Internal stringer inspection system for integrated structures

An inspection apparatus comprising:

• a first plug configured for fitting within a hollow composite part and forming a leak-proof seal against an interior surface of the hollow composite part;
• a second plug configured for fitting within the hollow composite part, forming a leak-proof seal against the interior surface of the hollow composite part, and spaced a fixed distance apart from the first plug;
• a trolley configured to be positioned between the first plug and the second plug, moveable relative to the first and second plugs in a direction toward and away from the first and second plugs, and configured to support at least one inspection probe for testing an interior of a composite part;
• and
• an elongated actuation element extending through the first plug, the second plug, and the trolley and fixed relative to the trolley, wherein the elongated actuation element is slidable through the first and second plugs, wherein the elongated actuation element is configured to pull or push the trolley within the composite part and between the first and second plugs.

A method for inspecting an interior surface of a hollow composite part having at least one opening through which an inspection apparatus can be inserted, the method comprising:

• inserting the inspection apparatus through the opening of the hollow composite part, wherein the inspection apparatus comprises:
• a first plug configured for forming a leak-proof seal against the interior surface of the hollow composite part;
• a second plug configured for forming a leak-proof seal against the interior surface of the hollow composite part and spaced a distance apart from the first plug;
• a trolley positioned between the first plug and the second plug, slidable back and forth between the first and second plugs;
• and
• at least one inspection probe supported by the trolley and configured for testing the interior surface of the composite part;
• pushing or pulling an elongated actuation element attached to the inspection apparatus, moving the inspection apparatus to a desired area to be inspected within the composite part ;
• filling a space between first and second plugs with a liquid, such that liquid is trapped between the first and second plugs and surrounds the trolley and the at least one inspection probe;
• and
• inspecting the interior surface of the hollow composite part with the at least one inspection probe.

An inspection apparatus comprising:

• a first plug configured for fitting within a hollow composite part and forming a leak-proof seal against an interior surface of the hollow composite part;
• a second plug configured for fitting within the hollow composite part, forming a leak-proof seal against the interior surface of the hollow composite part, and spaced a distance apart from the first plug;
• a trolley configured to be positioned between the first plug and the second plug, independently moveable relative to the first and second plugs in a direction toward and away from the first and second plugs, and configured to support at least one inspection probe for testing an interior of a composite part;
• and
• one or more tubes extending through at least one of the first and second plugs and configured to supply a liquid to the space between the first and second plugs within the composite part.

An inspection apparatus comprising:

• a first plug configured for fitting within a hollow composite part and forming a leak-proof seal against an interior surface of the hollow composite part;
• a second plug configured for fitting within the hollow composite part, forming a leak-proof seal against the interior surface of the hollow composite part, and spaced a distance apart from the first plug;
• at least one inspection probe;
• a trolley configured to be positioned between the first plug and the second plug, independently moveable relative to the first and second plugs in a direction toward and away from the first and second plugs, and configured to support the at least one inspection probe for testing an interior of a composite part;
• and
• at least one of a power cable and a data cable extending from the inspection probe through at least one of the plugs and configured to provide at least one of power to the inspection probe and data from the inspection probe to a non-destructive inspection (NDI) system or computer to be analyzed thereby.