The Boeing Company

William Joseph Tapia

Gary E Georgeson

Michael D Fogarty

Barry Allen Fetzer

Jeffrey Reyner Kollgaard

Martin L Freet

Hong Hue Tat

James J Troy

Scott Wesley Lea

Joseph Lawrence Hafenrichter

Daniel James Wright

Jeffrey G Thompson

Ronald E VonWahlde

David W Anderson

James C Kennedy

Richard Henry Bossi

William Paul Motzer

Christopher David Brown

Andrew Michael Robb

Hien T Bui

Daniel James Kovach

Michael J Duncan

Steven Ray Walton

Jeffry J Garvey

Michael C Hutchinson

Christopher Ralph Brown

Justin D Serrill

Mark L Little

Robert L Carlsen

Richard C Krotzer

Edward L Puckett

David K Brooks

Shereef G Shehab

Gary Ernest Georgeson

Michael Joseph Duncan

Ronald E Vonwahlde

Disclosed herein is a method of measuring a gap between exterior structures and interior structures. The method comprises directing a transmitted m-wave signal from an exterior surface of the exterior structure into the exterior structure and the interior structure. The transmitted m-wave signal is generated by a gap sensing device that comprises an electromagnetic dual-tuned resonant coil sensor. The method also comprises measuring a received m-wave signal with the gap sensing device. The received m-wave signal comprises the transmitted m-wave signal influenced by the assembly. The method further comprises determining a size of the gap between the exterior structure and the interior structure based at least partially on at least one measured characteristic of the received m-wave signal.

Methods and systems for measuring gaps between exterior structures and interior structures

A non-destructive inspection system is presented. The non-destructive inspection system comprises a robotic end effector having an extendable actuator and a flange-mounted roller containing an ultrasonic sensor, the flange-mounted roller connected to the extendable actuator by a pivot connection, the extendable actuator configured to extend the flange-mounted roller until the flange-mounted roller contacts an inspection surface.

Robotic end effector system with surface tracking and methods for use

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 tool for detecting a covered edge of a structural member through sealant material of a fillet seal includes an edge detection probe mounted to a fixture. The probe outputs an interrogation signal toward the covered edge and receives a return signal indicative of a location of the covered edge. The tool includes an electronic control unit ('ECU') in communication with the edge detection probe and a display screen. The ECU is configured to generate, from the return signal, one or more XY coordinates indicative of the edge location, and to display the edge location on the display screen. Additionally, the tool includes a seal measurement device. In response to the edge location, the device measures a predetermined dimension of the fillet seal, including a thickness and/or a shape of the fillet seal. A method includes detecting the covered edge using the tool.

Lap joint fillet seal measurement tool when lap edges are sealed

An inspection system for detecting one or more misaligned seals is disclosed and includes a linear transducer array connected to a sleeve. The linear transducer array includes a plurality of ultrasonic transducers each configured to transmit and receive ultrasonic waves. The ultrasonic transducers direct the ultrasonic waves towards one or more seals that are disposed underneath the sleeve. The inspection system also includes a rotational device configured to move the ultrasonic transducers around a circumference of the sleeve, one or more processors in electronic communication with the linear transducer array, and a memory coupled to the one or more processors. The memory stores data into a database and program code that, when executed by the one or more processors, causes the inspection system to instruct the plurality of ultrasonic transducers to transmit and receive the ultrasonic waves.

Inspection system for detecting misaligned seals

There is provided a system for using eddy current edge effect to measure a gap between two conductive parts. The system includes the two conductive parts, each having predetermined properties. The system includes a probe having a housing with a coil, and includes a reference gap standard, based on one or more reference gap measurements taken between at least two reference conductive parts separated by a gap distance, as specified by predetermined engineering requirements. The system includes an inspection instrument assembly coupled to the probe and having an inspection apparatus calibrated to the probe and the reference gap standard. The probe with the coil uses the eddy current edge effect to take the gap measurement and measure the gap. The gap measurement is compared to the reference gap standard, to determine whether the gap measurement is an acceptable result or an unacceptable result, based on the predetermined engineering requirements.

System and method for using eddy current edge effect to measure a gap between two conductive parts

Methods are presented. Signals are sent into a first surface of a structure using an ultrasonic transducer. Ultrasound response signals are received at the ultrasonic transducer. A portion of a second surface of the structure is heated while the ultrasonic transducer is sending signals into the first surface, wherein the second surface is on an opposite side of the structure from the first surface. Infrared images of the portion of the second surface of the structure are taken after heating the second surface.

Thermography inspection for near-surface inconsistencies of composite structures

A signal is sent into a structure at an angle substantially parallel to a ramp of the structure using a transducer array positioned at a first surface of the structure. An ultrasound response signal is formed at a second surface of the structure. The ultrasound response signal is received at the transducer array.

Ultrasonic inspection of a structure with a ramp

Disclosed is an apparatus, method and system for inspecting structures, and more particularly for evaluating the condition of a structure. The disclosed nondestructive inspection testing method and apparatus enables an operator to assess the condition of a structure, such as a composite laminate part and determining the location and depth of anomalies. The method includes generating a subsurface longitudinal ultrasonic wave signal at a high incidence angle into a structure being evaluated and collecting at least one of any front, back or side reflected wave data. The method may include processing the reflected wave data to determine the condition of the structure, including any anomalies that may have been detected and their location, size and shape.

Apparatus and method for inspecting a laminated structure

Systems and methods for inspecting a hole in a laminated structure. An exemplary system includes a transducer assembly configured to direct sound waves substantially parallel to a surface of the hole. The system further includes a controller that collects A-scan data for multiple rotational positions of the transducer assembly as the transducer assembly is rotated within the hole. The controller processes the A-scan data for the multiple rotational positions of the transducer assembly to generate B-scan data, and displays the B-scan data.

An automated blade crawler capable of scanning a multiplicity of non-destructive inspection sensors over a surface of an airfoil-shaped body such as a blade component. The blade crawler is movable in a spanwise direction, thereby enabling a sensor array to inspect the surface area on one or both sides of the blade component in one pass. The sensors concurrently output scan imaging data which is multiplexed, the multiplexed being transmitted (via an electrical cable or wirelessly) to data collection and display hardware at an operations control center.

Apparatus for automated non-destructive inspection of airfoil-shaped bodies

A method and apparatus for evaluating an object having a wrinkle. Energy is sent into the object at a plurality of locations using an array of transmitting elements. Reflected energy is received at an array of receiving elements in response to a portion of the energy being reflected off a plurality of layers in the object. A three-dimensional model of the wrinkle in the object is created based on the reflected energy received at the array of receiving elements.

Quantification of wrinkles in composite objects

Systems and methods using fluid-filled hollow microspheres to assist in monitoring or indicating high-energy blunt impacts on structures such as aircraft. A multiplicity of microspheres may be adhered to or embedded in a coating applied on a surface of a substrate (e.g., a tape or an appliqu&#xe9;), which substrate in turn can be adhered to a surface of a structure to be monitored. The microspheres are designed to rupture at one or more specified pressure thresholds. In some embodiments, the microspheres are filled with electrically conductive fluid which, if released from ruptured microsphere, changes the electromagnetic state of the substrate. In response to the detection of a sufficiently large change in the electromagnetic state of the substrate, a blunt impact indication is generated. The impact site may then undergo non-destructive inspection.

Blunt impact indicator methods

A method and apparatus for inspecting a test object. A sound signal is sent from a first portion of a curved transducer array through the test object in a direction towards a second portion of the curved transducer array. The curved transducer array has a shape that is configured to cover a non-planar surface of the test object. A response signal in response to the sound signal is received at the second portion of the curved transducer array.

Ultrasonic inspection system for non-planar surfaces

A mechanism for adjusting the orientation of an end effector (e.g., a non-destructive inspection sensor) during movement over a contoured surface, comprising: (1) a pneumatic or spring-loaded plunger shaft that facilitates positioning of an end effector onto a highly contoured surface by allowing a wide range of vertical motion; (2) a rocker pivotably coupled to a distal end of the plunger shaft, the rocker being pivotable about a horizontal axis to allow a pair of follower wheels coupled to distal ends of the rocker arms to follow the contoured surface and keep the end effector oriented correctly relative to the surface without tipping over; and (3) a hozzle (i.e., an end effector holder) attached to the rocker for rotation therewith, the end effector being coupled to the hozzle by an elastomeric gasket or a plurality of springs which allow the orientation of the end effector relative to the hozzle to change in response to contact forces.

Growing community of inventors

Kapowsin, WA, United States of America

William Joseph Tapia