The Boeing Company

Theboeing Company

Steven Ray Walton

Barry Allen Fetzer

James C Kennedy

Hien T Bui

Michael J Duncan

James J Troy

William Paul Motzer

Michael C Hutchinson

Navpreet S Grewal

Scott Wesley Lea

Daniel James Wright

Christopher David Brown

William Joseph Tapia

Jeffry J Garvey

Martin L Freet

Patrick Lee Anderson

Noel A Spishak

Daniel L Nydegger

William R Schell

David M Kozy

Mark L Little

Richard C Krotzer

Ronald E VonWahlde

Stephen L Sembritzky

Kevin R Bray

Steve A Brink

Ray Henderson

Micheal C Hutchinson

Michael Joseph Duncan

Ronald E Vonwahlde

Method and apparatus for enabling ultrasonic inspection of a changing, insufficiently defined or unknown shape (e.g., a variable radius or a noncircular radius caused by the use of soft tooling) at a rate that meets production requirements. The apparatus comprises a linear ultrasonic array (i.e., sensor) incorporated in a toppler, which in turn is slidably supported by an oscillating sensor mechanism carried by a traveling trailer vehicle. As a result of this arrangement, the sensor can undergo a back-and-forth sweeping motion coupled with motion along the spar radius. The sensor is further able to displace radially relative to a sweep pivot axis and rotate (hereinafter 'topple') about a topple pivot axis. In this manner, the orientation of the sensor can adjust to the contour of the inspected surface as the sensor scans.

Variable radius inspection using sweeping linear array

System and method for enabling ultrasonic inspection of a variable and irregular shape. The system comprises one or more ultrasonic pulser/receivers, one or more ultrasonic transducer arrays, a shoe or jig to hold and position the array(s), data acquisition software to drive the array(s), and data analysis software to select a respective best return signal for each pixel to be displayed. This system starts with information about the general orientation of the array relative to the part and a general predicted part shape. More specific orientation of the transmitted ultrasound beams relative to the part surface is done electronically by phasing the elements in the array(s) to cover the expected (i.e., predicted) surface as well as the full range of part surface variability.

Method for ultrasonic inspection of irregular and variable shapes

As described herein, a system for inspecting a component includes an ultrasonic inspection probe with a component surface interface, and a robotic device with an end effector coupled to the ultrasonic inspection probe. The robotic device is automatably controllable to move the ultrasonic inspection probe across a surface of the component. Additionally, the system includes an angle sensor subsystem coupled between the ultrasonic inspection probe and the end effector. The angle sensor subsystem is configured to operably detect an actual orientation of the end effector relative to a presently inspected portion of the surface of the component. The system includes a controller configured to receive orientation data from the angle sensor subsystem, the orientation data comprising the actual orientation of the end effector, compare the actual orientation to a desired orientation, and control the robotic device to adjust an orientation of the end effector to be in the desired orientation.

Non-destructive ultrasonic inspection apparatus, systems, and methods

A system and method for inspecting a joint fillet having a surface whose radius varies along the length of the joint fillet. In one embodiment, the inspection apparatus comprises: a chassis; a shoe assembly supported by the chassis and comprising an axle; a transducer array assembly translatably coupled to the shoe assembly; biasing means for urging the transducer array assembly to translate relative to the shoe assembly in a first direction; and a lever assembly pivotably coupled to the axle of the shoe assembly and in contact with the transducer array assembly over a range of angular positions of the lever assembly. The transducer array will translate in a second direction opposite to the first direction when the net force exerted by the lever assembly is greater than the biasing force exerted by the biasing means. The lever assembly is used to automatically adjust the array position to the varying fillet radius.

Continuously adaptive ultrasonic inspection device

A system and method for inspecting a workpiece are provided. According to one embodiment, the system includes a plurality of illumination sources positioned proximate to the workpiece and each operable to generate at least one respective illumination beam to illuminate at least a portion of the workpiece, wherein each beam has a different respective color. The system also includes at least one camera positioned proximate to the workpiece and operable to capture at least one image of at least a portion of the workpiece including the illumination beams incident thereon. In addition, the system includes a data system capable of providing simultaneous two-dimensional and three-dimensional information indicative of the workpiece based on the image acquired by the camera.

Method and system for two-dimensional and three-dimensional inspection of a workpiece

A system and method that allow inspection of hollow structures made of composite material, such as an integrally stiffened wing box of an aircraft. A wing box comprises top and bottom skins connected by a plurality of spaced spars. The system employs a plurality of scanners for inspecting different portions of each spar. The system uses dynamically controlled magnetic coupling to connect an external drive tractor to computer-controlled scanners that carry respective sensors, e.g., linear ultrasonic transducer arrays. A system operator can control the various components by means of a graphical user interface comprising multiple interaction regions that represent the individual scanner motion paths and are associated with respective motion script files.

Automated inspection of soft-tooled hollow structure

A probe is used to inspect the health of a corner radius within an elongate internal cavity of a structure. The probe is transported through the cavity on a carriage that maintains the probe a substantially constant distance from the corner radius as the carriage traverses changes in the cross sectional shape of the cavity.

Device and method for inspecting a corner radius

A feature of a workpiece can be identified. Two-dimensional data of at least a region of a workpiece and three-dimensional data of a portion of the region of the workpiece are acquired, such as by illuminating at least the region with at least a first light source disposed at a first angle of incidence relative to a plane of the region and illuminating the portion with a second light source, such as at least one laser, disposed at a second angle of incidence greater than the first angle of incidence. An estimated location of an attribute of a feature of the workpiece is determined from the three-dimensional data, and the feature is identified by analyzing the two-dimensional data in an area surrounding the estimated location of the attribute. Attributes of features can include without limitation a point along a line of an edge.

System and method for identifying a feature of a workpiece

A system for measurement of pressure drop through a perforated panel having panel holes includes a sensor comprising an illumination source adapted to illuminate the perforated panel, a lens spaced-apart with respect to the illumination source and a camera interfacing with the lens. A controller is connected to the camera and adapted to receive image frames of the panel openings from the camera, measure an optical porosity of the perforated panel, identify a number and locations of missing and blocked panel holes in the perforated panel, determine a shape of a small region associated with each panel hole and calculate a pressure drop through the perforated panel based on the optical porosity of the perforated panel, the number and locations of the missing and blocked panel holes and the shape of the small region associated with each panel hole.

System and method for measurement of pressure drop through perforated panels

Apparatus and methods for inspecting a workpiece are provided. According to one embodiment, a method for inspecting a workpiece comprises illuminating at least a portion of the workpiece with at least one illumination beam and capturing at least one image including at least on line signature formed by illuminating the workpiece with the illumination beam. The method further includes performing two-dimensional and three-dimensional processes on the captured image and classifying at least one feature associated with the workpiece based at least in part on data generated by the two-dimensional and three-dimensional processes.

Apparatus and methods for two-dimensional and three-dimensional inspection of a workpiece

An apparatus and method is provided for cutting curved tube and duct assemblies using a high-powered laser, which locates, measures and follows a scribe line. The invention generally is comprised of a multi-axis laser-based machine tool to cut formed (i.e., curved) welded tube and duct detailed parts to a planar scribe line. It is further comprised of a laser focusing head positioned on a rotating and tilting platform; fixturing aids to position and hold the tubes or ducts to be cut; a machine vision system to locate and measure a scribe line in a plane on the tube or duct, thus determining its orientation; and a controller that tilts the turntable to a co-planar position, and then operates a high-powered laser to cut the duct at the scribe line.

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Wilkeson, WA, United States of America

Steven Ray Walton