Intelligent airfoil component surface inspection

• US 9,020,878 B2
• Filed: 03/09/2012
• Issued: 04/28/2015
• Est. Priority Date: 03/09/2011
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Kush, Matthew T., Ma, Kong, Moriarty, Robert
• Primary Examiner(s): Vincent, David
• Assistant Examiner(s): OLUDE AFOLABI, OLATOYOSI
• Application Number:
  US13/416,409
• Publication Number:
  US 20120233111A1
• Time in Patent Office: 1,145 Days
• Field of Search: 706/12
• US Class Current: 706/50
• CPC Class Codes: G01N 21/91 using penetration of dyes, e.g. fluorescent ink

Abstract

An apparatus includes a positioning system; a surface indicator system to collect an indication data set from a surface of a component utilizing a fluorescent penetration process; an indication data processing system to create an output data set in response to the indication data set utilizing a fuzzy logic algorithm; and a microprocessor to provide at least one surface variance in response to the indication data set and the output data set. A method including conducting a surface indication technique for a component; utilizing a positioning algorithm to manipulate positioning equipment in response to the component; directing an indication source to a surface of the component; collecting an indication data set in response to directing the indication source; applying a fuzzy logic analysis in response to the indication data set to provide an output data set; and providing at least one surface variance in response to the output data set.

Claims

1. An apparatus comprising:

a positioning system;

a surface indicator system structured to collect an indication data set from a surface of a component;

a surface indicator composition applied to the component and configured to emit an indication that can be sensed by the surface indication system;

an indication data processing system structured to create an output data set in response to the indication data set utilizing a fuzzy logic algorithm; and

a microprocessor structured to provide at least one surface variance in response to the indication data set and the output data set.

2. The apparatus of claim 1, wherein the positioning system further includes a manipulator structured to position the component in response to a positioning algorithm, and wherein the surface indicator composition can emit an electromagnetic signal.

3. The apparatus of claim 2, wherein the positioning algorithm further includes identifying the component with a component position database in response to the indication data set and a recognition source data set.

4. The apparatus of claim 1, wherein the surface indicator composition is a Fluorescent Penetrant Indicator (FPI).

5. The apparatus of claim 4, wherein the indication device further includes an indicator application system capable of applying the FPI to the surface of the component.

6. The apparatus of claim 1, wherein the at least one surface variance includes a variance selected from a group consisting of inhomogeneities, microstructural discontinuities, inclusions, micro and macro porosity and combinations thereof.

7. The apparatus of claim 6, wherein the at least one surface variance further includes a pass/fail signal.

8. The apparatus of claim 6, wherein the at least one surface variance further includes a variance report.

9. A method comprising:

applying a surface indicator material to a component;

utilizing a positioning algorithm to manipulate at least one piece of positioning equipment in response to the component;

directing an indication source to a surface of the component having the surface indicator material;

collecting an indication data set in response to directing the indication source to the surface of the component;

applying a fuzzy logic analysis in response to the indication data set, the fuzzy logic analysis capable of providing an output data set; and

providing at least one surface variance in response to the output data set.

10. The method of claim 9, wherein the surface indicator material is configured for use in a fluorescent penetration process.

11. The method of claim 9, wherein the fuzzy logic analysis includes an input collecting module, a processing module, a compiling module, and an output collecting module.

12. The method of claim 11, wherein the input collecting module further includes collecting the indication data set.

13. The method of claim 11, wherein the output collecting module further includes collecting the output data set.

14. The method of claim 9, further including performing a part recognition method with a component position database in response to at least one of the indication data set, a light source data set, and a recognition source data set.

15. The method of claim 9, wherein the at least one piece of positioning equipment further includes a robotic manipulator structured to position the component in response to the component and the positioning algorithm.

16. The method of claim 9, wherein the at least one surface variance includes a variance selected from a group consisting of inhomogeneities, microstructural discontinuities, inclusions, micro-porosity, and combinations thereof.

17. The method of claim 16, wherein the at least one surface variance further includes a pass/fail signal.

18. The method of claim 16, wherein the at least one surface variance further includes a variance report.

19. An apparatus comprising:

a positioning system having a manipulator device structured to position a component in response to a positioning algorithm;

an indication system structured to collect an indication data set utilizing a fluorescent penetration process;

an indication data processing system utilizing a fuzzy logic algorithm capable of;

applying the indication data set as a set of input variables;

assigning a degree of intensity to the set of input variables;

determining an output data set; and

converting the output data set to a set of solutions; and

a microprocessor structured to provide at least one surface variance in response to the set of solutions.

20. The apparatus of claim 19, wherein providing the at least one surface variance further includes characterization of at least one surface anomaly.