# US 2019/0173574 A1 · Automated Scanning Systems for Non-Destructive Inspection of Curved Cylinder-Like Workpieces

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- Number: US 2019/0173574 A1
- Document ID: US20190173574A1
- Status: Published application
- Kind: A1
- Application number: 16/268,159
- Filed: 2019-02-05
- Published: 2019-06-06
- Earliest claimed: 2014-05-16
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: Gary E. Georgeson; Barry A. Fetzer; James J. Troy; Scott W. Lea
- Web page: https://patentgrep.com/patent/US20190173574A1

## CPC

- H04B 7/2656: {for structure of frame, burst}
- B64F 5/60: Testing or inspecting aircraft components or systems
- G01N 29/0654: {Imaging}
- G01N 29/265: by moving the sensor relative to a stationary material
- G01N 29/44: Processing the detected response signal {, e.g. electronic circuits specially adapted therefor (digital signal processing per se G06F17/00)}
- H04L 41/0695: the faulty arrangement being the maintenance, administration or management system
- H04L 43/16: Threshold monitoring
- H04W 40/244: {using a network of reference devices, e.g. beaconing}
- H04W 72/0446: Resources in time domain, e.g. slots or frames
- G01N 2291/0231: Composite or layered materials
- G01N 2291/0258: Structural degradation, e.g. fatigue of composites, ageing of oils
- G01N 2291/0289: Internal structure, e.g. defects, grain size, texture
- G01N 2291/2634: cylindrical from outside
- G01N 2291/2694: Wings or other aircraft parts
- H04W 48/16: Discovering, processing access restriction or access information
- H04W 72/02: Selection of wireless resources by user or terminal
- H04W 72/23: in the downlink direction of a wireless link, i.e. towards a terminal
- Y02D 30/70: in wireless communication networks
- H04B: TRANSMISSION
- B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
- G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q)
- H04L: TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION (arrangements common to telegraphic and telephonic communication H04M)
- H04W: WIRELESS COMMUNICATION NETWORKS (broadcast communication H04H; communication systems using wireless links for non-selective communication, e.g. wireless extensions H04M1/72)
- Y02D: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN INFORMATION AND COMMUNICATION TECHNOLOGIES [ICT], I.E. INFORMATION AND COMMUNICATION TECHNOLOGIES AIMING AT THE REDUCTION OF THEIR OWN ENERGY USE

## Abstract

Systems and methods for high-speed non-destructive inspection of a half- or full-barrel-shaped workpiece, such as a barrel-shaped section of an aircraft fuselage. Such workpieces can be scanned externally using a mobile (e.g., translating) arch gantry system comprising a translatable arch frame disposed outside the fuselage section, a carriage that can travel along a curved track carried by the arch frame, a radially inward-extending telescopic arm having a proximal end fixedly coupled to the carriage, and an NDI sensor unit coupled to a distal end of the telescoping arm. The stiffeners of the fuselage sections can be scanned using a mobile scanner platform disposed inside the fuselage section, which platform comprises a radially outward-extending telescopic arm rotatably coupled to a mobile (e.g., holonomic or linear motion) platform and an NDI sensor unit coupled to a distal end of the telescoping arm. The scan data is matched with position data acquired using any one of a plurality of tracking systems to enable the display of NDI features/flaws on a three-dimensional representation of the workpiece.

## Claims

### Claim 1

A method for scanning a stringer in an inside of a workpiece having a curved section that extends longitudinally and circumferentially, the method comprising:
placing a workpiece having a curved section that extends longitudinally and circumferentially so that the workpiece is stationary relative to a floor;
moving a mobile platform to a starting position on the floor and underneath the workpiece;
pivoting an the extendible arm that is pivotably coupled to the mobile platform to a target tilt angle dependent on an angular position of a stringer to be inspected;
at the target tilt angle, extending an inner sleeve of the extendible arm until a first NDI sensor unit coupled to a distal end of the inner sleeve engages a first portion of the stringer to be inspected;
activating the first NDI sensor unit to inspect the first portion of the stringer;
processing signals output from the first NDI sensor unit to derive first scan data characterizing a structural state of the first portion of the stringer; and
acquiring first location data representing a first location of the first NDI sensor unit when the first NDI sensor unit engages the first portion of the stringer.

### Claim 2 (depends on 1)

The method as recited in claim 1, further comprising:
moving the mobile platform in a manner that causes the first NDI sensor unit to travel along the stringer until the first NDI sensor unit engages a second portion of the stringer;
activating the first NDI sensor unit to inspect the second portion of the stringer;
processing signals output from the first NDI sensor unit to derive second scan data characterizing a structural state of the second portion of the stringer; and
acquiring second location data representing a second location of the first NDI sensor unit when the first NDI sensor unit engages the second portion of the stringer.

### Claim 3 (depends on 2)

The method as recited in claim 2, further comprising:
moving a curved track along first and second linear tracks to a first longitudinal position, the curved track in the first longitudinal position being disposed radially outward from the curved section of the workpiece;
adjusting a position of a second NDI sensor unit relative to a carriage to which the second NDI sensor unit is adjustably coupled by an extendible arm, the carriage in turn being movable along the curved track;
moving the carriage along the curved track while the curved track is stationary at the first longitudinal position;
activating the second NDI sensor unit to inspect a strip-shaped area of the curved section of the workpiece as the carriage is moved along the curved track; and
processing signals output from the second NDI sensor unit to derive a strip of scan data characterizing a structural state of the strip-shaped area of the curved section of the workpiece.

### Claim 4 (depends on 3)

The method as recited in claim 3, wherein the second NDI sensor unit is activated while the first NDI sensor unit path is moving along the stringer.

### Claim 5 (depends on 1)

The method as recited in claim 1, wherein the path followed by the mobile platform during moving is parallel to a projection of an axis of the stringer onto the ground.

### Claim 6 (depends on 1)

The method as recited in claim 1, further comprising adjusting a radial position of the first NDI sensor unit as the first NDI sensor unit travels along the stringer.

### Claim 7 (depends on 1)

The method as recited in claim 1, wherein the mobile platform is a holonomic motion vehicle.

### Claim 8 (depends on 1)

The method as recited in claim 1, wherein the mobile platform moves on tracks.

### Claim 9 (depends on 1)

The method as recited in claim 1, wherein the workpiece is a fuselage section.

### Claim 10 (depends on 9)

The method as recited in claim 9, wherein the stringer is made of composite material.

### Claim 11 (depends on 1)

The method as recited in claim 1, wherein the first scan data is acquired from at least a central cap portion of the stringer and an angled side of the stringer.

### Claim 12

A system for scanning a stiffened curved cylinder-like workpiece, the system comprising:
first means for circumferentially scanning an outer mold line of the workpiece; and
second means for scanning a longitudinal stiffener attached to an inner mold line of the workpiece,
wherein said first and second means work in concert and concurrently.

### Claim 13 (depends on 12)

The system as recited in claim 12, further comprising an arch frame disposed outside the workpiece and comprising a curved track, said arch frame being translatable along a longitudinal axis of the workpiece, wherein said first means comprise:
a carriage that can travel along said curved track;
a radially extending telescopic arm having a proximal end fixedly coupled to said carriage; and
an NDI sensor unit coupled to a distal end of the telescoping arm.

### Claim 14 (depends on 12)

The system as recited in claim 12, further comprising a mobile scanner platform disposed inside the workpiece, wherein said second means comprise:
a radially extending telescopic arm rotatably coupled to said mobile scanner platform; and
an NDI sensor unit coupled to a distal end of said telescoping arm.

### Claim 15

A system for supporting a mobile platform inside a curved cylinder-like workpiece, comprising:
a first extendible support comprising a first pedestal, a first fixed outer sleeve projecting vertically upward from said first pedestal, a first inner sleeve that is translatable inside said first outer sleeve, and a first bearing mounted to a distal end of said first inner sleeve;
a second extendible support comprising a second pedestal, a second fixed outer sleeve projecting vertically upward from said second pedestal, a second inner sleeve that is translatable inside said second outer sleeve, and a second bearing mounted to a distal end of said second inner sleeve;
a bridge beam spanning a space between said first and second extendible supports, said bridge beam having a first end rotatably coupled to said distal end of said first inner sleeve by said first bearing and a second end rotatably coupled to said distal end of said first inner sleeve by said first bearing;
first and second cross beams attached to and projecting laterally from said bridge beam;
first and second linear rails which are attached to said first and second cross beams in a mutually parallel relationship; and
a mobile platform comprising a frame, a first set of rollers arranged on opposite sides of said first linear rail and a second set of rollers arranged on opposite sides of said second rail.

### Claim 16 (depends on 15)

The system as recited in claim 15, further comprising:
a first actuator which, when activated, exerts a force urging said mobile platform to move;
an extendible arm comprising a first member pivotably mounted to said frame of said mobile platform and a second member which is translatable relative to said first member;
a second actuator which, when activated, exerts a force urging said extendible arm to pivot relative to said frame;
an NDI sensor unit coupled to a distal end of said second member; and
an encoder device capable of outputting signals representing incremental movements of said NDI sensor unit along a substructure.

### Claim 17 (depends on 16)

The system as recited in claim 16, further comprising a third actuator which, when activated, exerts a force urging said second member to translate relative to said first member.

### Claim 18 (depends on 16)

The system as recited in claim 16, further comprising a compliant support structure between said NDI sensor unit and said distal end of said second member.

### Claim 19 (depends on 16)

The system as recited in claim 16, wherein said NDI sensor unit is an ultrasonic transducer array.

### Claim 20 (depends on 16)

The system as recited in claim 16, further comprising a pivot joint by which said extendible arm pivotably mounted to said frame of said mobile platform, wherein said first and second extendible supports and said bride beam are configured such that said bridge beam, said first and second cross beams, and said first and second linear tracks are translatable and rotatable between a first location in which said mobile platform is upright and said pivot joint has an elevation and a second location in which said mobile platform is upside down and said pivot joint has the same elevation.