the controlled application of forces to a structure during leveling and securing procedures. According to embodiments described herein, a structure is supported at a number of support locations. An upward force is applied to the structure by the force application devices to counteract an equivalent downward force from the structure at each support location. The forces applied by the force application devices are monitored to detect whenever one or more of the upward forces deviates outside of a threshold range of force values, which includes a quantity of force sufficient to counteract internal forces within a material of the structure. Each force may be adjusted to ensure no deviation outside of the allowed threshold range.

Controlled application of external forces to a structure for precision leveling and securing

Systems and methods provide for the controlled application of forces to a structure during assembly, machining, manufacturing, and/or transportation operations. According to embodiments described herein, a contour control system includes a number of force control modules that are communicatively linked to a control system. The control system receives or retrieves data indicating the shape of the structure and a shape associated with a desired structure, and determines if the structure is consistent with the design specifications and any associated tolerances. The control system controls the force control modules to apply calculated forces to the structure to control the contours of the structure and/or to maintain the structure in a desired configuration. According to embodiments, the force control modules include support cradles, air cushion pads, vacuum cups, and/or other structures for selectively applying dynamic and/or static forces to the structure.

Systems and methods for structure contour control

Methods and systems provide for the controlled application of forces to a structure during leveling and securing procedures. According to embodiments described herein, a force distribution system includes a number of force application devices that are communicatively linked to a computing system. The computing system controls the force application devices to apply calculated forces to the structure, monitor the forces, and adjust the forces when deviations occur. According to one embodiment, the force application devices include jack assemblies and the system is operative to level a structure and maintain the level position when the structure shifts. According to another embodiment, the force application devices include clamp assemblies and the system is operative to apply and maintain a constant and uniform pressure on a structure to secure the structure during machining. Other embodiments include using force application devices to secure a structure during transport.

Systems and methods to calibrate aircraft surfaces are provided. A particular method includes installing a set of laser targets. The set of laser targets includes at least first laser target and a second laser target. The first laser target is installed on a first side of a first aircraft surface and the second laser target is installed on a second side of the first aircraft surface at a known location relative to the first laser target. The method also includes determining a first position of the first laser target with a first laser device. The method further includes determining a second position of the second laser target with a second laser device. The method includes determining a position of the first aircraft surface based on the first position of the first laser target and the second position of the second laser target.

Calibrating aircraft surfaces

Fuselage sections of an aircraft are joined using splice elements that compensate for gaps caused by mismatches between mating surfaces on the fuselage sections. The fuselage sections are virtually assembled using computer models that are based on non-contact measurements of as-built fuselage sections. The virtually assembled fuselage sections are used to map the gaps between the mating surfaces. The mapped gaps are used to produce tool inserts having profiles that reflect the dimensions of the gaps. The tool inserts are used to manufacture splice elements having profiles that fill the gaps when the fuselage sections are assembled and joined, thereby eliminating the need for shims and spaces to fill the gaps.

Splicing fuselage sections without shims

A system for measuring a hole of a surface may include at least one light emitting member for emitting varied intensity flashes of light towards the hole of the surface. The system may further include a projector for projecting light beams onto the surface. The system may additionally include at least one camera for taking at least one picture of the hole of the surface each time the at least one light emitting member emits a flash of light towards the hole of the surface, and each time the projector projects light beams onto the surface. The system may also include a computer for determining measurements of the hole of the surface utilizing the at least one picture of the hole and Photogrammetry.

Photogrammetric contrasting light for hole recognition

Shims used to join part assemblies are automatically designed and fabricated without the need for fitting part assemblies together in order to determine the exact dimensions of voids filled by the shims. The locations of key features on part assemblies are surveyed using a merged photogrammetry and laser tracking technique that generate the dimensions of a virtual shim. The dimensions of the virtual shim are contained in a digital file that can be used to automatically fabricate the shim using automated fabrication equipment such as a CNC machining center. The automated virtual shim design may be modified to reflect the effect of part assembly fit on performance characteristics of the aircraft.

Method for fitting part assemblies

Systems and methods can automatically inspect a workpiece. Non-destructive inspection sensors are mounted on a frame mounted on a transport device. Position of a first predetermined location of a workpiece is measured with a tracking system. The transport device is moved to position the non-destructive inspection sensors proximate the first predetermined location of a workpiece. A first portion of a workpiece proximate the first predetermined location is non-destructively inspected with the non-destructive inspection sensors. Position of a second predetermined location of a workpiece can be measured with the tracking system. The transport device can be moved to position the non-destructive inspection sensors proximate the second predetermined location of a workpiece, and a second portion of a workpiece proximate the second predetermined location can be non-destructively inspected with the non-destructive inspection sensors. Data can be provided from the sensors to a computing system and analyzed by the computing system.

System and method for automated inspection of large-scale part

The invention relates to the use of one or more targets to measure surfaces. The target may comprise a first portion adapted to reflect a laser beam towards a laser tracking device, a second portion adapted to reflect a light beam towards a photogrammetry device, and a third portion adapted to identify to a computer a unique identifier of the target.

Coded target for use with combination laser and photogrammetry targets

The surface of a part is measured using a combination of laser tracking and Photogrammetry processes. Cameras used in the Photogrammetry process are mounted on a carriage for movement to positions along a predetermined path where images of the part surface are recorded and then converted to surface measurements. Laser tracking is used to both measure the part surface and track the position of the cameras. The measurements made by Photogrammetry and laser tracking processes are combined with the camera position to produce highly accurate part surface measurements.

Growing community of inventors

Lake Stevens, WA, United States of America

Bobby Joe Marsh