Protocol-based inspection system

• US 9,228,958 B2
• Filed: 03/09/2012
• Issued: 01/05/2016
• 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: Shirkhodaie, Amir, Moriarty, Robert, Ma, Kong
• Primary Examiner(s): Perungavoor, Sath V
• Assistant Examiner(s): WILLIAMS, JEFFERY A
• Application Number:
  US13/416,610
• Publication Number:
  US 20120229619A1
• Time in Patent Office: 1,397 Days
• Field of Search: 348/92
• US Class Current: 1/1
• CPC Class Codes: G01N 21/8901 Optical details; Scanning details per se G02B
• CPC Class Codes: G06T 2200/24 involving graphical user interfaces [GUIs]
• CPC Class Codes: G06T 2207/20081 Training; Learning
• CPC Class Codes: G06T 7/0004 Industrial image inspection

Abstract

One form of the present application provides a system comprising an illumination source capable of providing an electromagnetic illumination of an engine component, an imaging system structured to capture illumination of the engine component, a component manipulation system structured to position the engine component in a variety of orientations relative to one of the illumination source and the imaging system, a computer based user interface capable of identifying an inspection protocol defined to acquire an image of the engine component at the variety of positions using the illumination system, the imaging system and the component manipulation system, and a processor configured to process the inspection protocol for the purposes of analyzing the acquired image in response to the inspection protocol.

Claims

1. A system comprising:

an illumination source configured to illuminate an engine component using visible light;

an imaging system configured to capture a surface image of the engine component based on the illumination of the engine component using the visible light;

a component manipulation system configured to position the engine component in a variety of orientations relative to at least one of the illumination source and the imaging system; and

a computer based user interface comprising an inspection processor, wherein the computer based user interface is configured to allow a user to select an automated inspection protocol, and wherein the inspection processor is configured to perform the automated inspection protocol to;

acquire surface images of the engine component at the variety of positions using the illumination system, the imaging system, and the component manipulation system,

perform a fuzzy logic analysis on at least one of the surface images of the engine component to detect a defect on a surface of the engine component, and

report the defect to the computer based user interface.

2. The system of claim 1, wherein the computer based user interface is further configured to allow the user to select a plurality of inspection parameters, wherein the plurality of inspection parameters includes at least one of a contrast strength, a border strength, an edge strength, or a noise strength.

3. The system of claim 2, wherein the plurality of inspection parameters includes a masking feature applied to a surface image of the engine component.

4. The system of claim 1, wherein the computer based user interface is configured to allow the user to select a plurality of automated inspection protocols.

5. The system of claim 2, wherein the computer based user interface is further configured to allow the user to develop an inspection protocol based on at least one of a contrast strength, a border strength, an edge strength, or a noise strength of a surface image of the engine component, wherein the inspection protocol can be saved and performed by the inspection processor.

6. The system of claim 1, further comprising an image library comprising a plurality of stored images, wherein the inspection processor is configured to access the image library and compare at least one of the surface images of the engine component to the plurality of stored images as a result of the automated inspection protocol.

7. The system of claim 1, wherein the inspection processor is configured to operate the illumination source, the imaging system, and the component manipulation system while performing the automated inspection protocol.

14. The system of claim 4, wherein the plurality of automated inspection protocols includes at least one of background removal, mask application, or edge detection.

8. A method comprising:

developing an automated inspection protocol configured to acquire and analyze at least one surface image of an engine component, wherein developing the automated inspection protocol comprises

setting a plurality of inspection parameters for the automated inspection protocol, wherein the plurality of inspection parameters includes at least one of a contrast strength, a border strength, an edge strength, or a noise strength;

initiating the automated inspection protocol using a computer based user interface connected to an inspection processor; and

performing the automated inspection protocol using the inspection processor, wherein in preforming the automated inspection protocol comprises;

acquiring surface images of the engine component at a variety of positions using the inspection processor, wherein the inspection processor controls an illumination source, an imaging system, and an component manipulation system to acquire the surface images of the engine component, wherein the illumination source is configured to illuminate the engine component using visible light, wherein the imaging system is configured to capture the surface images of the engine component based on the illumination of the engine component using the visible light, and wherein the component manipulation system configured to position the engine component in the variety of orientations relative to at least one of the illumination source and the imaging system;

performing a fuzzy logic analysis on at least one of the surface images of the engine component to detect a defect on a surface of the engine component; and

reporting the defect to the computer based user interface.

9. The method of claim 8, wherein the developing the automated inspection protocol comprises selecting the automated inspection protocol from a predefined list of automated inspection protocols.

10. The method of claim 8, wherein setting a plurality of inspection parameters for the automated inspection protocol comprises applying a mask feature to a surface image of the engine component.

11. The method of claim 8, wherein reporting the defect to the computer based user interface comprises generating a report that describes the results of the automated inspection protocol.

12. The method of claim 11, wherein generating the report that describes the results of the automated inspection protocol further comprises determining at least one of a pass grade, a reject grade, and a repair grade for the engine component based on the defect.

13. The method of claim 8, wherein performing the automated inspection protocol using the inspection processor further comprises accessing an image library comprising a plurality of stored images and comparing at least one of the surface images of the engine component to the plurality of stored images as a result of the automated inspection protocol.