Compact automated inspection for foreign materials during the manufacture of large composite

• US 10,621,713 B2
• Filed: 08/30/2018
• Issued: 04/14/2020
• Est. Priority Date: 08/30/2018
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Safai, Morteza
• Primary Examiner(s): Wong, Allen C
• Application Number:
  US16/117,938
• Publication Number:
  US 20200074614A1
• Time in Patent Office: 593 Days
• Field of Search: 348 86
• CPC Class Codes: G01N 2021/8472 Investigation of composite materials
• CPC Class Codes: G01N 21/8851 Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges G01N21/8806 and G01N21/93 - G01N21/95692 take precedence; optical measurement of dimensions G01B11/00; optical scanning G02B26/10; image transformation G06T3/00; computerised image enhancement G06T5/00; image processing per se for flaw detection G06T7/0002
• CPC Class Codes: G01N 21/94 Investigating contamination, e.g. dust G01N21/85 takes precedence
• CPC Class Codes: G06T 2207/10024 Color image
• CPC Class Codes: G06T 2207/10048 Infrared image
• CPC Class Codes: G06T 7/0004 Industrial image inspection
• CPC Class Codes: G06V 10/141 Control of illumination
• CPC Class Codes: G06V 2201/06 Recognition of objects for industrial automation
• CPC Class Codes: H04N 23/11 for generating image signals from visible and infrared light wavelengths
• CPC Class Codes: H04N 23/51 Housings
• CPC Class Codes: H04N 23/52 Elements optimising image sensor operation, e.g. for electromagnetic interference [EMI] protection or temperature control by heat transfer or cooling elements
• CPC Class Codes: H04N 23/55 Optical parts specially adapted for electronic image sensors; Mounting thereof
• CPC Class Codes: H04N 23/56 provided with illuminating means
• CPC Class Codes: H04N 23/74 by influencing the scene brightness using illuminating means
• CPC Class Codes: H04N 23/80 Camera processing pipelines; Components thereof
• CPC Class Codes: H04N 23/90 Arrangement of cameras or camera modules, e.g. multiple cameras in TV studios or sports stadiums

Abstract

An example system includes a sensor housing defining a plurality of horizontal layers and a controller. The sensor housing includes a plurality of light-emitted diode (LED) light sources, a plurality of cameras, and a plurality of optical devices. Each camera of the plurality of cameras is positioned within a respective horizontal layer of the plurality of horizontal layers and configured to detect a respective range of wavelengths of light. The plurality of optical devices is configured to receive light reflected by the surface through a common input lens and direct the light to one of the cameras of the plurality of cameras depending on a wavelength of the light. The controller is configured to receive signals from the plurality of cameras indicative of the light reflected by the surface and determine whether there is any foreign object debris material on the surface using the signals from the plurality of cameras.

Claims

1. A system for inspecting a surface, comprising:

a sensor housing defining a plurality of horizontal layers, the sensor housing comprising;

a plurality of light-emitting diode (LED) light sources configured to illuminate the surface,

a plurality of cameras, each camera of the plurality of cameras positioned within a respective horizontal layer of the plurality of horizontal layers and configured to detect a respective range of wavelengths of light, and

a plurality of optical devices configured to receive light reflected by the surface through a common input lens and direct the light to one of the cameras of the plurality of cameras depending on a wavelength of the light; and

a controller communicatively coupled to the plurality of cameras, the controller configured to receive signals from the plurality of cameras indicative of the light reflected by the surface and determine whether there is any foreign object debris material on the surface using the signals from the plurality of cameras.

2. The system of claim 1, wherein the system is configured to be attached to a composite layup machine, and wherein the system further comprises a cooling source configured to cool the sensor housing.

3. The system of claim 2, wherein the system is configured to be attached to a head of the composite layup machine.

4. The system of claim 2, wherein the cooling source comprises a solid-state thermoelectric cooler.

5. The system of claim 1, wherein the plurality of cameras comprises an infrared camera positioned within a first horizontal layer of the plurality of horizontal layers, an ultraviolet light camera positioned within a second horizontal layer of the plurality of horizontal layers, and a visible light camera positioned within a third horizontal layer of the plurality of horizontal layers.

6. The system of claim 1, wherein the plurality of optical devices comprises a first dichroic filter positioned in a first horizontal layer of the plurality of horizontal layers, wherein the first dichroic filter is configured to pass light of a first range of wavelengths to a second horizontal layer of the plurality of horizontal layers that is higher than the first horizontal layer, and wherein the first dichroic filter is configured to reflect light of a second range of wavelengths that is different from the first range of wavelengths to a first camera of the plurality of cameras, the first camera being configured to detect light of the second range of wavelengths.

7. The system of claim 6, wherein the first dichroic filter is coated with a bandpass filter corresponding to the first range of wavelengths.

8. The system of claim 6, wherein the plurality of optical devices further comprises a second dichroic filter positioned in the second horizontal layer, wherein the second dichroic filter configured to pass light of a third range of wavelengths to a third horizontal layer of the plurality of horizontal layers that is higher than the second horizontal layer, and wherein the second dichroic filter is configured to reflect light of a fourth range of wavelengths that is different from the third range of wavelengths to a second camera of the plurality of cameras, the second camera being configured to detect light of the fourth range of wavelengths.

9. The system of claim 8, further comprising a mirror positioned in the third horizontal layer, the mirror configured to reflect light of the third range of wavelengths to a third camera of the plurality of cameras, the third camera being configured to detect light of the third range of wavelengths.

10. The system of claim 1, wherein the plurality of LED light sources comprises an ultraviolet light LED light source and a visible light LED light source.

11. The system of claim 10, wherein the ultraviolet light LED light source comprises multiple ultraviolet light LEDs arranged in a first ring, and wherein the visible light LED light source comprises multiple visible light LEDs arranged in a second ring.

12. The system of claim 1, further comprising a thermal excitation source configured to direct infrared radiation across the surface, wherein the plurality of cameras comprises an infrared camera configured to output signals indicative of infrared light emitted by the surface.

13. The system of claim 1, further comprising an air nozzle, wherein the controller is further configured to cause air to be directed through the air nozzle and towards foreign object debris material on the surface based on a determination that there is foreign object debris material on the surface.

14. The system of claim 1, further comprising a radio-frequency communication module configured to wirelessly transmit data indicative of whether there is any foreign object debris material on the surface.

15. The system of claim 1, further comprising a nitrogen purging system configured to purge the sensor housing with nitrogen.

16. The system of claim 1, wherein the controller is further configured to synchronize triggering of the plurality of cameras such that the signals indicative of the light reflected by the surface are indicative of light reflected by a same area of the surface.

17. A sensor housing for a system for inspecting a surface, the sensor housing defining a plurality of horizontal layers and comprising:

a plurality of light-emitting diode (LED) light sources configured to illuminate the surface;

a plurality of cameras, each camera of the plurality of cameras positioned within a respective horizontal layer of the plurality of horizontal layers and configured to detect a respective range of wavelengths of light; and

a plurality of optical devices configured to receive light reflected by the surface through a common input lens and direct the light to one of the cameras of the plurality of cameras depending on a wavelength of the light.

18. The sensor housing of claim 17, wherein the plurality of cameras comprises an infrared camera positioned within a first horizontal layer of the plurality of horizontal layers, an ultraviolet light camera positioned within a second horizontal layer of the plurality of horizontal layers, and a visible light camera positioned within a third horizontal layer of the plurality of horizontal layers.

19. A method for inspecting a surface comprising:

illuminating the surface using a plurality of light-emitting diode (LED) light sources of a sensor housing, the sensor housing defining a plurality of horizontal layers and comprising a plurality of cameras, wherein each camera of the plurality of cameras is positioned within a respective horizontal layer of the plurality of horizontal layers and configured to detect a respective range of wavelengths of light;

directing, using a plurality of optical devices of the sensor housing, light reflected by the surface and received through a common input lens of the sensor housing to one of the cameras of the plurality of cameras depending on a wavelength of the light;

receiving, by a controller from the plurality of cameras, signals indicative of the light reflected by the surface; and

determining, by the controller, whether there is any foreign object debris material on the surface using the signals indicative of the light reflected by the surface.

20. The method of claim 19, further comprising causing air to be directed through an air nozzle towards foreign object debris material on the surface based on a determination that there is foreign object debris material on the surface.