The Boeing Company

Robert William Grube

Paul Zack Thunemann

Raju Shankar Mattikalli

Ty Aaby Larsen

Huseyin Erdim

Hasan A Ghadialy

Mitchell Tyler Lee

Eric M Chapman

Gregg W Podnar

Jerry Dean Zayic

Emma Romig

Lisa C Thomas

Joseph D Doyle

Farshad Forouhar

Alexander J Coco

Stefanie Anita Meier

Scott H Fife

Lorrie Sivich

Paul S Fussell

Brianna K Nord

Aaron C Drollette

Dominic N Nwoke

Christopher H Rees

Kimberly Marie Craig

Carrie Rule

Christopher Marc Gast

Robert W Mattikalli

A method includes steps of: (1) obtaining a metrology data set and a build data set representing an article; (2) determining a surface geometry of the article in the metrology data set and the build data set; (4) selecting a metrology data subset from the metrology data set representing the surface geometry; (5) selecting a build data subset from the build data set representing the surface geometry; (6) generating a metrology point cloud in a metrology coordinate system; (7) generating a build point cloud in a build coordinate system; (8) registering the metrology point cloud and the build point cloud; (9) calculating a transform between the metrology coordinate system and the build coordinate system; and (10) applying the transform to the metrology data set to convert the metrology data set to the build coordinate system.

Systems and methods for registering data to a coordinate system

A method for detecting defects includes steps of: (1) calculating an average value for intensity of CT image voxels in a neighborhood; (2) calculating a difference value for the intensity of the voxels in the neighborhood; (3) calculating a standard deviation for the intensity of the voxels in the neighborhood; (4) calculating a z-score for each one of the voxels; (5) identifying a cluster of neighboring ones of the voxels; (6) determining a cluster-boundary parameter of the cluster; and (7) classifying the cluster as a defect when the cluster-boundary parameter of the cluster is above a parameter threshold.

Systems and methods for detecting defects in powder manufactured components

An example method for detection of impurities in additive manufacturing material includes illuminating, by a light source, a sample of additive manufacturing material with light, while illuminating the sample of the additive manufacturing material with light, causing a camera to acquire image data of the sample, and processing the image data to determine an amount of impurities in the sample of the additive manufacturing material. An example system for detection of impurities in additive manufacturing material includes a light source for illuminating a sample of additive manufacturing material with light, a camera for acquiring image data of the sample while illuminating the sample of the additive manufacturing material with light, and a computing device having one or more processors configured to execute instructions stored in memory for processing the image data to determine an amount of impurities in the sample of the additive manufacturing material.

Methods and systems for detection of impurities in additive manufacturing material

A method includes receiving topic names from a metrology interface device, where the topic names correspond to data generated by metrology devices associated with a manufacturing operation. The method also includes accessing a data stream from the metrology interface device. The data stream includes converted metrology data (in a common format) from the metrology devices and corresponding topic names. The method further includes extracting first converted metrology data from the data stream based on a first topic name of the topic names. The first converted metrology data is generated by converting first metrology data from a first metrology device of the metrology devices to the first converted metrology data having the common format. The method also includes comparing the first converted metrology data to a specification, detecting a condition based on the comparison, and sending a command to a manufacturing device based on the condition.

Manufacturing device control based on metrology data

A method and system are provided to position and drill an opening for a fastener through one or more workpieces. In the context of a method, a peen mark is formed on a workpiece at a location at which the opening is to be drilled. The method also includes utilizing a robotic vision system to identify the peen mark on the workpiece and thereafter drilling the opening configured to receive the fastener at the location designated by the peen mark. In the context of a system, the system includes a dot peen marking system configured to form a peen mark on a workpiece at a location at which the opening is to be drilled. The system also includes a robot comprising a vision system configured to identify the peen mark on the workpiece and a drilling machine configured to drill the opening at the location designated by the peen mark.

Method and system for defining the position of a fastener with a peen mark

An embodiment of the present disclosure provides a method and apparatus for managing a part. The method comprises identifying, by a computer system, parameters for the part. Further, the method comprises identifying, by the computer system, a number of additional parameters used in manufacturing the part from a preform. Yet further, the method comprises automatically generating, by the computer system, a preform design for the preform using the parameters for the part and the number of additional parameters, wherein the preform design enables manufacturing the preform using an additive manufacturing system in a manufacturing environment.

Preform fabrication system

An example method is described that includes providing, for display, a three-dimensional (3D) model of a part. The method also includes receiving, via a graphical user interface, data defining a cutting plane. The cutting plane intersects the 3D model of the part and divides the 3D model into a first portion and a second portion. The method further includes determining a first set of minimum-volume bounding boxes that is tangent to the cutting plane and encloses the first portion of the 3D model, and determining a second set of minimum-volume bounding boxes that is tangent to the cutting plane and encloses the second portion of the 3D model. The method also includes providing a preform geometry for the part. The preform geometry includes the first set of minimum-volume bounding boxes and the second set of minimum-volume bounding boxes.

Interactive graphical user interface (GUI) for designing preform geometries

A system, method, and computer program product for detecting, in real time, a fatigue level of a vehicle operator. Multiple physiological indicators of an individual vehicle operator can be monitored at different instances when the operator's level of fatigue is known and can be quantified. A statistical model of the vehicle operator's fatigue can be developed from the data from the multiple instances. In future instances, the statistical model can be applied to real-time physiological data collected from the operator during operation of the vehicle to determine a fatigue level. A warning can be provided when the statistically-calculated fatigue level exceeds a threshold level.

System for fatigue detection using a suite of physiological measurement devices

A software module apparatus for enabling a user to generate a virtual tripwire through a geographic area of interest using a plurality of sensors. The apparatus may make use of an input for allowing a user to input a digital elevation model (DEM) of the area of interest. An input responsive to a user controlled device may also be used for defining a swath of the area of interest, the swath representing a subregion laying over, or adjacent to, a border to be monitored. A display may be generated for illustrating computed locations of a plurality of independent sensors used to form the virtual tripwire through the swath of the area of interest.

System and method for forming optimized perimeter surveillance

A method for optimum sensor layout for detecting an intruder may include selecting candidate sensor locations within a representation of an area of regard. The method may also include determining a sub-region of detection for each sensor based on a preset probability of detection of the intruder traversing a sub-region associated with each sensor. The method may additionally include determining each pair of sensors with overlapping sub-regions of detection and determining a lowest probability of detection for any path between each pair of sensors with overlapping sub-regions of detection. The method may further include determining an optimum layout of sensor locations or sensors from candidate sensor locations based on a path of the lowest probability of detection for any path between each pair of sensors with overlapping sub-regions of detection.

Optimum sensor layout for detecting an intruder

A method for forming a virtual tripwire through a subregion of an area of interest. The method may involve performing a geometric analysis of terrain in the subregion, the geometric analysis determining a location for each one of a pre-designated plurality of candidate sensors that may potentially be used in forming the virtual tripwire. A viewshed for each candidate sensor is determined. Each viewshed represents a coverage region for its associated candidate sensor. A geometric beginning point and a geometric end point within the subregion are each defined for the virtual tripwire. The viewsheds are analyzed to determine a number of the candidate sensors required to form a path for the virtual tripwire from the beginning point to the end point.

A method for determining a path of travel of an intruder traversing an area of regard (AOR) to a predefined point, where the path of travel has a minimum probability of detection relative to other potential paths of travel of the intruder. The method may comprise: providing three dimensional terrain data concerning the AOR; providing the locations of a plurality of detection sensors implemented in the AOR, with each detection sensor having a known field of view; providing a predetermined single scan detection probability for each of the detection sensors; generating a grid of points that is laid over the AOR; and using the foregoing information to determine a particular path of travel, defined by selected arcs connecting specific ones of the grid of points, of the intruder to the predefined point that represents a minimum probability of detection of the intruder.

Growing community of inventors

Edmonds, WA, United States of America

Robert William Grube