Automated aircraft inspection system

A method, apparatus, and system for inspecting a fuselage of an aircraft. A rail is positioned within an interior portion of the fuselage of the aircraft such that the rail extends through the interior portion of the fuselage. An inspection device is attached to the rail. The inspection device moves along the rail and the position of the rail enables the inspection device to inspect the interior portion. Video data is sent to a computer system over a wireless communications link between the inspection device and the computer system. The video data is displayed on a display system for the computer system. Inspection operations are performed in the interior portion of the fuselage with the inspection device attached to the rail when a group of commands to perform the inspection operations are received from the computer system over a wireless communications link between the inspection device and the computer system.

BACKGROUND INFORMATION

The present disclosure relates generally to aircraft and in particular, to a method, apparatus, and system for inspecting the interior of a fuselage of an aircraft.

Aircraft inspections can take a number of different forms. For example, nondestructive examination in the form of nondestructive testing (NDT) can be performed on an aircraft. This type of testing can be performed both during manufacturing of the aircraft and during maintenance of the aircraft after delivery of the aircraft to a customer.

Nondestructive testing can include, for example, eddy current testing, magnetic particle testing, radiographic testing, ultrasonic testing, and visual testing. For example, visual inspections can be performed by a human inspector on the exterior and interior of an aircraft to look for nonconformances. A visual inspection can be performed using a number of different inspection tools. For example, the inspection tools used by the human inspector can include at least one of magnification devices, borescopes, cameras, and handheld microscopes, or other optical devices that can be used to inspect aircraft structures.

The visual inspection can be performed to identify nonconformances in an aircraft. These nonconformances can include at least one of an out of tolerance fit between parts, a missing fastener, a delamination, a crack, corrosion, a skin bulge, a scratch, a dent, warping, or other types of nonconformances.

The visual inspection is performed by a human inspector that has training and experience in performing visual inspections on aircraft. Currently, the inspector travels to the location of the aircraft and performs a visual inspection by moving around the outside of the aircraft, the inside of the aircraft, or both.

If the inspector locates a nonconformance on the aircraft, the inspector can place a marker on the aircraft on or near the location of the nonconformance. The inspector can mark the location of the nonconformance with a tape, an ink, a paint, or some other type of marker. Further, the inspector can record the locations of nonconformances found along with descriptions of the nonconformances.

This type of process can be more time-consuming than desired when the number of inspectors available to perform visual inspections at different locations is limited. Consequently, an aircraft may be out of service longer than desired with difficulties in scheduling an inspector to perform an inspection of the aircraft.

Therefore, it would be desirable to have a method and apparatus that take into account at least some of the issues discussed above, as well as other possible issues. For example, it would be desirable to have a method and apparatus that overcome a technical problem with the manner in which inspections such as visual inspections are currently performed on aircraft.

SUMMARY

An embodiment of the present disclosure provides a method for inspecting a fuselage of an aircraft. A rail is positioned within an interior portion of the fuselage of the aircraft such that the rail extends through the interior portion of the fuselage. An inspection device is attached to the rail. The inspection device moves along the rail, and a position of the rail enables the inspection device to inspect the interior portion. Video data is sent to a computer system over a wireless communications link between the inspection device and the computer system. The video data is displayed on a display system for the computer system. Inspection operations are performed in the interior portion of the fuselage with the inspection device attached to the rail when a group of commands to perform the inspection operations is received from the computer system over a wireless communications link between the inspection device and the computer system.

Another embodiment of the present disclosure provides an aircraft inspection system comprising a rail, a mounting system, an inspection device, and a computer system. The mounting system holds the rail in a position within an interior portion of a fuselage of an aircraft such that the rail extends through the interior portion of the fuselage. The inspection device is moveably attached to the rail, wherein the inspection device is linearly moveable along the rail and rotatably moveable about the rail and wherein the inspection device operates to generate sensor data in response to receiving a group of commands. The computer system is in a location remote to the inspection device. The computer system is in communication with the inspection device wherein the computer system receives video data from the inspection device, displays the video data on a display system, generates the group of commands based on a user input received from a human operator at the computer system, sends the group of commands to the inspection device, and receives sensor data from the inspection device.

Yet another embodiment of the present disclosure provides an aircraft inspection system comprising a rail, a mounting system, and an inspection device. The mounting system holds the rail in a position within an interior portion of a fuselage of an aircraft such that the rail extends through the interior portion of the fuselage. The inspection device is moveably attached to the rail. The inspection device is linearly moveable along the rail and rotatably moveable about the rail. The inspection device operates to generate sensor data for the interior portion of the fuselage.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that a limited number of inspectors, with training, experience, or both in inspecting aircraft, are available to travel to locations where aircraft are located to perform inspections. The illustrative embodiments recognize and take into account that with this situation, the amount of time needed to inspect an aircraft or inspect parts for an aircraft can be greater than desired when scheduling inspectors to travel to locations for inspections. The illustrative embodiments recognize and take into account that with this situation, aircraft may be out of service for maintenance longer than desired. The illustrative embodiments recognize and take into account that enabling remote inspections in which it is unnecessary for inspectors to travel to each site for inspections can reduce the need for additional inspectors, reduce inspection cycle time, increase aircraft availability, reduce maintenance down time, or some combination thereof.

With reference now to the figures and, in particular, with reference toFIG. 1, an illustration of a pictorial representation of a network of data processing systems is depicted in which illustrative embodiments may be implemented. Network data processing system100is a network of computers in which the illustrative embodiments may be implemented. Network data processing system100contains network102, which is the medium used to provide communications links between various devices and computers connected together within network data processing system100. Network102may include connections, such as wire, wireless communication links, or fiber optic cables.

In the depicted example, server computer104and server computer106connect to network102along with storage unit108. In addition, client devices110connect to network102. As depicted, client devices110include remote inspection system112, client computer114, and client computer116. Client devices110can be, for example, computers, workstations, or network computers. In the depicted example, server computer104provides information, such as boot files, operating system images, and applications to client devices110. Further, client devices110can also include other types of client devices such as mobile phone118, tablet computer120, and smart glasses122. In this illustrative example, server computer104, server computer106, storage unit108, and client devices110are network devices that connect to network102in which network102is the communications media for these network devices. Some or all of client devices110may form an Internet of things (IoT) in which these physical devices can connect to network102and exchange information with each other over network102.

Client devices110are clients to server computer104in this example. Network data processing system100may include additional server computers, client computers, and other devices not shown. Client devices110connect to network102utilizing at least one of wired, optical fiber, or wireless connections.

Program code located in network data processing system100can be stored on a computer-recordable storage medium and downloaded to a data processing system or other device for use. For example, program code can be stored on a computer-recordable storage medium on server computer104and downloaded to client devices110over network102for use on client devices110.

In this illustrative example, remote inspection system112can be installed in aircraft124to perform inspection of aircraft124. As depicted, remote inspection system112can be installed in the interior of fuselage126of aircraft124. The installation can be performed by human operators who are not trained or experienced in visual inspections.

As depicted, human operator128interacts with device manager130running on server computer104to control the operation of remote inspection system112. In this illustrative example, human operator128has at least one of training or experience in performing inspections on aircraft.

Human operator128and server computer104are in a remote location to remote inspection system112installed in fuselage126of aircraft124. A remote location is a location in which human operator128is not in the interior portion of fuselage126of aircraft124. Human operator128can be in a different building, city, state, or other geographic location from aircraft124. For example, human operator128can be in a maintenance building for a maintenance provider while aircraft124can be in a maintenance hanger for an airline.

In this depicted example, remote inspection system112has wireless communications link132to network102. Wireless communications link132can be establish using WiFi signals, cellular signals, or other types of wireless signals. Server computer104has wired communications link134to network102in this depicted example. In other illustrative examples, remote inspection system112can have a wired communications link and server computer104can have a wireless communications link.

As depicted, remote inspection system112sends video data136to device manager130which displays video data136on a display device in server computer104to human operator128. Video data136is displayed to provide a live view of the interior of fuselage126.

In this illustrative example, device manager130can also display information on the live view displayed using video data136to provide an augmented reality display to human operator128. The information can include at least one of schematics, wiring diagrams, inspection instructions, work orders, graphical indicators identifying nonconformances, or other suitable information that can be viewed by human operator128for use in performing an inspection of fuselage126from the remote location.

In this illustrative example, human operator128performs a visual inspection on fuselage126of aircraft124. In other illustrative examples, human operator128, controlling the operation of remote inspection system112, can perform visual inspections, x-ray inspections, ultrasound inspections, eddy current inspections, or other suitable types of inspections in fuselage126of aircraft124.

Human operator128performs the inspection remotely from aircraft124through user input sent to device manager130. Device manager130generates a group of commands138from the user input. Device manager130sends the group of commands138to remote inspection system112and causes remote inspection system112to perform operations to inspect fuselage126of aircraft124. Remote inspection system112sends sensor data140to device manager130.

With reference now toFIG. 2, an illustration of a block diagram of an inspection environment is depicted in accordance with an illustrative embodiment. In this illustrative example, inspection environment200includes components that can be implemented in hardware such as the hardware shown in network data processing system100inFIG. 1.

In inspection environment200, inspection system202operates to inspect aircraft structure204in aircraft206. Inspection system202can also be referred to as an aircraft inspection system. Aircraft206can take a number of different forms. For example, aircraft206can be selected from a group comprising an airplane, a cargo plane, a commercial passenger jet, a regional jet, a narrow body aircraft, a fuel tanker, a wide-body airliner or other suitable types of aircraft.

The inspection of aircraft structure204can take place during a number of different stages in the lifecycle of aircraft206. For example, aircraft structure204can be inspected during manufacturing of aircraft structure204prior to aircraft structure204being assembled with other aircraft structures. In other illustrative examples, aircraft structure204can be located in aircraft206which has been delivered to a customer for use. The inspection of aircraft structure204can take place as part of maintenance for aircraft206. In this illustrative example, aircraft structure204is fuselage208of aircraft206.

In this example, fuselage208can be the entire fuselage that forms aircraft206. In some illustrative examples, fuselage208is a fuselage section that can be connected to other fuselage sections to form an entire fuselage for aircraft206.

In this illustrative example, inspection system202comprises a number of different components. As depicted, inspection system202includes device manager210in computer system212and remote inspection system214.

Remote inspection system112is a physical hardware system and can include software components. In this illustrative example, remote inspection system214is located in location216and can be installed in fuselage208to perform inspections of fuselage208of aircraft206in location216. Location216can be, for example, a maintenance facility, an aircraft manufacturing factory, a hanger, or some other suitable location in which inspection of fuselage208can be made.

In this illustrative example, remote inspection system214can be installed within interior portion218of fuselage208of aircraft206. Interior portion218can be one of a passenger area, a cargo area, or some other suitable area in the interior of fuselage208. The installation of remote inspection system214is a temporary installation for purposes of performing an inspection on interior portion218of fuselage208. After the inspection is completed, remote inspection system214can be removed from interior portion218of fuselage208. The installation and removal of remote inspection system214does not require a human operator that is skilled, trained, or experienced in performing inspections.

As depicted, computer system212is in remote location220while remote inspection system214is in location216. Remote inspection system214and computer system212communicate with each other through network222. Network222can be comprised of at least one of the Internet, an intranet, a local area network (LAN), a metropolitan area network (MAN), or a wide area network (WAN), or some other suitable network data or communications medium.

As depicted, remote inspection system214connects to network222via wireless communications links. In some illustrative examples, a wired or optical communications link can be used by remote inspection system214to connect to network222.

As depicted, computer system212connects to network222by a physical communications link such as a wired link or optical link. In some examples, a wireless link can also be used.

In this illustrative example, human operator224controls the operation of remote inspection system214using computer system212at remote location220. Remote location220and location216are physically different locations. These locations can be, for example, in different buildings in the same facility, different areas in the same building, in different facilities, different cities, different cities, different counties, or different continents. For example, location216can be a maintenance hangar for an airline in one state while remote location220is an office building for an aircraft manufacturer in a different state.

Human operator224interacts with device manager210in computer system212to remotely operate remote inspection system214. As depicted, the interaction occurs using display system226and input system228for computer system212.

As depicted, display system226is a physical hardware system and includes one or more display devices on which graphical user interface230can be displayed. The display devices may include at least one of a light emitting diode (LED) display, a liquid crystal display (LCD), an organic light emitting diode (OLED) display, a computer monitor, a projector, a flat panel display, a heads-up display (HUD, or some other suitable device that can output information for the presentation of information.

In this illustrative example, display system226is configured to display graphical user interface230for device manager210. Human operator224is a person that can interact with graphical user interface230through user input232generated by input system228for computer system212. Input system228is a physical hardware system and can be selected from at least one of a mouse, a keyboard, a trackball, a touchscreen, a stylus, a motion sensing input device, a cyber glove, or some other suitable type of input device.

Device manager210can be implemented in software, hardware, firmware or a combination thereof. When software is used, the operations performed by device manager210can be implemented in program code configured to run on hardware, such as a processor unit. When firmware is used, the operations performed by device manager210can be implemented in program code and data and stored in persistent memory to run on a processor unit. When hardware is employed, the hardware can include circuits that operate to perform the operations in device manager210.

During the operation of inspection system202, computer system212is in communication with remote inspection system214. Device manager210in computer system212receives video data234from remote inspection system214and displays video data234on display system226for computer system212. This display of video data234provides human operator224with live view236of interior portion218of fuselage208of aircraft206.

In one illustrative example, device manager210displays live view236of fuselage208and information238on display system226as an augmented reality display240of fuselage208. As depicted, information238is for use in inspecting fuselage208and can take a number of different forms. For example, information238can be selected from at least one of one of a diagram of components in fuselage208, a portion of a model of the fuselage, a work order, a prior scan of the fuselage, a graphical indicator on an inspection location in the interior portion of fuselage208, or other suitable information that can be utilized in inspecting interior portion218of fuselage208.

As depicted, device manager210generates commands242based on user input232received from human operator224at computer system212in remote location220. In the illustrative example, commands242are for use by remote inspection system214to perform inspection operations. In this illustrative example, device manager210sends commands242to remote inspection system214and receives sensor data244from the remote inspection system214.

In the illustrative example, sensor data244can be the same data as video data234if the inspection being performed is a visual inspection. The depending the type of inspection, other types of sensor data244may be received. For example, at least one of x-ray data from x-ray devices, voltages from eddy current sensors, or other types of sensor data244can make up sensor data244depending on the type of tools used in remote inspection system214to perform inspection of interior portion218of fuselage208. This data can be viewed by human operator224, analyzed in computer system212, stored, or otherwise used as part of the inspection process of fuselage208.

As depicted, human operator224can perform a visual inspection on fuselage208. Human operator views live view236displayed on display system226using video data234. When human operator224sees nonconformance246at physical location248in interior portion218of fuselage208on live view236, human operator224can generate user input232to mark nonconformance246.

In one illustrative example, device manager210receives user input232to mark nonconformance246in live view236of fuselage208. For example, human operator224can move a pointer over physical location248seen in live view236and generate user input232to mark physical location248.

Model location250can later be used to guide personnel to physical location248in interior portion218of fuselage208for performing additional operations. These additional operations can include at least one of an onsite visual inspection, rework, and component replacement, or other operations to resolve nonconformance246.

In another illustrative example, in response to receiving user input232to mark nonconformance246at physical location248of live view236of fuselage208, device manager210can generate a command in commands242to place marker256at physical location248on fuselage208that corresponds to physical location248of nonconformance246marked in live view236of interior portion218of fuselage208. In this example, device manager210sends the command to remote inspection system214such that remote inspection system214places marker256on interior portion218of fuselage208at physical location248. In other words, marker256is a physical marker.

In this illustrative example, marker256is a physical object and can take a number of different forms. For example, marker256can be a tape, a sticky note, an ink, a paint, a radio frequency identifier device, or some other type of physical indicator that can be physically placed on physical location248in interior portion218of fuselage208.

With reference now toFIG. 3, an illustration of a remote inspection system is depicted in accordance with an illustrative embodiment. In the illustrative examples, the same reference numeral may be used in more than one figure. This reuse of a reference numeral in different figures represents the same element in the different figures.

An example of components that can be used in remote inspection system214is depicted in this figure. In this example, remote inspection system214comprises rail300, mounting system302, and inspection device304.

Rail300is a physical component on which an inspection device304can move. In the illustrative example, rail300can take a number of different forms. For example, rail300can be selected from one of a rod with a helical groove, a track, a bar, a linear gear, or other suitable elongate member.

In this illustrative example, mounting system302is a physical system and is configured to hold rail300in position306within interior portion218of fuselage208of aircraft206in position306such that rail300extends through interior portion218of fuselage208. For example, position306can be such that rail300extends centrally through interior portion218of fuselage208.

Mounting system302can be connected to at least one of fuselage208or a structure in an inspection area in location216in which fuselage208is located such that rail300has position306that extends through interior portion218of fuselage208. Mounting system302can include at least one of a stand, a sawhorse, a tripod, a tether, a bracket, a strap, a harness, a frame, a platform, or some other structure that capable of supporting rail300.

In the illustrative example, rail300can be connected to mounting system302in a number of different ways. For example, the ends of rail300can be connected to mounting system302, the middle of rail300can be connected to mounting system302, or some other part or parts of rail300can be connected to mounting system302.

As depicted, inspection device304is a physical system and can include computing devices and software. Inspection device304is moveably attached to rail300. For example, inspection device304can be at least one of linearly moveable308along the rail or rotatably moveable310about rail300.

In this illustrative example, inspection devices304receives commands242from device manager210. As depicted, commands242are selected from at least one of move inspection device304along rail300, rotate inspection device304about rail300, activate a tool connected to inspection device304to perform a test, move the tool towards a wall of fuselage208, move the tool away from a wall of fuselage208, or send sensor data244to computer system212. For example, move the tool towards or away from the wall can be performed by changing the length of a telescoping rod on which the tool is connected.

Thus, inspection device304can operate to generate sensor data244in response to receiving commands242. Additionally, inspection device304can also move within interior portion218in response to commands242.

With reference nextFIG. 4, an illustration of a block diagram of an inspection device is depicted in accordance with an illustrative embodiment. This figure illustrates an example of components for inspection device304inFIG. 3. In this illustrative example, inspection device304comprises carriage400, mobility system402, a group of inspection tools404, and controller406.

As used herein, a group of items is one or more items. For example, a group of inspection tools404is one or more of inspection tools404.

As depicted, carriage400is a physical structure that provides a platform for other components in inspection device304. Carriage400can be a frame, a body, a housing, or some other components. Carriage400can be linearly movable along rail300and can also be rotatably movable about rail300.

In this example, carriage400is movably attached to rail300through mobility system402. Mobility system402is a physical system and provides for the mobility of carriage400on rail300. Mobility system402can move carriage400along rail300or rotate about rail300. In other words, carriage400can rotate about an axis extending through rail300. In this illustrative example, mobility system402can include at least one of a propulsion system, a steering system, a braking system, and other mobility components such as wheels or guides.

As depicted, the group of inspection tools404is one or more physical tools that generate sensor data244that can be analyzed as part of inspecting fuselage208. The sensor data can include video data234. The group of inspection tools404is selected from at least one of a visible light camera, an x-ray system, an ultrasound transducer array, a thermographic camera, an eddy current probe, or some other suitable type of tool.

In this illustrative example, controller406is a physical hardware device and can include software. For example, controller406can be implemented using a data processing system, a computer, a card, a chip, or standalone device that can communicate with a set of peripheral devices. In this depicted example, the set of peripheral devices includes mobility system402and the group of inspection tools404.

Thus, controller406controls the operation of inspection device304including the mobility system402and the group of inspection tools404. For example, controller406can receive commands242.

Controller406includes communications components such as a radio frequency transceiver or other suitable communications components that enable receiving commands242and transmitting sensor data244generated by the group of inspection tools404. Controller406processes commands242to perform operations such as activating and generating sensor data244using the group of inspection tools404.

Further, controller406can also process commands242to control the positioning and movement of carriage400on rail300. For example, controller406can control mobility system402to cause carriage400to move along rail300. Further, controller406can also control mobility system402to rotate carriage400. This rotation of carriage400causes rotation of the group of inspection tools404to enable inspecting interior portion218of fuselage208without having to disassemble, move, and reassemble rail300and inspection device304to inspect interior portion218of fuselage208.

In this manner, the different components of inspection device304can operate to perform a 360 degree inspection along an axis through fuselage208. In the illustrative example, rail300can be positioned centrally within interior portion218of fuselage208. For example, rail300can be positioned in the middle the fuselage above or below the floor line.

In one illustrative example, one or more technical solutions are present that overcome a technical problem with the manner in which inspections such as visual inspections are currently performed on aircraft when a limited number of inspectors with training, experience, or both are available to travel to the locations where aircraft maintenance or aircraft manufacturing occurs to perform visual inspection of aircraft. In the illustrative example, one or more technical solutions can provide a technical effect reducing or eliminating travel time needed by an inspector to inspect aircraft.

In the illustrative example, one or more technical solutions are present in which an inspector can remotely inspect an aircraft using remote inspection system214. Remote inspection system214can be assembled and installed by personnel at the location. These personnel do not need to have experience or training in performing inspection operations. The inspector can operate inspection device304in remote inspection system214and perform inspection operations without needing to be present the location fuselage to perform the inspection.

Computer system212can be configured to perform at least one of the steps, operations, or actions described in the different illustrative examples using software, hardware, firmware or a combination thereof. As a result, computer system212operates as a special purpose computer system in which device manager210in computer system212enables human operator224to operate remote inspection system214to remotely inspect fuselage208. In particular, device manager210transforms computer system212into a special purpose computer system as compared to currently available general computer systems that do not have the device manager210.

For example, although the inspection of aircraft structure204has been described with reference to fuselage208, aircraft structure can take other forms in other implementations. As another example, aircraft structure204can be any structure for aircraft206that has an interior cavity in which remote inspection system214can be installed. For example, aircraft structure204can also take the form of a wing box that can be inspected during manufacturing of aircraft206.

In yet another example, remote inspection system214can include one or more inspection devices in addition to inspection device304. With this illustrative example, the additional inspection devices can be controlled by human operator224. In some illustrative examples, additional human operators can be assigned to control the operation of the additional inspection devices.

Turning toFIG. 5, an illustration of remote inspection systems installed in a fuselage of an aircraft is depicted in accordance with an illustrative embodiment. As depicted, remote inspection system500and remote inspection system502are installed within fuselage504. Remote inspection system502is installed within interior portion506that is a passenger area in fuselage504. Remote inspection system502is installed in interior portion508that is a cargo area in fuselage504.

As depicted, remote inspection system500in interior portion506of fuselage504comprises helical rod510connected to plate512and plate514. Helical rod510is an example of a physical implementation of rail300shown in block form inFIG. 3. In this illustrative example, helical rod510is comprised of section522, section524, section526, section528, and section530joined together to form helical rod510.

Plate512is connected to bulkhead518, and plate514is connected to bulkhead520. Plate512and plate514are examples of physical components for mounting system302shown in block form inFIG. 3. These plates can be connected to bulkhead518and bulkhead520using fasteners or other types of connecting mechanisms. As depicted in this example, helical rod510is centrally located within interior portion506.

Inspection device516is connected to helical rod510. Inspection device516is an example of an implementation for inspection device304shown in block form inFIG. 3.

As depicted, inspection device516is configured to move along helical rod510while performing inspection operations to generate sensor data. Further, inspection device516is also configured to rotate about helical rod510to perform inspection operations to generate sensor data. Inspection device516can rotate to position a tool and cause the tool to operate to generate sensor data or can rotate while the tool operates to generate sensor data.

Helical rod532is an example of a physical implementation of rail300shown in block form inFIG. 3. Plate534is connected to bulkhead518, and plate536is connected to bulkhead520. Plate534and plate536are examples of physical components for mounting system302shown in block form inFIG. 3. These plates can be connected to bulkhead518and bulkhead520using fasteners or other types of connecting mechanisms. As depicted in this example, helical rod532is centrally located within interior portion508.

Inspection device516is connected to helical rod510. Inspection device538is another example of an implementation for inspection device304shown in block form inFIG. 3. As depicted, inspection device538is configured to move along helical rod532and rotate about helical rod532to perform inspection operations to generate sensor data.

An enlarged illustration of inspection device516in section560is shown inFIG. 6. Turning now toFIG. 6, an illustration of an enlarged view of inspection device is depicted in accordance with an illustrative embodiment. In this figure, an enlarged view of section560inFIG. 5is depicted.

Inspection device516comprises housing600on which tools are connected via telescoping rods. Housing600is an example of a physical implementation for carriage400shown in block form inFIG. 4. In this example, housing600has a cylindrical shape.

In this illustrative example, the tools comprises visible light camera604, visible light camera606, thermographic camera608, thermographic camera610, eddy current probe612, eddy current probe614, ultrasound transducer array616, and ultrasound transducer array618.

As depicted, these tools are connected to the ends of the telescoping rods. In this illustrative example, visible light camera604is connected to telescoping rod620, and visible light camera606is connected to telescoping rod622. As depicted, thermographic camera608is connected to telescoping rod624, and thermographic camera610is connected to telescoping rod626. Eddy current probe612is connected to telescoping rod628, and eddy current probe614is connected to telescoping rod630. In the illustrative example, ultrasound transducer array616is connected to telescoping rod632, and ultrasound transducer array618is connected to telescoping rod634.

With the tools connected to the ends of the telescoping rods, the tools can be independently moved towards and away from surface636in interior portion506of fuselage504. Surface636can include wall638of fuselage504and floor640in fuselage504.

For example, telescoping rod628can move eddy current probe612to contact wall638in fuselage504. The detection of eddy currents by an eddy current probe612can be used to determine whether corrosion is present within wall638of fuselage504. As another example, telescoping rod632can move ultrasound transducer array616to contact to contact floor640. Ultrasound transducer array616can be used to determine whether nonconformances such as voids, cracks, delamination, or other types of nonconformances are present within floor640in fuselage504.

Further, a mobility system inside of housing600can engage helical groove642to move inspection device516axially along helical rod532in the direction of arrow644. The mobility system inside of housing600can also rotate housing600in the direction of arrow646.

With reference now toFIG. 7, an illustration of a remote inspection system installed in the fuselage of an aircraft is depicted in accordance with an illustrative embodiment. In this illustrative example, remote inspection system700is installed within interior portion702of fuselage704. As depicted, remote inspection system700comprises elongate bar706, post708, post710, and inspection device712.

In this illustrative example, elongate bar706has a T-shaped cross-section. Elongate bar706is an example of one physical implementation for rail300shown in block form inFIG. 3.

Elongate bar706is positioned centrally within interior portion702of fuselage704using post708and post710. Post708and post710are examples of physical components that can be used to implement mounting system302shown in block form inFIG. 3. In this illustrative example, post708and post710are mounted on floor715within fuselage704.

In this illustrative example, inspection device712is an example of a physical implementation for inspection device304shown in block form inFIG. 3. As depicted, housing713for remote inspection system700is an example of one implementation for carriage400shown in block form inFIG. 4. As depicted, housing713has a cylindrical shape.

In this illustrative example, telescoping rods are connected to housing713and tools are connected to the ends of the telescoping rods. As depicted, visible light camera714is connected telescoping rod716, visible light camera718is connected to telescoping rod720, and visible light camera722is connected to telescoping rod724. Thermographic camera726is connected to telescoping rod728, thermographic camera730is connected telescoping rod732, thermographic camera734is connected telescoping rod736, and thermographic camera738is connected telescoping rod740.

As depicted, mobility system742includes wheel744, wheel746, wheel748, wheel750, and wheel752. Another wheel hidden from view by elongate bar706is present. One or more of these wheels are motorized wheels enabling moving inspection device712in the direction of arrow754. Further, mobility system742can also rotate housing713around elongate bar706in the direction of arrow756. In this illustrative example, housing713includes gap758which enables housing713to move over and past post708and post710.

With reference now toFIG. 8, an illustration of a remote inspection system installed in the fuselage of an aircraft is depicted in accordance with an illustrative embodiment. In this illustrative example, remote inspection system800is installed within interior portion802of fuselage804. As depicted, remote inspection system800comprises linear gear806, post808, post810, and inspection device812.

Linear gear806is positioned centrally within interior portion802of fuselage804using post808and post810mounted to floor815. Linear gear806is an example of a physical implementation for rail300shown in block form inFIG. 3. Post808and post810are examples of physical components that can be used to implement mounting system302shown in block form inFIG. 3.

In this illustrative example, tools are connected to housing814through telescoping rods. As depicted, visible light camera816is connected to telescoping rod818, visible light camera820is connected to telescoping rod822, and visible light camera824is connected to telescoping rod826.

In this illustrative example, mobility system828comprises circular gear830and circular gear832. The circular gears are motorized and engage linear gear806to move inspection device812along the linear gear806in the direction of arrow834. Mobility system828can also rotate housing814to rotate the different tools about linear gear806in the direction of arrow836.

Housing814also includes gap838that enables inspection device812to move over and past post808and post810.

The illustration of the remote inspection systems inFIGS. 5-8are provided for purposes of illustrating some examples of how remote inspection system214shown in block form inFIG. 2can be implemented. These illustrations are not meant to limit the manner in which other illustrative examples can be implemented.

For example, the housing600inFIG. 6and housing713inFIG. 7can have housings of shapes other than a cylindrical shape. For example, the housing could be a box shaped or some other shape. In yet other examples, a frame can be used instead of a housing.

Further, in another illustrative example, only visible light cameras can be used. As yet another example, fixed rods or elongate members can be used in place of telescoping rods. As another example, helical rod510inFIG. 5, helical rod532inFIG. 5, elongate bar706inFIG. 7, and linear gear806inFIG. 8are examples of implementations for rail300shown in block form inFIG. 3and are shown as being straight. Rails in other illustrative examples can be curved.

Turning next toFIG. 9, an illustration of a flowchart of a process for inspecting a fuselage of an aircraft is depicted in accordance with an illustrative embodiment. The process inFIG. 9can be implemented in hardware, software, or both. When implemented in software, the process can take the form of program code that is run by one of more processor units located in one or more hardware devices in one or more computer systems. For example, the process can be implemented in inspection system202inFIG. 2.

The process begins by positioning a rail within an interior portion of the fuselage of the aircraft such that the rail has a position that extends through the interior portion of the fuselage (operation900). In this illustrative example, the rail can extend as far as physically possible within the interior portion of the fuselage, such as from one bulkhead to another bulkhead in the fuselage or from one open end to another open end of a fuselage that has not yet been assembled with other components to form the aircraft.

The interior portion in operation900can be a passenger area, a cargo area, or some other area within the fuselage of the aircraft. As another example, the interior portion can be the entire fuselage if a floor or other structure is not installed in the fuselage to partition the fuselage into more than one area.

The process attaches an inspection device to the rail (operation902). In operation902, the inspection device is configured to move along the rail linearly and about the rail rotationally when the inspection device is attached to the rail. The position of the rail is selected to enable the inspection device to inspect the interior portion of the fuselage.

The process sends video data to a computer system over a wireless communications link between the inspection device and the computer system (operation904). The video data is displayed on a display system for the computer system. The process performs inspection operations in the interior portion of the fuselage with the robotic inspection device attached to the rail when commands to perform inspection operations are received from the computer system over a wireless communications link between the inspection device and the computer system (operation906). The process terminates thereafter.

With reference nextFIG. 10, an illustration of a flowchart of a process for installing a remote inspection system is depicted in accordance with an illustrative embodiment. In this depicted example, the process can be performed by one or more human operators in inspection environment200to install remote inspection system214in interior portion218of fuselage208of aircraft206inFIG. 2.

The process begins by installing a mounting system (operation1000). The mounting system is connected to at least one of the fuselage or a structure in a location in which the fuselage is located. For example, a mounting system can be installed within the fuselage or on the floor of the area in which the fuselage is being installed. In another example, if the mounting system is installed in aircraft, mounting system can be installed within the fuselage. If the fuselage is a component of the aircraft that has not yet been assembled with other components, the mounting system can be installed on floor or on other structures in the manufacturing facility.

The process attaches the rail to the mounting system (operation1002). The process terminates thereafter. In operation1002, the attachment of the rail to the mounting system is such that the rail has the position that extends through the interior portion of the fuselage when connected to the mounting system.

With reference next toFIG. 11, an illustration of a flowchart of a process for remotely controlling operation of an inspection device is depicted in accordance with an illustrative embodiment. The process inFIG. 11can be implemented in hardware, software, or both. When implemented in software, the process can take the form of program code that is run by one of more processor units located in one or more hardware devices in one or more computer systems. The different operations can be implemented in the device manager210in computer system212in inspection system202inFIG. 2.

The process begins by receiving video data from inspection device (operation1100). In operation1100, inspection device is attached to a rail position in a fuselage of an aircraft for remote inspection.

The process displays the video data on a display system as a live view of the interior portion of the fuselage (operation1102). The live view can be viewed by a human operator that is in a remote location to the location of the inspection device in the remote inspection system installed in the fuselage of the aircraft.

This interior portion can be the entire interior of fuselage that has not yet been assembled with other parts of aircraft. The interior portion also can be, for example, a passenger area or a cargo area in an aircraft that is already in service or being prepared for delivery to a customer.

The process identifies information about the fuselage (operation1104). This information can be obtained from a database or other data structure. The information can include at least one of a diagram of components in the fuselage, a portion of a model of the fuselage, a work order, a prior scan of the fuselage, a graphical indicator on an inspection location in the interior portion of the fuselage, instructions for performing a particular type of inspection, or other suitable information.

The process displays this information on the live view of the interior portion of the fuselage (operation1106). In this manner, an augmented reality view of the interior portion of the fuselage is provided to the human operator.

The process receives user input through an input system operated by human operator (operation1108). The process generates a group of commands based on the user input (operation1110). These commands are commands for the inspection device. The commands can include at least one of moving the inspection device along the rail, rotating the inspection device about the rail, activating an inspection tool connected to the inspection device to perform a test, moving the tool towards a wall of the fuselage, moving the inspection tool away from the wall of the fuselage, marking a nonconformance, sending sensor data to the computer system, or other suitable commands for performing the inspection of the interior portion of the fuselage.

The process then sends the group of commands to the inspection device (operation1112). The process then returns to operation1100. This process can be repeated any number of times during the inspection performed by human operator.

With reference next toFIG. 12, an illustration of a flowchart process for marking nonconformances is depicted in accordance with an illustrative embodiment. The process inFIG. 12can be implemented in hardware, software, or both. When implemented in software, the process can take the form of program code that is run by one of more processor units located in one or more hardware devices in one or more computer systems. For example, the process can be implemented in device manager210in computer system212in inspection system202inFIG. 2.

The process begins by receiving a user input to mark a nonconformance at a physical location in the live view of the fuselage (operation1200). In this illustrative example, the user input can be an input selecting a portion of the video data displayed in the live view in which the nonconformance is seen by the human operator. The selection can be used identify a physical location on the fuselage where the nonconformance has been identified by human operator. This physical location is a three-dimensional location and can be described using coordinates for a coordinate system for the fuselage. The coordinate system can be a Cartesian coordinate system with a selected location in or outside of the aircraft being the origin.

The process identifies a model location in a model of the fuselage that corresponds to the nonconformance marked in the live view of the fuselage (operation1202). In operation1202, the process can transform the coordinate system for the fuselage into a coordinate system for the model and identify the location in the model corresponding to the location on the fuselage identified by human operator.

The process associates a graphical indicator with the model location in the model (operation1204). The process terminates thereafter.

In operation1204, the position identified in the physical location by the user input can be correlated to the coordinate system for the model to enable associating the graphical indicator with a position in the model that corresponds to physical position indicated by human operator in the user input. The position is a three-dimensional position described using coordinates in a coordinate system such as a Cartesian coordinate system.

With reference now toFIG. 13, an illustration of a flowchart process for physically marking nonconformances is depicted in accordance with an illustrative embodiment. The process inFIG. 13can be implemented in hardware, software, or both. When implemented in software, the process can take the form of program code that is run by one of more processor units located in one or more hardware devices in one or more computer systems. For example, the process can be implemented in device manager210in computer system212in inspection system202inFIG. 2.

The process begins by receiving a user input to mark a nonconformance at a physical location of the live view of the fuselage (operation1300). In this example, the user input can select a point in the live view where the human operator sees the nonconformance on the interior portion of the fuselage.

The process generates a command to place a marker at the physical location on the interior portion of the fuselage that corresponds to the nonconformance marked in the live view of the fuselage (operation1304). The process can identify location on the fuselage on the user input. This location can be described in a coordinate system such as a Cartesian coordinate system for the aircraft.

The process sends the command to the inspection device (operation1306). The inspection device places the marker on the interior portion of the fuselage at the physical location using the command received from the device manager computer system (operation1308). The process terminates thereafter. In operation1308, the marker can be a tape, a sticky note, an ink, a paint, or some other type of physical visual indicator that can be physically placed on physical location in the interior portion of the fuselage208. As another example, a radio frequency identifier device can provide both a visual indication and a wireless indicator. The wireless indicator can include information such as coordinates of the nonconformance.

Turning now toFIG. 14, an illustration of a block diagram of a data processing system is depicted in accordance with an illustrative embodiment. Data processing system1400can be used to implement server computer104, server computer106, client devices110, inFIG. 1. Data processing system1400can also be used to implement computer system212inFIG. 2. In this illustrative example, data processing system1400includes communications framework1402, which provides communications between processor unit1404, memory1406, persistent storage1408, communications unit1410, input/output (I/O) unit1412, and display1414. In this example, communications framework1402takes the form of a bus system.

Processor unit1404serves to execute instructions for software that can be loaded into memory1406. Processor unit1404includes one or more processors. For example, processor unit1404can be selected from at least one of a multicore processor, a central processing unit (CPU), a graphics processing unit (GPU), a physics processing unit (PPU), a digital signal processor (DSP), a network processor, or some other suitable type of processor.

Memory1406and persistent storage1408are examples of storage devices1416. A storage device is any piece of hardware that is capable of storing information, such as, for example, without limitation, at least one of data, program code in functional form, or other suitable information either on a temporary basis, a permanent basis, or both on a temporary basis and a permanent basis. Storage devices1416may also be referred to as computer-readable storage devices in these illustrative examples. Memory1406, in these examples, can be, for example, a random-access memory or any other suitable volatile or non-volatile storage device. Persistent storage1408can take various forms, depending on the particular implementation.

For example, persistent storage1408may contain one or more components or devices. For example, persistent storage1408can be a hard drive, a solid-state drive (SSD), a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by persistent storage1408also can be removable. For example, a removable hard drive can be used for persistent storage1408.

Communications unit1410, in these illustrative examples, provides for communications with other data processing systems or devices. In these illustrative examples, communications unit1410is a network interface card.

Input/output unit1412allows for input and output of data with other devices that can be connected to data processing system1400. For example, input/output unit1412can provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, input/output unit1412can send output to a printer. Display1414provides a mechanism to display information to a user.

Instructions for at least one of the operating system, applications, or programs can be located in storage devices1416, which are in communication with processor unit1404through communications framework1402. The processes of the different embodiments can be performed by processor unit1404using computer-implemented instructions, which can be located in a memory, such as memory1406.

These instructions are referred to as program code, computer usable program code, or computer-readable program code that can be read and executed by a processor in processor unit1404. The program code in the different embodiments can be embodied on different physical or computer-readable storage media, such as memory1406or persistent storage1408.

Program code1418is located in a functional form on computer-readable media1420that is selectively removable and can be loaded onto or transferred to data processing system1400for execution by processor unit1404. Program code1418and computer-readable media1420form computer program product1422in these illustrative examples. In the illustrative example, computer-readable media1420is computer-readable storage media1424.

In these illustrative examples, computer-readable storage media1424is a physical or tangible storage device used to store program code1418rather than a medium that propagates or transmits program code1418.

Alternatively, program code1418can be transferred to data processing system1400using a computer-readable signal media. The computer-readable signal media can be, for example, a propagated data signal containing program code1418. For example, the computer-readable signal media can be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals can be transmitted over connections, such as wireless connections, optical fiber cable, coaxial cable, a wire, or any other suitable type of connection.

The different components illustrated for data processing system1400are not meant to provide architectural limitations to the manner in which different embodiments can be implemented. In some illustrative examples, one or more of the components may be incorporated in or otherwise form a portion of, another component. For example, memory1406, or portions thereof, can be incorporated in processor unit1404in some illustrative examples. The different illustrative embodiments can be implemented in a data processing system including components in addition to or in place of those illustrated for data processing system1400. Other components shown inFIG. 14can be varied from the illustrative examples shown. The different embodiments can be implemented using any hardware device or system capable of running program code1418.

Illustrative embodiments of the disclosure may be described in the context of aircraft manufacturing and service method1500as shown inFIG. 15and aircraft1600as shown inFIG. 16. Turning first toFIG. 15, an illustration of an aircraft manufacturing and service method is depicted in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method1500may include specification and design1502of aircraft1600inFIG. 16and material procurement1504.

During production, component and subassembly manufacturing1506and system integration1508of aircraft1600inFIG. 16takes place. Thereafter, aircraft1600inFIG. 16can go through certification and delivery1510in order to be placed in service1512. While in service1512by a customer, aircraft1600inFIG. 16is scheduled for routine maintenance and service1514, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

With reference now toFIG. 16, an illustration of an aircraft is depicted in which an illustrative embodiment may be implemented. In this example, aircraft1600is produced by aircraft manufacturing and service method1500inFIG. 15and may include airframe1602with plurality of systems1604and interior1606. Examples of systems1604include one or more of propulsion system1608, electrical system1610, hydraulic system1612, and environmental system1614. Any number of other systems may be included. Although an aerospace example is shown, different illustrative embodiments may be applied to other industries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method1500inFIG. 15.

In one illustrative example, components or subassemblies produced in component and subassembly manufacturing1506inFIG. 15can be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft1600is in service1512inFIG. 15. As yet another example, one or more apparatus embodiments, method embodiments, or a combination thereof can be utilized during production stages, such as component and subassembly manufacturing1506and system integration1508inFIG. 15. One or more apparatus embodiments, method embodiments, or a combination thereof may be utilized while aircraft1600is in service1512, during maintenance and service1514inFIG. 15, or both. For example, inspection system202inFIG. 2can be used to inspect a fuselage in airframe1602inFIG. 16during at least one of component and subassembly manufacturing1506and system integration1508. Inspection system202can also be used during maintenance and service1504to inspect the fuselage in airframe1602in aircraft1600. The use of a number of the different illustrative embodiments may substantially expedite the assembly of aircraft1600, reduce the cost of aircraft1600, or both expedite the assembly of aircraft1600and reduce the cost of aircraft1600. For example, inspections can be performed more quickly by enabling inspectors to remotely inspect aircraft without having to travel to the aircraft for inspections.

Turning now toFIG. 17, an illustration of a block diagram of a product management system is depicted in accordance with an illustrative embodiment. Product management system1700is a physical hardware system. In this illustrative example, product management system1700includes at least one of manufacturing system1702or maintenance system1704.

Manufacturing system1702is configured to manufacture products, such as aircraft1600inFIG. 16. As depicted, manufacturing system1702includes manufacturing equipment1706. Manufacturing equipment1706includes at least one of fabrication equipment1708or assembly equipment1710.

Fabrication equipment1708is equipment that used to fabricate components for parts used to form aircraft1600inFIG. 16. For example, fabrication equipment1708can include machines and tools. These machines and tools can be at least one of a drill, a hydraulic press, a furnace, a mold, a composite tape laying machine, a vacuum system, a lathe, or other suitable types of equipment. Fabrication equipment1708can be used to fabricate at least one of metal parts, composite parts, semiconductors, circuits, fasteners, ribs, skin panels, spars, antennas, or other suitable types of parts.

Assembly equipment1710is equipment used to assemble parts to form aircraft1600inFIG. 16. In particular, assembly equipment1710is used to assemble components and parts to form aircraft1600inFIG. 16. Assembly equipment1710also can include machines and tools. These machines and tools may be at least one of a robotic arm, a crawler, a faster installation system, a rail-based drilling system, or a robot. Assembly equipment1710can be used to assemble parts such as seats, horizontal stabilizers, wings, engines, engine housings, landing gear systems, and other parts for aircraft1600inFIG. 16. In this illustrative example, assembly equipment1710can also include equipment, such as remote inspection system214, to perform inspections for components and parts that are assembled to form aircraft1600. For example, remote inspection system214can be used to inspect fuselage sections or a fuselage for aircraft1600.

In this illustrative example, maintenance system1704includes maintenance equipment1712. Maintenance equipment1712can include any equipment needed to perform maintenance on aircraft1600inFIG. 16. Maintenance equipment1712may include tools for performing different operations on parts on aircraft1600inFIG. 16. These operations can include at least one of disassembling parts, refurbishing parts, inspecting parts, reworking parts, manufacturing replacement parts, or other operations for performing maintenance on aircraft1600inFIG. 16. These operations can be for routine maintenance, inspections, upgrades, refurbishment, or other types of maintenance operations.

In the illustrative example, maintenance equipment1712may include ultrasonic inspection devices, x-ray imaging systems, vision systems, drills, crawlers, and other suitable devices. In some cases, maintenance equipment1712can include fabrication equipment1708, assembly equipment1710, or both to produce and assemble parts that needed for maintenance. Maintenance equipment1712can also include equipment, such as remote inspection system214, to perform inspections as part of maintenance aircraft1600. For example, remote inspection system214can be used to inspect fuselage sections or a fuselage for aircraft1600.

Product management system1700also includes control system1714. Control system1714is a hardware system and may also include software or other types of components. Control system1714is configured to control the operation of at least one of manufacturing system1702or maintenance system1704. In particular, control system1714can control the operation of at least one of fabrication equipment1708, assembly equipment1710, or maintenance equipment1712.

The hardware in control system1714can be implemented using hardware that may include computers, circuits, networks, and other types of equipment. The control may take the form of direct control of manufacturing equipment1706. For example, robots, computer-controlled machines, and other equipment can be controlled by control system1714. In other illustrative examples, control system1714can manage operations performed by human operators1716in manufacturing or performing maintenance on aircraft1600. For example, control system1714can assign tasks, provide instructions, display models, or perform other operations to manage operations performed by human operators1716. In these illustrative examples, device manager210inFIG. 2can be implemented in control system1714to manage at least one of the manufacturing or maintenance of aircraft1600inFIG. 16.

In the different illustrative examples, human operators1716can operate or interact with at least one of manufacturing equipment1706, maintenance equipment1712, or control system1714. This interaction can occur to manufacture aircraft1600inFIG. 16.

Of course, product management system1700may be configured to manage other products other than aircraft1600inFIG. 16. Although product management system1700has been described with respect to manufacturing in the aerospace industry, product management system1700can be configured to manage products for other industries. For example, product management system1700can be configured to manufacture products for the automotive industry as well as any other suitable industries.

Thus, illustrative examples provide a method, apparatus, and system for inspecting aircraft structures such as a fuselage of an aircraft. In one illustrative example, a fuselage of an aircraft is inspected. In this process, a rail is positioned within an interior portion of the fuselage of the aircraft such that the rail extends through the interior portion of the fuselage. An inspection device is attached to the rail. The inspection device moves along the rail, and the position of the rail enables the inspection device to inspect the interior portion. Video data is sent to a computer system over a wireless communications link between the inspection device and the computer system. The video data is displayed on a display system for the computer system. Inspection operations are performed in the interior portion of the fuselage with the inspection device attached to the rail when commands to perform inspection operations are received from the computer system over a wireless communications link between the inspection device and the computer system.

In one illustrative example, one or more solutions are present that overcome a problem with the manner in which inspections such as visual inspections are currently performed on aircraft when a limited number of inspectors that are trained or experienced and are available to travel to the locations where aircraft maintenance for aircraft manufacturing is performing visual inspection of aircraft. One or more solutions in the illustrative examples can reduce or eliminate travel time needed by an inspector to inspect aircraft.

In the illustrative example, one or more technical solutions are present in which an inspector can remotely inspect an aircraft using remote inspection system214. Remote inspection system214can be assembled and installed by personnel at the location. The inspector can operate inspection device304in remote inspection system214perform inspection operations without needing to be present the location fuselage to perform the inspection.

As a result, the use of inspection system214can enable performing remote inspections in which it is unnecessary for inspectors to travel to each site for inspections such that at least one of a need for additional inspectors or inspection cycle time is reduced. Further, aircraft availability can be increased and maintenance down time reduced by using remote inspection system214.

The description of the different illustrative embodiments has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the embodiments in the form disclosed. The different illustrative examples describe components that perform actions or operations. In an illustrative embodiment, a component can be configured to perform the action or operation described. For example, the component can have a configuration or design for a structure that provides the component an ability to perform the action or operation that is described in the illustrative examples as being performed by the component.