Mobilized sensor network for structural health monitoring

• US 8,930,042 B2
• Filed: 07/15/2011
• Issued: 01/06/2015
• Est. Priority Date: 07/15/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Jang, Jung Soon, Ihn, Jeong-Beom
• Primary Examiner(s): Cheung, Calvin
• Assistant Examiner(s): Ramesh, Krishnan
• Application Number:
  US13/183,580
• Publication Number:
  US 20130018525A1
• Time in Patent Office: 1,271 Days
• Field of Search: None
• US Class Current: 701/2
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/106 one or more transducer arrays
• CPC Class Codes: G01N 2291/2694 Wings or other aircraft parts
• CPC Class Codes: G01N 29/225 Supports, positioning or alignment in moving situation
• CPC Class Codes: G01N 29/2475 Embedded probes, i.e. probes incorporated in objects to be inspected
• CPC Class Codes: G01N 29/2481 Wireless probes, e.g. with transponders or radio links
• CPC Class Codes: G01N 29/2493 Wheel shaped probes
• CPC Class Codes: G01N 29/265 by moving the sensor relative to a stationary material
• CPC Class Codes: G01N 29/4427 with stored values, e.g. threshold values
• CPC Class Codes: G01N 29/4472 Mathematical theories or simulation

Abstract

A method and apparatus for inspecting an object is provided. Movement of inspection vehicles relative to a surface of the object is controlled using a controller. Generation of data about the object by sensor systems configured to generate the data when the sensor systems are in a configuration with respect to a location on the object for inspection and receiving power from the inspection vehicles is controlled using the controller. The data generated by the sensor systems is stored.

Claims

1. An apparatus comprising:

inspection vehicles, including at least a first inspection vehicle and a second inspection vehicle, the inspection vehicles configured to be placed on a surface of an object to move relative to the surface of the object and transmit data generated about the object;

wherein the inspection vehicles move with respect to one or more sensor systems, including a first sensor system attached to the object at a first location and a second sensor system attached to the object at a second location, the first inspection vehicle configured to provide power to the first sensor system and the second inspection vehicle configured to provide power to the second sensor system, the sensor systems configured to generate the data about the object when the sensor systems are in a configuration with respect to a location on the object for inspection and when receiving power from the inspection vehicles, the first sensor system configured to generate a signal that passes through the object and the second sensor system configured to receive the signal;

a controller configured to control movement of the inspection vehicles, control operation of the sensor systems to generate the data, and receive the data transmitted by the inspection vehicles, the inspection vehicle configured to receive data generated about the object, and the inspection vehicle further configured to transmit received data generated about the object to the controller, and the controller configured to determine whether an undesirable inconsistency is present for the object using data generated about the object and historical data, the controller also configured to control when the first inspection vehicle provides power to the first sensor system and the second inspection vehicle provides power to the second sensor system; and

a robotic system configured to pick up, hold, and release the inspection vehicles via one or more robotic arms.

2. The apparatus of claim 1, wherein the sensor systems are ultrasonic sensor systems in which a first portion of the ultrasonic sensor systems is configured to transmit a number of signals into the object and a second portion of the ultrasonic sensor systems is configured to receive a number of response signals generated in response to the number of signals transmitted into the object, the sensor systems configured to generate data for a surface of the object and for a structure under the surface of the object, and wherein at least one of the first inspection vehicle and the second inspection vehicle provide power to the sensor systems via wireless transmission.

3. The apparatus of claim 1, wherein the sensor systems and the inspection vehicles form a mobile sensor network when the sensor systems and the inspection vehicles are in the configuration with respect to the location on the object for the inspection, the first inspection vehicle and the second inspection vehicle each contacting a surface of the object and moving over the surface of the object.

4. The apparatus of claim 1, wherein the controller is configured to control the movement of the inspection vehicles using a model of the object.

5. The apparatus of claim 1, wherein the controller is configured to store the data in a database in association with coordinates identifying the location for which the data was generated by the sensor systems.

6. The apparatus of claim 5, wherein the database includes historical data for a number of inspections for the location performed a number of times prior to generation of the data.

7. The apparatus of claim 1, wherein the inspection vehicles transmit the data over a number of wireless communications links to the controller.

8. The apparatus of claim 1, wherein the sensor systems are configured to transmit the data to the inspection vehicles.

9. The apparatus of claim 1 further comprising:

a movement system configured to move the inspection vehicles relative to the object, the movement system comprising a number of suction cups; and

a positioning system configured to identify a location of the inspection vehicles relative to the object.

10. The apparatus of claim 1, wherein the object is selected from one of a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, a space-based structure, an aircraft, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a manufacturing facility, and a building.

11. The apparatus of claim 1, wherein the controller is configured to store data generated about the object in association with coordinates for the object, and wherein the sensor systems are configured to generate data for a surface of the object and for a structure under the surface of the object.

12. The apparatus of claim 1, wherein the sensor systems are embedded within the object.

13. A health monitoring system comprising:

a movement system associated with a hangar;

inspection vehicles, including at least a first inspection vehicle and a second inspection vehicle, the inspection vehicles configured to be placed on a surface of an object to move relative to the surface of the object and transmit data generated about the object, wherein the first inspection vehicle and the second inspection vehicle are connected to the movement system such that the movement system places the first inspection vehicle and the second inspection vehicle onto a surface of an aircraft;

wherein the inspection vehicles move with respect to one or more sensor systems, including a first sensor system associated with the first inspection vehicle and a second sensor system associated with the second inspection vehicle, the sensor systems associated with the inspection vehicles, wherein the sensor systems are configured to generate the data about the object, the first sensor system configured to generate a signal that passes through the object and the second sensor system configured to receive the signal; and

a controller configured to control movement of the inspection vehicles into a configuration with respect to a location for inspection, control operation of the sensor systems to generate the data about the object for the location, and receive the data transmitted by the inspection vehicles, the sensor system configured to transmit data generated about the object to the inspection vehicles, and the inspection vehicles configured to transmit received data generated about the object to the controller, the controller storing data generated about the object in association with coordinates for the object, the controller configured to determine whether an undesirable inconsistency is present for the object using data generated about the object and historical data about the object pursuant to a policy;

wherein the inspection vehicles transmit the data over a number of wireless communications links to the controller; and

a robotic system configured to pick up, hold, and release the inspection vehicles via one or more robotic arms.

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

controlling, using a controller, movement of inspection vehicles placed on a surface of the object relative to the surface of the object, the object having a first sensor system and a second sensor system, the inspection vehicles including at least a first inspection vehicle and a second inspection vehicle, the controller configured to move the first inspection vehicle so as to associate with the first sensor system and to move the second inspection vehicle so as to associate with the second sensor system, wherein the inspection vehicles are moved with respect to the sensor systems;

controlling when the first inspection vehicle provides power to the first sensor system and when the second inspection vehicle provides power to the second sensor system;

controlling, using the controller, generation of data about the object by sensor systems, including a first sensor system associated with the first inspection vehicle and a second sensor system associated with the second inspection vehicle, the sensor systems configured to generate the data when the sensor systems are in a configuration with respect to a location on the object for inspection and receiving power from the inspection vehicles, the first sensor system configured to generate a signal that passes through the object and the second sensor system configured to receive the signal;

transmitting, by the sensor system, data generated about the object to the inspection vehicles;

transmitting, by the inspection vehicles, data generated about the object to the controller;

storing the data generated by the sensor systems;

determining whether an undesired inconsistency is present at the location on the object using the data generated about the object; and

picking up, holding, and releasing the inspection vehicles via one or more robotic arms of a robotic system;

wherein the inspection vehicles transmit the data over a number of wireless communications links to the controller.

15. The method of claim 14, wherein the step of determining whether the undesired inconsistency is present at the location on the object using the data comprises:

determining whether an inconsistency identified using the data and historical data generated for the object at times prior to the generation of the data is the undesired inconsistency, the determining including using a policy.

16. The method of claim 14, wherein the step of controlling the generation of the data about the object by the sensor systems configured to generate the data when the sensor systems are in the configuration with respect to the location on the object for the inspection and receiving the power from the inspection vehicles comprises:

causing a first portion of the sensor systems to transmit a number of signals into the object; and

causing a second portion of the sensor systems to detect a number of response signals generated in response to the number of signals transmitted into the object, wherein the number of response signals forms the data.

17. The method of claim 14, wherein the sensor systems are associated with the object at locations on the object and wherein the step of controlling, using the controller, the movement of the inspection vehicles relative to the surface of the object comprises:

controlling the inspection vehicles to move to the locations on the object, the locations associated with coordinates for the object, wherein the inspection vehicles are configured to send the power to the sensor systems when the inspection vehicles are at the locations on the object.

18. The method of claim 14, wherein the sensor systems are associated with the inspection vehicles and wherein the step of controlling, using the controller, the movement of the inspection vehicles relative to the surface of the object comprises:

identifying the location for the inspection using a model of the object; and

controlling the inspection vehicles to move into the configuration with respect to the location for the inspection.

19. The method of claim 14, wherein the step of storing the data generated by the sensor systems comprises:

storing the data in a database in association with coordinates identifying the location for which the data was generated by the sensor systems.

20. An inspection system to inspect an aircraft in a hangar, the inspection system comprising:

a movement system associated with the hangar, the movement system comprising a robotic system;

the robotic system configured to pick up, hold, and release one or more inspection vehicles via one or more robotic arms;

the robotic arms configured to place the inspection vehicles onto a surface of the aircraft;

the inspection vehicles, once placed onto the aircraft, configured to move on the surface to different locations on the aircraft to perform non-destructive inspection;

one or more sensor systems embedded within the aircraft, the sensor systems configured to receive power from the inspection vehicles when power sources of the inspection vehicles come into contact with the sensor systems;

a controller configured to receive, from the inspection vehicles, data generated during the non-destructive inspection using wireless communication and configured to send locations for inspection to the robotic system; and

a track and crane system wherein a crane of the track and crane system is configured to hold and move the robotic system and the crane is configured to move along a track of the track and crane system with respect to the aircraft.