Method and system for providing feedback from a non-destructive inspection of a composite part

• US 6,549,820 B1
• Filed: 07/27/1999
• Issued: 04/15/2003
• Est. Priority Date: 07/31/1998
• Status: Expired due to Term

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Welch, John M., Kitt, Brian R., Jundt, Darrell C., Fischer, Jon J., Garrett, Kenneth E., Stewart, Kenneth C., Holdeman, Timothy L., Jansen, Sandra L., Barrett, Russell A., Gayle, David M., Russell, Brett E., Ruebke, Donald D.
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): Bahta, Kidest
• Application Number:
  US09/361,666
• Time in Patent Office: 1,358 Days
• Field of Search: 700/109, 700/108, 700/110, 700/111, 700/222, 700/279, 700/162, 700/182, 700/195, 700/121, 700/169, 700/173, 700/175, 702/84, 702/179, 702/82, 702/81, 705/3, 382/141, 736/11, 736/33, 736/28, 345/790
• US Class Current: 700/110
• CPC Class Codes: G01N 2291/2632 flat
• CPC Class Codes: G01N 29/0609 Display arrangements, e.g. colour displays indicating or recording in connection with measuring in general G01D
• CPC Class Codes: G01N 29/0636 with permanent recording
• CPC Class Codes: G01N 29/4445 Classification of defects

Abstract

A computer-implemented method for providing on-line ultrasonically scanned images of composite parts for immediate feedback in a manufacturing environment is discussed. The scanned images are edited to indicate each deficiency that has been repaired on a previously assembled composite part. Quality assurance personnel enter data associated with each composite part and verify the data content. Repair personnel enter data associated with correcting an identified deficiency of the composite part. Historical data suitable for developing statistics and trends are stored for each type of composite part. When queries are launched, the statistical and trend data is filtered to produce reports that are displayed. That is, reports are generated that identify particular statistics and trends. The scan image and data associated with a composite part are linked together for cross-referencing and stored in a database that is accessible by client and server computers on a network. Images produced by an ultrasonic scanner(s) coupled to the network are stored for retrieval.

Claims

1. A method of providing nondestructive inspection (NDI) and other information about manufactured parts to a crew building the part and others, said computer-implementable method comprising:

gathering NDI information about parts as they are manufactured, wherein gathering NDI information about the parts comprises ultrasonically scanning the parts for defects and producing image data of at least one part that is ultrasonically scanned;

gathering other information about the parts, including repair information, part record and trend information;

linking the gathered NDI and other information, including repair information, part record and trend information, and image data, about the parts;

storing the linked, gathered NDI and other information, including repair information, part record and trend information, and image data, about the parts in a database;

at a user'"'"'s request, selectively deriving information about the parts from the information about the parts stored in the database; and

displaying reports based on the derived information.

2. The method claimed in claim 1, wherein gathering NDI information about parts as they are manufactured comprises ultrasonically scanning the parts for defects and producing at least one scanned image of each part that is ultrasonically scanned.

3. The method claimed in claim 2, wherein gathering NDI information about parts as they are manufactured also includes editing the scanned images of the parts.

4. The method claimed in claim 3, wherein gathering other information about the parts, including repair information, includes displaying a QA DATA RECORD window, said QA DATA RECORD window including boxes for QA personnel to enter data about the parts.

5. The method claimed in claim 4, wherein gathering other information about parts, including repair information, includes displaying a REPAIR RECORD window, said REPAIR RECORD window including boxes for repair personnel to enter data about the parts.

6. The method claimed in claim 5, wherein the QA DATA RECORD window includes an actuatable button that when actuated causes said REPAIR RECORD window to be displayed.

7. The method claimed in claim 6, wherein said QA window includes actuatable buttons that when actuated cause the selective deriving of information about the parts from the information about the parts stored in the database and the displaying of reports based on the derived information.

8. The method claimed in claim 7, wherein said repair window also includes actuatable buttons that when actuated cause the selective deriving of information about the parts from the information about the parts stored in the database and the displaying of reports based on the derived information.

9. The method claimed in claim 8 including a MORE QUERIES and other window that includes actuatable buttons that when actuated cause the selective deriving of information about the parts from the information about the parts stored in the database and the displaying of reports based on the derived information.

10. The method claimed in claim 9, wherein said QA DATA RECORD window includes a MORE QUERIES button that when actuated causes said MORE QUERIES and other window to be displayed.

11. The method claimed in claim 1, wherein gathering other information about parts, including repair information, includes displaying a REPAIR RECORD window, said REPAIR RECORD window including boxes for repair personnel to enter data about the parts.

12. The method claimed in claim 11, wherein said repair window includes actuatable buttons that when actuated cause the selective deriving of information about the parts from the information about the parts stored in the database and the displaying of reports based on the derived information.

13. The method claimed in claim 1 including a MORE QUERIES and other window that includes actuatable buttons that when actuated cause the selective deriving of information about the parts from the information about the parts stored in the database and the displaying of reports based on the derived information.

14. A computer-readable medium having computer-executable instructions for carrying out the method recited in any of claims 1-13.

15. A quality tracking system for providing nondestructive inspection (NDI) information about manufactured parts to a crew building the parts and others comprising:

an NDI system for producing NDI information about manufactured parts, wherein the NDI information about the parts comprises data for at least one image of each part that is ultrasonically scanned;

at least one computer for gathering other information about the manufactured parts, including repair information, part record and trend information, linking the NDI information to the part record and trend information, repair information and image data, and producing reports;

a database for storing the linked information obtained from said NDI system and said at least one computer; and

a network for coupling said NDI system, said database, and said at least one computer system together.

16. The quality tracking system claimed in claim 15, wherein said NDI system is an ultrasonic scanning system, said ultrasonic scanning image system producing at least one scan image of each part that is scanned, said scan images stored in said database.

17. The quality tracking system claimed in claim 16, wherein the at least one computer has a user interface that includes a QA DATA RECORD window, said QA DATA RECORD window including boxes for QA personnel to enter said other information about the manufactured parts.

18. The quality tracking system claimed in claim 17, wherein the user interface of the at least one computer also includes a REPAIR RECORD window, said REPAIR RECORD window including boxes for repair personnel to enter repair information about the manufactured parts.

19. The quality tracking system claimed in claim 18, wherein the QA DATA RECORD window includes an actuatable button that when actuated causes said REPAIR RECORD window to be displayed.

20. The quality tracking system claimed in claim 19, wherein said QA DATA RECORD window includes other actuatable elements that when actuated causes said quality tracking system to selectively derive information about parts from the information stored in the database and display reports based on the derived information.

21. The quality tracking system claimed in claim 20, wherein said REPAIR RECORD window includes other actuatable buttons that when actuated cause said quality tracking system to selectively derive information about the parts from the information about the parts stored in the database and display reports based on the derived information.

22. The quality tracking system claimed in claim 21, wherein the user interface of said at least one computer also includes a MORE QUERIES and other window that includes actuatable buttons that when actuated cause said quality tracking system to selectively derive information about the parts from the information about the parts stored in the database and display reports based on the derived information.

23. The quality tracking system claimed in claim 22, wherein the MORE QUERIES and other window is displayed when a actuatable button in said QA window is actuated.

24. The quality tracking system of claim 15, wherein said at least one computer has a user interface that includes a REPAIR WINDOW, said REPAIR WINDOW including boxes for repair personnel to enter repair information.

25. The quality tracking system claimed in claim 24, wherein said REPAIR RECORD window includes other actuatable buttons that when actuated cause said quality tracking system to selectively derive information about the parts from the information about the parts stored in the database and display reports based on the derived information.

26. The quality tracking system of claim 15, wherein said at least one computer has a user interface that includes a MORE QUERIES and other window that includes actuatable buttons that when actuated cause said quality tracking system to selectively derive information about the parts from the information about the past stored in the database and display reports based on the derived information.