Method and system for inspecting and measuring installed one-sided fasteners in a structure

A method for inspecting and measuring one or more installed one-sided fasteners in an aircraft structure, the method comprising the steps of:

• positioning an X-ray imaging system directed at a first side of the aircraft structure at a location of the one or more installed one-sided fasteners installed through one or more openings in the aircraft structure, the one or more installed one-sided fasteners each having a fastener body protruding from a second side of the aircraft structure;
• emitting X-rays at the first side of the aircraft structure at the location of the one or more installed one-sided fasteners;
• detecting backscatter from the one or more installed one-sided fasteners;
• generating image data from the X-ray imaging system, in real time, in response to detecting the backscatter, the image data comprising one or more images of the fastener body of the one or more installed one-sided fasteners;
• measuring and analyzing the image data, with an image processing system, to obtain one or more measurements of one or more dimensions of the one or more installed one-sided fasteners, wherein the one or more measurements comprise one or more of:
• a diameter of a fastener bulb of the one or more installed one-sided fasteners, wherein the fastener bulb is formed against an interior side of the aircraft structure when the fastener is installed in the aircraft structure;
• a length of a pin protrusion of the one or more installed one-sided fasteners;
• and
• a grip length of the one or more installed one-sided fasteners;
• and
• using the image data to inspect the one or more installed one-sided fasteners, and to detect any out-of-specification parameters of the one or more measurements of the one or more dimensions of the one or more installed one-sided fasteners.

A system for inspecting and measuring one or more installed one-sided fasteners in a structure, the system comprising:

• the structure having a first side and a second side;
• the one or more installed one-sided fasteners installed through one or more openings in the structure, the one or more installed one-sided fasteners each having a fastener body protruding from the second side of the structure;
• an X-ray imaging system configured to emit X-rays at the first side of the structure at a location of the one or more installed one-sided fasteners, and configured to detect backscatter from the one or more installed one-sided fasteners;
• image data generated from the X-ray imaging system in response to detecting the backscatter, the image data comprising one or more images of the fastener body of the one or more installed one-sided fasteners;
• and
• an image processing system to measure and analyze the image data, to obtain one or more measurements of one or more dimensions of the one or more installed one-sided fasteners, to inspect the one or more installed one-sided fasteners, and to detect any out-of-specification parameters of the one or more measurements of the one or more dimensions of the one or more installed one-sided fasteners, the one or more measurements comprising one or more of:
• a diameter of a fastener bulb of the one or more installed one-sided fasteners, wherein the fastener bulb is formed against an interior side of the structure when the fastener is installed in the structure;
• a length of a pin protrusion of the one or more installed one-sided fasteners;
• and
• a grip length of the one or more installed one-sided fasteners.