The Boeing Company

Gregory James Sweers

Gary E Georgeson

James J Troy

Joseph Lawrence Hafenrichter

Walter J Jarecki

Jeong-Beom Ihn

Armando Xavier Membrila

Phillip R Riste

Scott Wesley Lea

Andrew Michael Robb

Aydin Akdeniz

Blake Anthony Bertrand

Carol Elizabeth Anway

Samuel R Goertz

Nathan P Renaud

Charles T Coccia

Systems and methods for tracking the location of a non-destructive inspection (NDI) scanner using scan data converted into images of a target object. Scan images are formed by aggregating successive scan strips acquired using one or two one-dimensional sensor arrays. An image processor computes a change in location of the NDI scanner relative to a previous location based on the respective positions of common features in partially overlapping scan images. The performance of the NDI scanner tracking system is enhanced by: (1) using depth and intensity filtering of the scan image data to differentiate features for improved landmark identification during real-time motion control; and (2) applying a loop-closure technique using scan image data to correct for drift in computed location. The enhancements are used to improve localization, which enables better motion control and coordinate accuracy for NDI scan data.

Enhanced vehicle navigation using non-destructive inspection one-dimensional sensor arrays

Methods and apparatus for UAV-enabled marking of surfaces during manufacture, inspection, or repair of limited-access structures and objects. A UAV is equipped with a marking module that is configured to apply marking patterns (e.g., alignment features) of known dimensions to surfaces. The marking module may include a 2-D plotter that enables free-form drawing capability. The marking process may involve depositing material on the surface. The marking material may be either permanent or removable. A 'clean-up' module may be attached to the UAV platform instead of the marking module, and may include solvents and oscillating or vibrating pads to remove the marks via scrubbing. The clean-up module can also be used for initial surface preparation.

Methods for marking surfaces using unmanned aerial vehicles

Certain aspects of the present disclosure provide techniques for a method, including: receiving multi-dimensional event data associated with a vehicle event; determining, based on the multi-dimensional event data, an inspection classification for the vehicle event; receiving multi-dimensional analysis data associated with the inspection classification for the vehicle event; determining, based on the multi-dimensional analysis data, a repair classification for the vehicle event; receiving multi-dimensional action data associated with the repair classification for the vehicle event; and determining, based on the multi-dimensional action data, a monitoring classification for the vehicle event.

Smart system for rapid and accurate aircraft maintenance decision making

A method, apparatus, system, and computer program product for inspecting an aircraft. A computer system receives captured data associated with a flight path flown by an unmanned aircraft system to acquire the captured data for the aircraft. The computer system compares the captured data with reference data for the aircraft to form a comparison. The computer system determines whether the captured data is within a set of tolerances for valid captured data using a result of the comparison. Prior to detecting anomalies for the aircraft using the captured data, the computer system determines a set of corrective actions in response to the captured data being outside of the set of tolerances for the valid captured data in which the set of corrective actions is performed.

Automated method and system for aircraft inspection with data validation

A method includes obtaining, at an unmanned aerial vehicle, a flight plan for the unmanned aerial vehicle. The flight plan is based on an aircraft type of an aircraft to be inspected. The method also includes coordinating, with a control device onboard the aircraft, an operation of a particular device of the aircraft based on the flight plan such that a state of the particular device changes when a particular sensor of the one or more sensors is located (i.e., positioned and oriented) to perform a sensing operation on the particular exterior light. The method further includes performing the sensing operation on the particular device using the particular sensor. The method also includes determining a functionality metric associated with the particular device based on the sensing operation.

Lighting system inspection using an unmanned aerial vehicle

A system and method for detecting an anomaly of an optically transparent or translucent object are disclosed. The system and method include a light source configured to emit light, a light transmission element having a textured surface, and an optical couplant configured to be disposed between the light transmission element and the object. At least a portion of the light emitted by the light source is configured to pass into the light transmission element through the textured surface and pass into the object through the optical couplant. At least a portion of the light that passes into the object internally reflects within the object and impinges on the anomaly to provide an illumination that indicates the location of the anomaly.

Systems and methods for detecting anomalies in objects

A method for wirelessly coupling respective transducers of an automated motion platform and a sub-surface sensor node through a skin of a limited-access structure for the purpose of wireless power and data transfer. Coordinates of an as-designed position of the transducer of the sensor node in a local coordinate system of the limited-access structure are retrieved from a non-transitory tangible computer-readable storage medium. Then coordinates of a target position on an external surface of the skin of the limited-access structure are estimated. The target position is calculated to be aligned with the as-designed position of the transducer of the sensor node. The motion platform is moved under computer control so that the transducer onboard the motion platform moves toward the target position. Movement ceases when the transducer onboard the motion platform is at the target position. Then wave energy is transferred between the aligned transducers.

Methods for through-structure power and data transfer between mobile robots and sensor nodes

A method includes obtaining, at an unmanned aerial vehicle, a flight plan for the unmanned aerial vehicle. The flight plan is based on an aircraft type of an aircraft to be inspected. The method also includes coordinating, with a lighting control device onboard the aircraft, activation of a particular exterior light of the aircraft based on the flight plan such that the particular exterior light activates or deactivates when a particular sensor of the one or more sensors is located (i.e., positioned and oriented) to perform a sensing operation on the particular exterior light. The method further includes performing the sensing operation on the particular exterior light using the particular sensor. The method also includes determining a functionality metric associated with the particular exterior light based on the sensing operation.

Methods and apparatus for performing repair operations using an unmanned aerial vehicle (UAV). The methods are enabled by equipping the UAV with tools for rapidly repairing a large structure or object (e.g., an aircraft or a wind turbine blade) that is not easily accessible to maintenance personnel. A plurality of tools are available for robotic selection and placement at the repair site. The tools are designed to perform respective repair operations in sequence in accordance with a specified repair plan, which plan may take into account the results of a previously performed UAV-enabled inspection.

Repair of structures using unmanned aerial vehicles

A method of performing an automated non-destructive examination of a composite structure includes identifying surface damage on the composite structure, coupling an automated tap tester device to a surface of the composite structure at a location of the surface damage, and performing, with the automated tap tester device, a plurality of tapping impacts on the surface within a testing area that encapsulates the surface damage. The method also includes receiving a plurality of acoustic signals associated with the plurality of tapping impacts, modeling sub-surface damage associated with the surface damage based on an analysis of the plurality of acoustic signals.

Device and method for use in examining a composite structure

Systems, methods, and apparatus for acquiring surface profile information (e.g., depths at multiple points) from limited-access structures and objects using an autonomous or remotely operated flying platform (such as an unmanned aerial vehicle). The systems proposed herein use a profilometer to measure the profile of an area on a surface where visual inspection has indicated that the surface has a potential anomaly. After the system has gathered data representing the surface profile in the area containing the potential anomaly, a determination may be made whether the collected image data indicates that the structure or object should be repaired or may be used as is.

Measurement of surface profiles using unmanned aerial vehicles

Methods and apparatus for performing repair operations using an unmanned aerial vehicle (UAV). A UAV carries a repair patch ensemble containing all repair materials (including a repair patch, a heating blanket and other ensemble materials) in a prepackaged form to the repair area. During flight of the UAV, the repair patch is vacuum adhered to the heating blanket. Vacuum pressure is also used to hold the repair patch ensemble in position on the composite surface of the structure. Then the hot bond process is enacted to bond the repair patch to the repair area. In accordance with one embodiment, the hot bond process involves heating the repair patch to adhesively bond the repair patch while applying vacuum pressure to consolidate the composite material. Then the repair patch is released from the ensemble and residual ensemble materials (heating blanket, bleeder material, and release films) are removed by the UAV.

Growing community of inventors

Renton, WA, United States of America

Gregory James Sweers