Autonomous non-destructive evaluation system for aircraft structures

• US 8,713,998 B2
• Filed: 06/14/2011
• Issued: 05/06/2014
• Est. Priority Date: 06/14/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Troy, James J., Georgeson, Gary Ernest, Nelson, Karl Edward, Lea, Scott Wesley
• Primary Examiner(s): MCCALL, ERIC SCOTT
• Application Number:
  US13/160,238
• Publication Number:
  US 20120320372A1
• Time in Patent Office: 1,057 Days
• Field of Search: 731/04, 731/05, 731/120.1, 731/180.3
• US Class Current: 73/104
• CPC Class Codes: B64F 5/60 Testing or inspecting aircraft components or systems
• CPC Class Codes: G01M 17/00 Testing of vehicles testing fluid tightness G01M3/00; testing elastic properties of bodies or chassis, e.g. torsion-testing, G01M5/00; testing alignment of vehicle headlight devices G01M11/06; testing of engines G01M15/00
• CPC Class Codes: G01N 21/00 Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light G01N3/00 - G01N19/00 take precedence
• CPC Class Codes: G01N 21/9515 Objects of complex shape, e.g. examined with use of a surface follower device measuring contours and curvatures G01B11/24
• CPC Class Codes: G01N 2291/2694 Wings or other aircraft parts
• CPC Class Codes: G01N 25/72 Investigating presence of flaws
• CPC Class Codes: G01N 27/00 Investigating or analysing materials by the use of electric, electrochemical, or magnetic means G01N3/00 – G01N25/00 take precedence; measurement or testing of electric or magnetic variables or of electric or magnetic properties of materials G01R
• CPC Class Codes: G01N 27/90 using eddy currents
• CPC Class Codes: G01N 29/00 Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object G01N3/00, G01N5/00, G01N7/00, G01N9/00, G01N11/00, G01N13/00, G01N15/00, G01N17/00, G01N19/00, G01N21/00, G01N22/00, G01N23/00, G01N24/00, G01N25/00, G01N27/00 take precedence
• CPC Class Codes: G01N 29/043 in the interior, e.g. by shear waves
• CPC Class Codes: G01N 29/4481 Neural networks
• CPC Class Codes: G01N 35/00584 Control arrangements for automatic analysers

Abstract

An apparatus comprises an inspection vehicle, a sensor system, a positioning system, a controller, and a support system. The inspection vehicle is configured to move on a surface of an object. The sensor system is associated with the inspection vehicle and is configured to generate information about the object when the inspection vehicle is on the surface of the object. The positioning system is configured to determine a location of the inspection vehicle on the object. The controller is configured to control movement of the inspection vehicle using the positioning system and control operation of the sensor system. The support system is connected to the inspection vehicle and is configured to support the inspection vehicle in response to an undesired release of the inspection vehicle from the surface of the object.

Claims

1. An apparatus comprising:

an inspection vehicle including a movement system, the inspection vehicle being configured to move on a surface of an object;

a sensor system associated with the inspection vehicle and configured to generate information about the object when the inspection vehicle is on the surface of the object;

a positioning system including a global positioning system and receiver configured to generate at least one of coordinate information and orientation information about a location of the inspection vehicle on the object;

a controller configured to control movement of the inspection vehicle using the positioning system and control operation of the sensor system; and

a support system connected to the inspection vehicle and configured to support the inspection vehicle in response to an undesired release of the inspection vehicle from the surface of the object, wherein the support system comprises an elongate member, a line system connected to the elongate member and to the inspection vehicle, a reel configured to hold a line in the line system and supply a level of tension to the line, and a brake unit configured to reduce rotation of the reel when tension is present in the line.

2. The apparatus of claim 1, wherein the inspection vehicle, the sensor system, the positioning system, the controller, and the support system are part of a non-destructive evaluation system.

3. The apparatus of claim 1, wherein the sensor system comprises at least one of an ultrasonic sensor system, an imaging system, an eddy current sensor system, a laser shearography system, a thermography system, a magnetic and optical imaging system, a magnetic and resistive sensor system, and an optical system.

4. The apparatus of claim 1, wherein the line system comprises at least one of a tether, a power line, a fluid transport line, and a data line.

5. The apparatus of claim 1, wherein the positioning system comprises at least one of a camera system, a camera tracking system, a laser range meter, a global positioning system receiver, a motion capture positioning system, a laser tracking system, an inertial navigation positioning system, and a radio frequency identification receiver system.

6. The apparatus of claim 1, wherein the movement system comprises at least one of wheels, continuous tracks, and legs.

7. The apparatus of claim 1 further comprising:

a marker system configured to provide information to the positioning system for use in determining the location of the inspection vehicle.

8. The apparatus of claim 7, wherein the marker system comprises:

a number of optical targets connected to the inspection vehicle.

9. An apparatus comprising:

an inspection vehicle including a movement system, the inspection vehicle being configured to move on a surface of an object;

a sensor system associated with the inspection vehicle and configured to generate information about the object when the inspection vehicle is on the surface of the object;

a positioning system including a global positioning system and receiver configured to generate at least one of coordinate information and orientation information about a location of the inspection vehicle on the object;

a controller configured to control a movement of the inspection vehicle using the positioning system and control operation of the sensor system; and

a support system connected to the inspection vehicle and configured to support the inspection vehicle in response to an undesired release of the inspection vehicle from the surface of the object, wherein the support system comprises an elongate member, a line system connected to the elongate member and to the inspection vehicle, and a line controller configured to control a set of lines connected to the line controller to perform at least one of supporting the inspection vehicle in response to the undesired release of the inspection vehicle from the surface of the object, slowing the movement of the inspection vehicle, halting the movement of the inspection vehicle, supporting the inspection vehicle as the inspection vehicle moves on the surface of the object, and lifting the inspection vehicle.

10. The apparatus of claim 9, wherein the line controller is configured to control the set of lines in response to a number of commands received from the controller.

11. A non-destructive evaluation inspection system for an aircraft comprising:

an inspection vehicle including a movement system, the inspection vehicle being configured to move on a surface of the aircraft;

a sensor system connected to the inspection vehicle and configured to obtain information about the aircraft when the inspection vehicle is on the surface of the aircraft;

a support system comprising a reel, an elongate member, and a number of lines connected to the elongate member and the inspection vehicle, wherein the support system is configured to support the inspection vehicle in response to an undesired release of the inspection vehicle from the surface of the aircraft;

a positioning system including a global positioning system and receiver configured to generate at least one of coordinate information and orientation information about a location of the inspection vehicle on the aircraft; and

a controller configured to control movement of the inspection vehicle based on the location of the inspection vehicle.

12. A method for inspecting an object, the method comprising:

determining at least one of coordinate information and orientation information about a location of an inspection vehicle on a surface of the object using a positioning system including a global positioning system and receiver;

generating information about the object using a sensor system connected to the inspection vehicle while the inspection vehicle is on the surface of the object;

controlling movement of the inspection vehicle, wherein the inspection vehicle includes a movement system, the inspection vehicle being configured to move on the surface of an aircraft using a controller;

supporting the inspection vehicle in response to an undesired release of the inspection vehicle from the surface of the object using a support system connected to the inspection vehicle; and

storing the information generated about the object in a historical test database, wherein storing the information generated about the object in the historical test database comprises;

determining coordinates for the information using a coordinate system for a model of the object;

identifying a date of when the information was generated; and

storing the information generated about the object in the historical test database with the coordinates and the date.

13. The method of claim 12, wherein supporting the inspection vehicle in response to the undesired release of the inspection vehicle from the surface of the object comprises:

limiting at least one of a type and range of motion of the inspection vehicle to reduce a possibility of the undesired release of the inspection vehicle causing undesired effects to at least one of the inspection vehicle and the object.

14. The method of claim 12 further comprising:

determining whether an inconsistency is present at a location on the object using the information generated by the sensor system at the location; and

responsive to a determination that the inconsistency is present at the location on the object, tagging the location on the object using a tagging system.

15. The method of claim 12, wherein the sensor system comprises at least one of an ultrasonic testing system, an imaging system, an eddy current sensor system, a laser shearography system, a thermography system, a magnetic and optical imaging system, a magnetic and resistive sensor system, and an optical system.

16. The method of claim 12, wherein the step of determining the location of the inspection vehicle on the surface of the object using the positioning system comprises:

generating location information using the positioning system and information received from a marker system; and

determining the location of the inspection vehicle on the surface of the object with respect to a coordinate system for the object using the location information and a model for the object.