Inspection system for alignment in restricted volumes

An inspection system is presented. The inspection system comprises a remotely controllable imaging assembly and a scale reticle. The remotely controllable imaging assembly includes a camera and a lens system. The lens system includes a tunable-focus lens and a magnifying lens between the camera and the tunable-focus lens. The scale reticle is positioned within a sight line of the camera of the imaging assembly such that the scale reticle is between the imaging assembly and a target.

BACKGROUND INFORMATION

This disclosure relates generally to inspection systems, and more specifically, to inspection systems within a restricted volume. Still more particularly, the present disclosure relates to systems and methods for measuring an alignment of components.

A folding wing design may be used to reduce the span of wings to fit within the limitations of an existing airport's infrastructure. A folding wing design has folding wing tips that may be folded to fit within runways, taxiways, and gate areas, and that may be extended prior to takeoff to increase wingspan.

Folding wing systems include latch pins to secure the folding wing systems in an extended position. Each latch pin desirably extends into bores within two structures, such as a clevis and a lug, to secure the folding wing system. Misalignment between the bores creates side loading in the latch pin actuator as the pin extends. Side loading on the latch pin actuator is undesirable.

To prevent or reduce misalignment, structural end stop shims are used to adjust the extended position of the wing tip for flight. However, placing and altering structural end stop shims is an iterative process. Shims are added and removed until the bores are aligned, such that a latch pin does not scrape undesirably against the bores.

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. Specifically, one issue is to find a method and apparatus for aligning components of a folding wingtip system without trial and error adding and removing of shims.

SUMMARY

An illustrative embodiment of the present disclosure provides an inspection system. The inspection system comprises a remotely controllable imaging assembly and a scale reticle. The remotely controllable imaging assembly includes a camera and a lens system. The lens system includes a tunable-focus lens and a magnifying lens between the camera and the tunable-focus lens. The scale reticle is positioned within a sight line of the camera of the imaging assembly such that the scale reticle is between the imaging assembly and a target.

Another illustrative embodiment of the present disclosure provides an inspection system. The inspection system comprises a remotely controllable imaging assembly including a camera and a lens system. The imaging assembly is configured to take an image of a target at a first focal plane of the lens system and take a second image of a reticle at a second focal plane of the lens system. The imaging assembly is configured such that the second image of the scale reticle has a resolution of 0.001 inch when the scale reticle is between approximately 0.5 inches and approximately 6 inches from the imaging assembly and the reticle is up to an inch away from the target.

A further illustrative embodiment of the present disclosure provides a method. An imaging assembly is attached to a component. A reticle of the inspection system is positioned within a sight line of the camera, such that the reticle is between the imaging assembly and a target. A first image of the target is taken at a first focal plane of the lens system. A second image of the reticle is taken at a second focal plane of the lens system. An alignment of the target is measured relative to the reticle using the first image and the second image.

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 an aircraft may benefit from a long wingspan in flight while being able to reduce the wingspan when operating at an airport. The illustrative embodiments recognize and take into account that folding wing tip assemblies may be desirable with respect to increasing the flexibility of where an aircraft may operate. In particular, by being able to reduce the wingspan while on the ground, an aircraft may be able to operate at more airports than if the aircraft could not reduce its wingspan while on the ground. With the longer wingspan during flight, benefits may include increased fuel efficiency.

The illustrative embodiments recognize and take into account that several designs of a folding wing tip (FWT) assembly use four pin and bushing sets to lock the folding wing tip (FWT) in ready-for-flight condition prior to take-off. The illustrative embodiments recognize and take into account that the alignment of each individual pin to each individual bushing is critical for desirable latch or unlatch performance and load transfer during flight. The illustrative embodiments also recognize and take into account that having desired alignment of each pin may increase actuator life or decrease maintenance frequency. The illustrative embodiments recognize and take into account that each individual pin/bushing set uses individually measured, fitted and installed shims to assure proper pin-to-bushing alignment during operation. The illustrative embodiments recognize and take into account that four sets of pin/bushing fittings are not in single bore alignment and do not have a single visible line of sight. The illustrative embodiments further recognize and take into account that the four sets of pin/bushing fittings require precise measurements in the transverse axes at different focal planes located along the longitudinal sight axis. The illustrative embodiments allow simultaneous measurement of initial pin-to-bushing bore alignment, and measurement of desired shim thickness.

The illustrative embodiments recognize and take into account that existing methods of alignment include mechanical fit checks, using a borescope, using a camera, or using laser-line and sensor systems. The illustrative embodiments recognize and take into account that each of these methods may be at least one of undesirably expensive, time-consuming, or difficult to implement.

For example, “at least one of item A, item B, or item C” may include, without limitation, item A, item A and item B, or item B. This example also may include item A, item B, and item C or item B and item C. Of course, any combination of these items may be present. In other examples, “at least one of” may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or other suitable combinations.

The illustrative embodiments recognize and take into account that mechanical fit checks use metal bluing to show where pin-and-bushing interferences occur, then trial and error shim fitting to reduce said interferences. The illustrative embodiments recognize and take into account that after using a borescope to acquire a single image at a time, an operator uses his own judgment to determine proper shim size for the bushing or pin housings. The illustrative embodiments recognize and take into account that laser-line and sensor systems may be difficult or impossible to install and use on pin-and-bushing alignment systems which use cycling during alignment checks.

The illustrative embodiments recognize and take into account that a camera and target system with a manually adjusted lens to focus at several distances on intermediate and far distance targets may use extra operator precautions when preloading is present. Accordingly, a manually adjusted lens may be undesirable when preloading is present. The illustrative embodiments recognize and take into account that a camera and target system without a remotely adjusted lens may provide protection for the operator from preloading. The illustrative embodiments recognize and take into account that the safety of a manufacturing environment may be increased through the use of a camera and target system with a remotely adjusted lens.

The illustrative embodiments further recognize and take into account that maintenance and repair of aircraft contribute to undesirable downtime for commercial flights. Further, maintenance and repair contributes to loss of revenue for commercial flights. For example, some revenue flights may need to be canceled or delayed to perform maintenance or trouble-shooting. Thus, the illustrative embodiments recognize and take into account that reducing maintenance and trouble-shooting downtime is desirable.

The illustrative examples further recognize and take into account that other components having restricted volumes may benefit from inspection. Yet more specifically, the illustrative examples additionally recognize and take into account that other components other than folding wingtip assemblies, such as, but not limited to, doors, aircraft fuselage components, or other large hinged structures may benefit from alignment inspection and quantifiable shimming or other modifications.

The illustrative embodiments present a machine-vision based system enabling simultaneous alignment or adjustment of one or multiple bearing or bushing-and-pin sets in areas of restricted access. The system consists of one or multiple imaging devices, such as controllable-focus digital cameras controlled remotely, that can sequentially focus on a series of alignment targets and reticles located at different focal lengths from the imaging devices. Each target and reticle is precisely positioned to the bearing or bushing-and-pin sets in question. A monitor or computer may be used to view all images simultaneously, allowing all component sets to be aligned or adjusted simultaneously.

With reference now to the figures, and in particular, with reference toFIGS. 1, 2, and 3, illustrations of an aircraft having a folding wing system is depicted in accordance with illustrative embodiments.FIG. 1depicts aircraft100in a flight position,FIG. 2depicts aircraft100in a taxiing or folded position, andFIG. 3depicts aircraft100in a preloaded position. Reference numerals used inFIG. 1are also used inFIGS. 2 and 3.

Aircraft100is an example of an aircraft in which a folding wing system may be implemented in accordance with an illustrative embodiment. In the illustrative embodiment, aircraft100includes wing102and wing104attached to body106; engine108attached to wing102; and engine110attached to wing104.

Wing104includes wing fold system128to move unfixed portion122with respect to fixed portion126. Wing102includes wing fold system130to move unfixed portion120with respect to fixed portion124. Wing fold system128and wing fold system130each include a latch assembly (not depicted inFIG. 1orFIG. 2) in accordance with an illustrative embodiment.

FIG. 3depicts wing102and wing104in a preloaded position. A preloaded position for wing104is one in which a load is applied to overextend unfixed portion122relative to fixed portion126. A preloaded position for wing102is one in which a load is applied to overextend unfixed portion120relative to fixed portion124. By applying a preload to a folding wing tip, the wing tip hinge is stiffened such that the bores will not “bounce” during insertion of latch pins. By applying a preload to a folding wing tip, the wing tip is restricted from additional motion in one direction by the preload and restricted from additional motion in the opposite direction by a wing stop. The amount that unfixed portion122or unfixed portion120is overextended is affected by the wing stops.

In some illustrative examples, a preloaded position for wing102and wing104may only have unfixed portion122and unfixed portion120at a small (greater than zero, but less than five degrees) angle relative to fixed portion126and fixed portion124respectively. In one illustrative example, the preloaded position for a wing is between approximately 1 degree and 2 degrees.

Aircraft100is an example of an aircraft in which a folding wing system is implemented in accordance with an illustrative embodiment. For example, folding wingtip assembly404ofFIG. 4discussed below, is implemented in at least one of wing102or wing104.

This illustration of aircraft100is provided for purposes of illustrating one environment in which the different illustrative embodiments may be implemented. The illustration of aircraft100inFIG. 1is not meant to imply architectural limitations to the manner in which different illustrative embodiments may be implemented. For example, aircraft100is shown as a commercial passenger aircraft. The different illustrative embodiments may be applied to other types of aircraft, such as private passenger aircraft, a rotorcraft, and other suitable types of aircraft.

Further, although inspection systems such as inspection system434are described to inspect folding wingtip assemblies, inspection system434may be used to inspect other components or other structures.

Turning now toFIG. 4, an illustration of a block diagram of a manufacturing environment is depicted in accordance with an illustrative embodiment. Manufacturing environment400includes platform401. Platform401is any desirable type of structure receiving assembly, manufacturing, or other desirable processes in manufacturing environment400. In some illustrative examples, platform401takes the form of aircraft402. Aircraft402may be a representation of aircraft100ofFIGS. 1-3. Thus, manufacturing environment400is an example of an environment in which aircraft100may be manufactured or assembled.

In this illustrative example, aircraft402includes folding wingtip assembly404. Folding wingtip assembly404is a component of at least one of wing102or wing104. Folding wingtip assembly404includes pin and bushing assemblies406. Pin and bushing assemblies406form a rotational axis for folding wingtip assembly404. Pin and bushing assemblies406includes any desirable number of pin and bushing assemblies. In this illustrative example, pin and bushing assemblies406includes pin and bushing assembly408, pin and bushing assembly410, pin and bushing assembly412, and pin and bushing assembly414.

Components of pin and bushing assembly414may be representative of components of the remaining pin and bushing assemblies of pin and bushing assemblies406. Pin and bushing assembly414includes pin416and bushing418. Pin416extends through bushing418to hold folding wingtip assembly404in extended position419. Extended position419is an operating position during flight.

Bushing418includes lug420and clevis422. Lug420is a moving lug. In some illustrative examples, lug420is a component of folding wingtip assembly404that moves relative to clevis422when moving folding wingtip assembly404between extended position419, retracted position424, and preloaded position426. Retracted position424may be a position for folding wingtip assembly404when aircraft402is taxiing or parked.

Preloaded position426is when the load of the wingtip is loaded into the fixed portion of the wing. An actuator is used to overextend the folding wing tip to push it into the stops in the extended position. A pre-load is an advanced load pre-applied before flight loads are applied to the wing. In preloaded position426, a pushing action is applied to press against end stops of folding wingtip assembly404.

In preloaded position426, folding wingtip assembly404is held tight, such that folding wingtip assembly404doesn't move when moving pin416. In preloaded position426, pin416may be placed into or out of bore430and bore428. Any desirable amount of force may be used to place folding wingtip assembly404into preloaded position426. In one illustrative example, 70,000 in/lbs of torque is the load applied to folding wingtip assembly404.

During manufacturing of aircraft402, pin and bushing assemblies406are aligned. Pin and bushing assemblies406are aligned to reduce or prevent pin416from impacting clevis422or lug420when pin416is inserted or removed from bore428and bore430.

Pin and bushing assemblies406are positioned in a restricted volume within folding wingtip assembly404. Inspection system434is used to inspect the alignment of pin and bushing assembly414within the restricted volume. Inspection system434is configured to fit within the restricted volume within folding wingtip assembly404.

Although this illustrative example discusses the use of inspection system434with reference to folding wingtip assembly404of aircraft402, inspection system434may be used in any desirable restricted volume. Further, inspection system434may be used in any situation in which an inspection system434is desirably used remotely. Yet further, inspection system434may be used in any situation in which inspection system434meets the technical inspection requirements, such as resolution, magnification, distance to target, or any other inspection standards.

Inspection system434comprises remotely controllable imaging assembly436and scale reticle437. In some illustrative examples, imaging assembly436is configured to fit within an envelope having maximum dimensions of 4.6 inch by 2 inch by 2 inch. In one illustrative example, imaging assembly436is configured to fit within a confined space of less than 50 cubic inches. In some illustrative examples, imaging assembly436may be yet smaller. In one of these illustrative examples, imaging assembly436is configured to fit within a confined space of less than 20 cubic inches.

When imaging assembly436is used to inspect pin and bushing assembly414, imaging assembly436is horizontal. Imaging assembly436is positioned such that the sight line of camera438is parallel to a floor of manufacturing environment400.

In some illustrative examples, scale reticle437is up to an inch away from target446. In these illustrative examples, imaging assembly436is configured to provide 1 inch of tunable-focus in front of target446.

Magnifying lens444increases or decreases the effective size of an image captured by camera438. In imaging assembly436, magnifying lens444is between camera438and tunable-focus lens442.

Tunable-focus lens442takes the form of any desirable lens having a focus that may be tuned. In some illustrative examples, tunable-focus lens442may be a liquid lens. In other illustrative examples, tunable-focus lens442is an electro-mechanical lens.

Imaging assembly436may be remotely controlled to inspect the alignment of pin and bushing assemblies406. In some illustrative examples, each of camera438, magnifying lens444, and tunable-focus lens442is controllable remotely. By having imaging assembly436remotely controlled, operators may be a desirable distance from folding wingtip assembly404when folding wingtip assembly404is preloaded.

The alignment of pin and bushing assemblies406is determined based on the alignment of scale reticle437and target446. Imaging assembly436is configured to take images of scale reticle437and target446. In this illustrative example, target446is associated with pin416configured to move from bore432of clevis422through bore428of lug420and into bore430of clevis422.

When one component is “associated” with another component, the association is a physical association in the depicted examples. For example, a first component may be considered to be associated with a second component by being secured to the second component, bonded to the second component, mounted to the second component, welded to the second component, fastened to the second component, and/or connected to the second component in some other suitable manner. The first component also may be connected to the second component using a third component. The first component may also be considered to be associated with the second component by being formed as part of and/or an extension of the second component.

In these illustrative examples, target446may be associated with pin416by being painted onto, formed as a part of, or otherwise bonded to pin416. For example, target446may be cut or formed into an end of pin416. As another example, target446may be a sticker or other item adhered to pin416. In yet another example, target446is painted or drawn onto an end of pin416.

By determining the alignment of scale reticle437and target446, the alignment of bore428and bore432is determined. By determining the alignment of scale reticle437and target446, the alignment of clevis422and lug420is determined.

Measuring the alignment of scale reticle437and target446may also be referred to as measuring an axial offset of scale reticle437and target446. An axial offset of scale reticle437and target446is a difference in locations of the central axis running through the center of scale reticle437and into imaging assembly436and the central axis running through target446and into imaging assembly436. Some axial offset is considered within tolerance. An axial offset that is within tolerance does not cause undesirable interference between pin416and lug420or clevis422. When the axial offset is found to be within tolerance, scale reticle437and target446are found to be desirably aligned.

Inspection system434further comprises mount448. Mount448may also be referred to as a centering mount. Mount448supports camera438and lens system440. Mount448is configured to attach imaging assembly436to first component450and center imaging assembly436relative to bore430of first component450.

As depicted, inspection system434also includes reticle mount454. Reticle mount454is configured to secure scale reticle437within bore428of second component456. In some illustrative examples, reticle mount454includes two sides positioned on opposite sides of bore428. The two sides of reticle mount454may be secured using any desirable means. In one illustrative example, reticle mount454is secured using bolt-type fasteners. In another illustrative example, reticle mount454is secured using spring loaded locks.

As depicted, imaging assembly436is connected to first component450, and scale reticle437is connected to second component456. In one illustrative example, first component450is a fixed component and second component456is a moveable component. Imaging assembly436is configured to take an image of scale reticle437within the moveable component and an image of target446for measurement of an alignment of target446relative to scale reticle437. Imaging assembly436is configured such that an image of scale reticle437has a resolution of 0.001 inch. More specifically, in some illustrative examples, imaging assembly436is configured such that an image of scale reticle437has a resolution of 0.001 inch when scale reticle437is between approximately 0.5 inches and approximately 6 inches from imaging assembly436.

Scale reticle437has distance marks445of 0.001 inch. When an image of scale reticle437has a resolution of 0.001 inch, distance marks445of 0.001 inch distance are clear in the image.

Imaging assembly436is connected to computer system458via cables460. Computer system458is used to remotely control imaging assembly436, including remote control of tuning of tunable-focus lens442and remotely controlling capture of images using image sensor462of camera438. Computer system458may also be used to analysis of images captured using image sensor462. For example, processor464may be used to analyze a first image and a second image by overlaying either the second image or data representative of the second image onto the first image.

The illustration of inspection system434and platform401inFIG. 4are not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the ones illustrated may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in an illustrative embodiment. For example, although the design and layout of inspection system434are described as configured to fit within a specified space of folding wingtip assembly404of aircraft402, inspection system434may be used in any desirable type of platform401.

As another example, lighting system466may be present and adhered to or connected to a portion of platform401to be inspected by inspection system434. Lighting system466may provide sufficient light for taking images of at least one of scale reticle437or target446with inspection system434. In one illustrative example, lighting system466is formed of LED's468removably connected to lug420of pin and bushing assembly414.

As yet another example, although cables460are depicted as connecting computer system458and imaging assembly436, in other illustrative examples, imaging assembly436may be connected to computer system458wirelessly. Wireless communications between computer system458and imaging assembly436may affect at least one of camera438or lens system440.

As a further example, a number of additional components may connect camera438and lens system440. In one illustrative example, a number of mirrors and a desirable housing connects camera438and lens system440. This number of mirrors and desirable housing may function similarly to a periscope. By providing a number of mirrors and a housing, camera438need not be in-line with lens system440. Although camera438may not be in-line with lens system440, lens system440is still within the sight line of camera438due to the number of mirrors and housing. Likewise, if a number of mirrors and a housing are present, scale reticle437may still be present in the sight line of camera438even if scale reticle437is not in-line with camera438.

Further, by providing a number of mirrors and a housing, camera438may be outside of a small or limited space. By providing a number of mirrors and a housing, camera438may have a larger volume or larger dimensions than allowed by a confined space for inspection.

In another illustrative example, a coherent fiber optic bundle may connect camera438and lens system440. In this illustrative example, coherent fiber optic bundle may function similarly to a flexible periscope. Similar to using a number of mirrors and a housing, coherent fiber optic bundle may allow camera438to take images within a small or limited space without placing camera438within the small or limited space.

Turning now toFIG. 5, an illustration of an isometric view of a folding wingtip assembly which may be aligned using an inspection system is depicted in accordance with an illustrative embodiment. Folding wingtip assembly500may be a physical implementation of folding wingtip assembly404ofFIG. 4.

Folding wingtip assembly500includes fixed portion502and unfixed portion504. As depicted, unfixed portion504is wing tip506. Wing tip506is folded in order to facilitate the installation of a scale reticle, such as scale reticle437ofFIG. 4, within a bore, such as bore508, bore510, bore512, or bore514of unfixed portion504. As depicted, bore508is within moving lug516, bore510is within moving lug518, bore512is within moving lug520, and bore514is within moving lug522.

As depicted, scale reticle524is installed within bore510of moving lug518. During installation, reticle mount526may be aligned with an indicator. In one non-limiting example, reticle mount526is aligned during installation with cross hairs drawn on a moving lug surface. In this illustrative example, when wing tip506is folded, the line of scale reticle524will be horizontal. The line of scale reticle524will rotate 90 degrees when wing tip506is extended. When scale reticle524is installed horizontally, scale reticle524will be vertical when the tip is extended.

Each moving lug is paired with a clevis to form a respective bushing. To inspect a bushing and pin assembly for alignment, unfixed portion504will be rotated such that the scale reticle is in line of sight of a camera of an imaging assembly, such as camera438of imaging assembly436ofFIG. 4.

One or more scale reticles may be installed in folding wingtip assembly500at one time. The greater number of scale reticles and imaging assemblies, the lower the inspection and alignment time. For example, when only one scale reticle and imaging assembly is utilized, the scale reticle will be used to align one of bore508, bore510, bore512, or bore514and then folding wingtip assembly500will be powered down, and the scale reticle moved to another bore of bore508, bore510, bore512, or bore514. This scale reticle would be used in each of bore508, bore510, bore512, and bore514to inspect each bore.

However, if four scale reticles and four imaging assemblies were provided, respective alignments for each of bore508, bore510, bore512, or bore514could be performed substantially simultaneously. Substantially simultaneous alignment would result in at least one of reduced cycle time, reduced alignment time, or reduced cost.

The imaging assemblies can be installed either when wing tip506is folded, or may be extended through the maintenance access hatches on the underside of wing tip506. Imaging assemblies may be tested prior to extending wing tip506. For example, to test an imaging assembly, a camera is turned on and the lens system is used to sight/focus a target under ambient (low) light. When performed, this check verifies that the cameras are operating prior to extending wing tip506.

Turning now toFIG. 6, an illustration of a cross-sectional view of a folding wingtip assembly and inspection systems for aligning the folding wingtip assembly is depicted in accordance with an illustrative embodiment.

Folding wingtip assembly600is a physical implementation of folding wingtip assembly404ofFIG. 4. Folding wingtip assembly600has pin and bushing assembly602, pin and bushing assembly604, pin and bushing assembly606, and pin and bushing assembly608.

As depicted, four inspection systems are installed relative to the four pin and bushing assemblies. By providing four inspection systems, the four pin and bushing assemblies may be aligned substantially simultaneously.

For example, inspection system610is connected to pin and bushing assembly602. Inspection system612is connected to pin and bushing assembly604. Inspection system614is connected to pin and bushing assembly606. Inspection system616is connected to pin and bushing assembly608.

Inspection system610includes imaging assembly618and scale reticle620. Imaging assembly618is connected to bore622of clevis624. Imaging assembly618includes a camera (not depicted) and a lens system (not depicted). The lens system includes a tunable-focus lens (not depicted) and a magnifying lens (not depicted) between the camera and the tunable-focus lens.

Each of inspection system610, inspection system612, inspection system614, and inspection system616have a respective camera and lens system. In some illustrative examples, each of inspection system610, inspection system612, inspection system614and inspection system616have substantially the same camera and lens system. For example, the same type of camera and the same type of lenses may be present in inspection system610, inspection system612, inspection system614and inspection system616.

Scale reticle620is connected to bore626of moving lug628. Imaging assembly618takes a first image of target630on latch pin632at a first focal plane of a lens system of imaging assembly618. In the first image, target630on latch pin632is within focus. Imaging assembly618takes a second image of scale reticle620at a second focal plane of a lens system of imaging assembly618. In the first image, target630on latch pin632is within focus. In the second image, scale reticle620is in focus. An axial offset of a central axis of scale reticle620and a central axis of target630is determined. Alignment of clevis624and moving lug628is determined based on the axial offset.

Inspection system612includes imaging assembly634and scale reticle636. Imaging assembly634is connected to bore638of clevis640. Scale reticle636is connected to bore642of moving lug644. Imaging assembly634takes a first image of target646on latch pin648at a first focal plane of a lens system of imaging assembly634. Imaging assembly634takes a second image of scale reticle636at a second focal plane of a lens system of imaging assembly634. In the first image, target646on latch pin648is within focus. In the second image, scale reticle636is in focus. An axial offset of a central axis of scale reticle636and a central axis of target646is determined. Alignment of clevis640and moving lug644is determined based on the axial offset.

Inspection system614includes imaging assembly649and scale reticle650. Imaging assembly649is connected to bore652of clevis654. Scale reticle650is connected to bore656of moving lug658. Imaging assembly649takes a first image of target660on latch pin662at a first focal plane of a lens system of imaging assembly649. Imaging assembly649takes a second image of scale reticle650at a second focal plane of a lens system of imaging assembly649. In the first image, target660on latch pin662is within focus. In the second image, scale reticle650is in focus. An axial offset of a central axis of scale reticle650and a central axis of target660is determined. Alignment of clevis654and moving lug658is determined based on the axial offset.

Inspection system616includes imaging assembly663and scale reticle664. Imaging assembly663is connected to bore665of clevis666. Scale reticle664is connected to bore668of moving lug670. Imaging assembly663takes a first image of target672on latch pin674at a first focal plane of a lens system of imaging assembly663. Imaging assembly663takes a second image of scale reticle664at a second focal plane of a lens system of imaging assembly663. In the first image, target672on latch pin674is within focus. In the second image, scale reticle664is in focus. An axial offset of a central axis of scale reticle664and a central axis of target672is determined. Alignment of clevis666and moving lug670is determined based on the axial offset.

Following installation of inspection system610, inspection system612, inspection system614, and inspection system616, the wing tip is lowered. Once the wing tip has been lowered, the wing tip is commanded to the preloaded position. The preloaded position may be many tens of thousands of pounds of force applied to the joint. Images of the respective scale reticles and targets are taken when the wing tip is in the preloaded position.

Although four inspection systems are depicted, any desirable number of inspection systems may be used. For example, only two inspection systems may be used, as opposed to four. When two inspection systems are used, the two inspection systems are initially used to determine an alignment of two of the pin and bushing assemblies. After aligning two of the pin and bushing assemblies, the two inspection systems would be removed and then relocated to the other two of the pin and bushing assemblies. Relocation of the inspection systems leads to an extra set of steps to repeat image capture after folding the wing tip and moving the setups to the remaining locations.

Each imaging assembly and scale reticle is removable. As can be seen inFIG. 6, the four inspection systems should be removed to allow the latch pins to extend through each of the four pin and bushing assemblies during normal operation of folding wingtip assembly600. Thus, following inspection and alignment, the imaging assemblies and scale reticles are removed from the assembly.

Turning now toFIG. 7, an illustration of an exploded view of an inspection system is depicted in accordance with an illustrative embodiment. Inspection system700is a physical implementation of inspection system434ofFIG. 4.

Imaging assembly704may be remotely controlled to inspect alignment of components in a structure. Imaging assembly704may be referred to as a remotely controllable imaging assembly. In some illustrative examples, each of camera710, magnifying lens712, and tunable-focus lens714is controllable remotely. By having imaging assembly704remotely controlled, operators may be a desirable distance from a structure during inspection.

Mount702is a physical implementation of mount448ofFIG. 4. Mount702holds camera710relative to a first component (not depicted). In some illustrative examples, mount702may also be referred to as a “camera mount.” Imaging assembly704is a physical implementation of imaging assembly436ofFIG. 4. Scale reticle706is a physical implementation of scale reticle437ofFIG. 4. Reticle mount708is a physical implementation of reticle mount454.

As can be seen inFIG. 7, scale reticle706is connected to reticle mount708to connect. Reticle mount708connects scale reticle706to a second component (not depicted). Imaging assembly704rests on mount702which is connected to ring703to connect imaging assembly704to a first component.

The first component and the second component may be any desirable components or structures. As can be seen from the description above, there are two sets of mounting hardware per location. In some illustrative examples, the first component and the second component are portions of a folding wingtip assembly. In these illustrative examples, scale reticle706is installed in the bore (not depicted) of the moving lug (not depicted). In these illustrative examples, mount702is installed on the forward fixed lug (not depicted), with camera710facing aft toward its locking pin actuator (LPA) (not depicted).

Turning now toFIG. 8, an illustration of an isometric view of portions of an inspection system is depicted in accordance with an illustrative embodiment. View800is a view of an assembled portion of inspection system700ofFIG. 7. The assembled portion includes mount702, ring703, and imaging assembly704ofFIG. 7. As depicted, imaging assembly704rests on shelf portion802of mount702. Ring portion804of mount702is connected to ring703. When inspection system700ofFIG. 7is installed, ring portion804is positioned on one side of a bore, while ring703is positioned on the opposite side of the bore.

FIG. 8is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Although camera710is depicted as directly connected to a lens system comprising magnifying lens712and tunable-focus lens714, additional components may be present in other illustrative examples. In some non-depicted illustrated examples, a number of optic structures, such as mirrors, prisms, fiber optic materials, or other optic structures may be present between camera710and magnifying lens712.

When additional components are present between camera710and magnifying lens712, camera710may not rest on mount702. In some illustrative examples when a number of optic structures are positioned between camera710and magnifying lens712, camera710may extend past mount702. When a number of optic structures are positioned between camera710and magnifying lens712, camera710need not be positioned within an area to be inspected. For example, when a number of optic structures are positioned between camera710and magnifying lens712, camera710need not be in-line with a joint, such as pin and bushing assembly602, pin and bushing assembly604, pin and bushing assembly606, or pin and bushing assembly608ofFIG. 6.

Turning now toFIG. 9, an illustration of an exploded view of a mount and imaging assembly is depicted in accordance with an illustrative embodiment. View900is a view of imaging assembly704and mount702. More specifically, view900is a view of imaging assembly704separated from mount702. However, in view900, imaging assembly704is assembled. As depicted, tunable-focus lens714is a liquid lens. However, tunable-focus lens714may take the form of any desirable type of tunable lens. For example, tunable-focus lens714may instead be an electro-mechanical lens.

Turning now toFIG. 10, an illustration of an isometric view of an imaging assembly is depicted in accordance with an illustrative embodiment. View1000is an isometric view of imaging assembly704ofFIGS. 7-9. In view1000, ports1002for connecting camera710and tunable-focus lens714to a computer system are visible.

Turning now toFIG. 11, an illustration of an isometric side view of an imaging assembly connected to a folding wingtip assembly is depicted in accordance with an illustrative embodiment. As depicted in view1100, imaging assembly704rests on mount702such that tunable-focus lens714is closest to items of folding wingtip assembly1102to be inspected, while camera710is the farthest from the items to be inspected.

Turning now toFIG. 12, an illustration of an exploded view of a scale reticle and a reticle mount is depicted in accordance with an illustrative embodiment. As depicted in view1200, scale reticle706is connected to first portion1202of reticle mount708. Scale reticle706has distance marks1204. To connect scale reticle706to a bore (not depicted) of a component (not depicted), first portion1202of reticle mount708and scale reticle706is placed on one side of a bore while securing portion1206of reticle mount708is placed on the opposite side (not depicted).

In other words, to install reticle mount708, the two pieces, first portion1202of reticle mount708and securing portion1206of reticle mount708, are secured on either side of the moving lug bore (not depicted). Fasteners extend through first portion1202attached to scale reticle706and connects reticle mount708on both sides of the component.

In this illustrative example, the side of first portion1202with the three screws faces out toward the latch pin actuator (LPA) (not depicted). Reticle mount708may be aligned with cross hairs drawn on a component's surface, such as a moving lug surface. When the wing tip is folded, the reference line of the scale reticle will be horizontal. It will rotate 90 degrees to be vertical when the wing tip is extended.

Turning now toFIG. 13, an illustration of an isometric view of a lighting system installed on a moving lug of a folding wingtip assembly is depicted in accordance with an illustrative embodiment. Lighting system1300may be optionally included to enhance inspection system700ofFIG. 7, or inspection system434ofFIG. 4. As depicted, moving lug1302of folding wingtip assembly1304may be a physical implementation of lug420of folding wingtip assembly404inFIG. 4. Moving lug1302may be one of moving lug516, moving lug518, moving lug520, or moving lug522ofFIG. 5.

As depicted, lighting system1300includes light emitting diode (LED) strips1306. Like components of inspection system434, lighting system1300is desirably removable and reusable.

In some illustrative examples, to install lighting system1300, two-sided tape is applied to each of LED strip1308and LED strip1310. Two-sided tape provides a removable adhesive force. After applying two-sided tape to each of LED strip1308and LED strip1310of LED strips1306, the LED strips are attached to a component.

In some illustrative examples, LED strips1306are attached to an aft side of moving lug1302. As depicted, a portion of a reticle mount such as reticle mount454ofFIG. 4is also positioned within moving lug1302. LED strips1306may be applied in any desirable pattern. LED strips1306desirably provide sufficient light to view the scale reticle (not depicted) and the target (not depicted). As depicted, LED strips1306are applied on opposite sides of bore1312with the reticle (not depicted) installed. In some other illustrative examples, LED strips1306may include an additional LED strip and may be applied in a triangle pattern around the bore.

LED strips1306are desirably installed to be as flush as possible. LED strip wires1314are routed desirably back along spine1316of moving lug1302and out of the wing tip (not depicted). In routing LED strip wires1314, it is desirable to prevent or reduce rubbing or binding of LED strip wires1314. In some illustrative examples, there is a sizable gap at the back when the wing tip is extended and LED strip wires1314will not rub or bind.

Turning now toFIG. 14, an illustration of a view of a target taken with an inspection system is depicted in accordance with an illustrative embodiment. View1400is a physical depiction of an image of target446ofFIG. 4. View1400includes target1402. As depicted, target1402is a dot substantially centered on an end of a latch pin. More specifically, target1402is a dot substantially centered on end1404of latch pin1406, such as pin416shown inFIG. 4, closest to a scale reticle (not depicted).

In view1400, representation1408is overlaid on target1402. Representation1408is a circle having substantially the same diameter and center as target1402. In some illustrative examples, representation1408is used to determine an axial offset between target1402and a scale reticle, such as scale reticle437ofFIG. 4. In some illustrative examples, the image of target1402is used to determine an axial offset between target1402and a scale reticle (not depicted), such as scale reticle437.

Representation1408may be set by an operator. In other illustrative examples, representation1408may be set by an automated program. Although representation1408is depicted as a circle, representation1408may take any desirable form. For example, representation1408may be a solid dot, a circle with a center point, a set of cross-hairs, or any desirable combination of shapes. Representation1408is created from an image taken by a camera, such as camera710ofFIG. 7.

Turning now toFIG. 15, an illustration of a view of a representation of a target overlaid onto an image of a scale reticle and the out of focus target is depicted in accordance with an illustrative embodiment. View1500is a physical depiction of an image of scale reticle437and target446ofFIG. 4.

View1500includes target1402and representation1408ofFIG. 14. In view1500, distance marks1502of scale reticle1504are also visible. In some illustrative examples, scale reticle1504may be the same as scale reticle706. In other illustrative examples, scale reticle1504and scale reticle706are different. Distance marks1502are a physical implementation of distance marks445ofFIG. 4. View1500may be referred to as an image of scale reticle1504.

In view1500, distance marks445of 0.001 inch spacing are visible and clear. Thus, view1500may be referred to as an image of scale reticle1504with a resolution of 0.001 inch. An unedited view of a scale reticle, such as scale reticle1504, with a resolution of 0.001 inch would not have representation1408superimposed.

View1500is an image of scale reticle1504modified to overlay representation1408. Once images of target1402and scale reticle1504are captured, an analyzer computer program is utilized to identify the axial offset (not depicted) of target1402from scale reticle1504. This axial offset may also be referred to as the offset of latch pin1406associated with target1402. As depicted, this offset may be an offset in the vertical direction.

Using the analyzer, paired pin and reticle image files (such asFIG. 14andFIG. 15without representation1408) for a given location (1-4, such as pin and bushing assemblies602,604,606, or608) are analyzed. A representation, such as representation1408may be created by aligning a red circle with target1402on the pin image file. In some illustrative examples, target1402is a circular indentation machined into the center of the face of latch pin1406. When viewing the pin image file, the center of the pin image may be identified by aligning representation1408with target1402.

After creating representation1408, a reticle image with the pin center digitally overlaid on the original image is displayed.FIG. 15is an example of a reticle image with a pin center overlaid. The pin center digitally overlaid may either be target1402or representation1408. InFIG. 15, representation1408is overlaid onto the reticle image.

The distance from the center of latch pin1406to the center of scale reticle1504is measured. The distance between the center of latch pin1406and the center of scale reticle1504is either manually or automatically measured.

In some illustrative examples, the center of latch pin1406to be measured is point1506within representation1408. Note that the reticle is printed with 0.000 at its center. This serves as the center of the moving lug bore, when measured against either target1402or representation1408indicating the center of latch pin1406. In these illustrative examples, measuring the difference includes measuring a distance between point1506and the 0.000 at the center of scale reticle1504.

In other illustrative examples in which a point is not centered within either target1402or representation1408, the pin center may be determined by the outer diameter of target1402or representation1408. For example, when there is not a point centered within target1402, an axial offset may be determined by determining the difference between the measurements of the intersections of the diameter of target1402with distance marks1502.

After determining the offset for all four pin locations, such as those shown inFIG. 6, a shim thickness is determined. If all four pin locations are individually within the +/−0.015 inches of allowable range, no action is required. If not, the wing tip is folded to access the end stop plates and adjust the shim stack installed under the end stops.

Increasing the shim stack-up will lower the moving lug bore, such as bore428ofFIG. 4, with respect to aligning with the latch pin, such as pin416, (when viewed from the perspective of the pin itself). Decreasing the shim stack-up will raise the moving lug bore, such as bore428ofFIG. 4, with respect to the pin surface.

After any adjustment, the area is cleared of personnel and the hydraulic system is pressurized. Extension of the wing tip and image capture/verification steps are repeated until the allowable clearance is achieved.

Turning now toFIG. 16, an illustration of a diagrammatic representation of imaging assemblies and connections to a computer system is depicted in accordance with an illustrative embodiment.FIG. 16may be a diagrammatic representation of connections between computer system458and imaging assembly436ofFIG. 4with an additional imaging assembly. Assembly1600includes imaging assembly1602, imaging assembly1604, and computer system1606. Imaging assembly1602and imaging assembly1604may take any desirable form. In some illustrative examples, imaging assembly704is a physical implementation of at least one of imaging assembly1602or imaging assembly1604. Imaging assembly1602and imaging assembly1604may be remotely controlled using computer system1606.

Connection1608connects computer system1606to a power source. After connecting computer system1606to the power source, the computer system may be turned on. After connecting computer system1606to the power source, USB hub1609is then connected to the power source as well using connection1610.

USB hub1609is connected to one of the USB ports, USB port1611of computer system1606, using connection1612. Each tunable-focus lens driver is connected to a USB hub port of computer system1606using connections1614. Connections1614may take the form of USB cables.

Tunable-focus lens driver1615is connected to computer system1606using connection1616. Tunable-focus lens driver1618is connected to computer system1606using connection1620. In some illustrative examples, connections1614is eliminated by connecting connection1616and connection1620direction to USB hub1609.

Ethernet hub1630is connected to the power source using power cable1636. Connection1638connects the “In” port of first Power over Ethernet (PoE) Injector1640to Ethernet hub1630. In some illustrative examples, connection1638takes the form of Cat 5 cable. Connection1642connects the “out” port of first PoE Injector1640to camera1644. Connection1642provides power over Ethernet to camera1644.

First PoE Injector1640is connected to the power source using connection1646. In some illustrative examples, connection1646is a power cord.

Connection1648connects the “In” port of second PoE Injector1650to Ethernet hub1630. In some illustrative examples, connection1648takes the form of Cat 5 cable. Connection1652connects the “out” port of second PoE Injector1650to camera1654. Connection1652provides power over Ethernet to camera1654.

Second PoE Injector1650is connected to the power source using connection1656. In some illustrative examples, connection1656is a power cord.

The illustrations of aircraft100inFIGS. 1-3, manufacturing environment400inFIG. 4, and inspection system700or portions of inspection system700inFIGS. 7-16are not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components, in addition to or in place of the ones illustrated, may be used. Some components may be unnecessary.

The different components shown inFIGS. 1-3 and 5-16may be combined with components inFIG. 4, used with components inFIG. 4, or a combination of the two. Additionally, some of the components inFIGS. 1-3 and 5-16may be illustrative examples of how components shown in block form inFIG. 4may be implemented as physical structures.

Turning now toFIG. 17, an illustration of a flowchart of a method for aligning a component and a target is depicted in accordance with an illustrative embodiment. Method1700may use inspection system434ofFIG. 4. Method1700may be used to align folding wingtip assembly500ofFIG. 5. Method1700may be used to align folding wingtip assembly600ofFIG. 6. Method1700attaches a remotely controllable imaging assembly to a component (operation1702).

Method1700positions a scale reticle of the inspection system within a sight line of the camera such that the reticle is between the imaging assembly and a target (operation1704). In some illustrative examples, positioning the scale reticle of the inspection system within the sight line of the camera of the imaging assembly is positioning the scale reticle between 0.5 inches and 6 inches from the imaging assembly.

Method1700takes a first image of the target at a first focal plane of the lens system (operation1706). Method1700takes a second image of the reticle at a second focal plane of the lens system (operation1708). Method1700measures an alignment of the target relative to the reticle using the first image and the second image (operation1710). Afterwards the method terminates.

In some illustrative examples, measuring the alignment of the target relative to the scale reticle comprises at least one of overlaying a portion of the second image onto the first image or overlaying data representative of the target within second image onto the first image. In some illustrative examples, the scale reticle is up to an inch away from the target.

For example, method1700also remotely focuses the tunable lens onto the scale reticle to change from the first focal plane of the lens system to the second focal plane of the lens system. As another illustrative example, method1700also focuses the magnifying lens on the target to set the first focal plane.

In some illustrative examples, method1700further comprises attaching the scale reticle to a bore of a movable lug, and attaching the imaging assembly of the inspection system to the component comprises attaching the imaging assembly to a bore of a clevis.

In these illustrative examples, positioning the scale reticle of the inspection system within the sight line of the camera of the imaging assembly comprises positioning the movable lug such that a bore of the movable lug is substantially concentric with the bore of the clevis. In some illustrative examples, the target is associated with a pin configured to move through the bore of the movable lug and into the bore of the clevis.

Turning now toFIG. 18, an illustration of a data processing system in the form of a block diagram is depicted in accordance with an illustrative embodiment. Data processing system1800may be used to implement processor464ofFIG. 4. Data processing system1800may be used to process data, such as images, from image sensor462ofFIG. 4. Data processing system1800may be used to send commands to equipment, such as camera438or tunable-focus lens442ofFIG. 4. As depicted, data processing system1800includes communications framework1802, which provides communications between processor unit1804, storage devices1806, communications unit1808, input/output unit1810, and display1812. In some cases, communications framework1802may be implemented as a bus system.

Processor unit1804is configured to execute instructions for software to perform a number of operations. Processor unit1804may comprise a number of processors, a multi-processor core, and/or some other type of processor, depending on the implementation. In some cases, processor unit1804may take the form of a hardware unit, such as a circuit system, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware unit.

Instructions for the operating system, applications, and/or programs run by processor unit1804may be located in storage devices1806. Storage devices1806may be in communication with processor unit1804through communications framework1802. As used herein, a storage device, also referred to as a computer-readable storage device, is any piece of hardware capable of storing information on a temporary and/or permanent basis. This information may include, but is not limited to, data, program code, and/or other information.

Memory1814and persistent storage1816are examples of storage devices1806. Memory1814may take the form of, for example, a random-access memory or some type of volatile or non-volatile storage device. Persistent storage1816may comprise any number of components or devices. For example, persistent storage1816may comprise a hard drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by persistent storage1816may or may not be removable.

Communications unit1808allows data processing system1800to communicate with other data processing systems and/or devices. Communications unit1808may provide communications using physical and/or wireless communications links.

Input/output unit1810allows input to be received from and output to be sent to other devices connected to data processing system1800. For example, input/output unit1810may allow user input to be received through a keyboard, a mouse, and/or some other type of input device. As another example, input/output unit1810may allow output to be sent to a printer connected to data processing system1800.

Display1812is configured to display information to a user. Display1812may comprise, for example, without limitation, a monitor, a touch screen, a laser display, a holographic display, a virtual display device, and/or some other type of display device.

In this illustrative example, the processes of the different illustrative embodiments may be performed by processor unit1804using computer-implemented instructions. These instructions may be referred to as program code, computer-usable program code, or computer-readable program code, and may be read and executed by one or more processors in processor unit1804.

In these examples, program code1818is located in a functional form on computer-readable media1820, which is selectively removable, and may be loaded onto or transferred to data processing system1800for execution by processor unit1804. Program code1818and computer-readable media1820together form computer program product1822. In this illustrative example, computer-readable media1820may be computer-readable storage media1824or computer-readable signal media1826.

Computer-readable storage media1824is a physical or tangible storage device used to store program code1818rather than a medium that propagates or transmits program code1818. Computer-readable storage media1824may be, for example, without limitation, an optical or magnetic disk or a persistent storage device that is connected to data processing system1800.

Alternatively, program code1818may be transferred to data processing system1800using computer-readable signal media1826. Computer-readable signal media1826may be, for example, a propagated data signal containing program code1818. This data signal may be an electromagnetic signal, an optical signal, and/or some other type of signal that can be transmitted over physical and/or wireless communications links.

The illustration of data processing system1800inFIG. 18is not meant to provide architectural limitations to the manner in which the illustrative embodiments may be implemented. The different illustrative embodiments may be implemented in a data processing system that includes components, in addition to or in place of those illustrated, for data processing system1800. Further, components shown inFIG. 18may be varied from the illustrative examples shown.

The illustrative embodiments of the disclosure may be described in the context of aircraft manufacturing and service method1900as shown inFIG. 19and aircraft2000as shown inFIG. 20. Turning first toFIG. 19, an illustration of a block diagram of an aircraft manufacturing and service method is depicted in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method1900may include specification and design1902of aircraft2000ofFIG. 20and material procurement1904.

During production, component and subassembly manufacturing1906and system integration1908of aircraft2000takes place. Thereafter, aircraft2000may go through certification and delivery1910in order to be placed in service1912. While in service1912by a customer, aircraft2000is scheduled for routine maintenance and service1914, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

With reference now toFIG. 20, an illustration of a block diagram of an aircraft is depicted in which an illustrative embodiment may be implemented. In this example, aircraft2000is produced by aircraft manufacturing and service method1900ofFIG. 19and may include airframe2002with plurality of systems2004and interior2006. Examples of systems2004include one or more of propulsion system2008, electrical system2010, hydraulic system2012, and environmental system2014. 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. The apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method1900ofFIG. 19.

One or more illustrative embodiments may be used during component and subassembly manufacturing1906and system integration1908to inspect alignment of components of airframe2002. For example, folding wingtip assembly404ofFIG. 4is installed during component and subassembly manufacturing1906and system integration1908ofFIG. 19. Further, inspection system434ofFIG. 4is attached, utilized, and removed during component and subassembly manufacturing1906and system integration1908ofFIG. 19. Inspection system434is used to align components of folding wingtip assembly404ofFIG. 4during component and subassembly manufacturing1906and system integration1908. Folding wingtip assembly404ofFIG. 4may be a component of airframe2002. If for any reason, a hinged joint is created or aligned during routine maintenance and service1914, inspection system434may be used to align the hinged joint.

The illustrative embodiments provide an apparatus and method for aligning multiple joints at installation, substantially simultaneously, using software camera controlled hardware instead of manual labor. In some illustrative examples, the multiple joints are joints of winglets.

The system uses anywhere from one to a plurality of electronically focused cameras and target (reticle) systems, mounting accessories intended to properly center said cameras in their respective bushing-and-pin arrangements to determine alignment, a machine vision computing device (for example, laptop computer or similar), and computer to camera cabling or wireless connection device (for example, Bluetooth). For alignment projects where multiple bushing-and-pin arrangements must be aligned, this inspection system permits all said arrangements to be analyzed and aligned substantially simultaneously, or in sequence at the operator's discretion.

The illustrative examples of inspection systems save production costs by alignment cycle time reduction. The illustrative examples of inspection systems also present an improvement in ergonomics and personnel safety.

The illustrative examples present a system comprising multiple camera systems remotely controlled by a software, each of the camera systems is paired to a joint, wherein the remote controlling software determines a joint alignment data for the multiple joints using data collected through their respective cameras and issues and command to enable alignment of all the joints at once, wherein the alignment data is determined while taking into account the different weight deflection, and wherein the different camera systems are focused automatically, and send their focus data to the controlling software to use to determine the joint alignment data.

Aligning folding wings can be time consuming and inefficient due to the multiple labor intensive rounds of adjusting the joints. The illustrative examples present hardware that comprises a camera with extreme depth of focus at each of the joints, a software that controls the focus at each of the cameras, and another software that jointly optimizes the alignment data for all the cameras at once, while balancing non-uniform and unsymmetrical weight deflection throughout the wing.

A two-camera system may be used twice to adjust and verify the proper alignment of the four hinge latch pins, relative to their corresponding clevis bushings, on a folding wingtip assembly test article. A compact mounting and lighting configuration may be used for the cameras and target reticles. The system was operated from a laptop computer, such as computer system458ofFIG. 4, with Ethernet connections to the cameras. State-of-the-art liquid lenses are one example of tunable-focus lenses, such as tunable-focus lens442ofFIG. 4, to control the camera focus. An interactive software program numerically measures the alignment offset. The measurements for a folding wingtip assembly, such as folding wingtip assembly404, are made with the hinge line preloaded to 73,000 pounds. The entire inspection system was designed to operate remotely, from up to 25 feet away from the test article. This distance keeps the operator at a safe distance from the energized structure. A four-camera version of the system may be used in production.

The Folding Wing Tip (FWT) Vision System, such as inspection system434, was developed for the purpose of sighting the alignment of the latch pin actuator (LPA) pins, such as pin416, and the moving lug bushings, such as bushing418, when under preload. It is an external set of cameras and imaging software that connects to a portable laptop. The Folding Wing Tip (FWT) Vision System was developed taking into account depth of field constraints that are part of the folding wing tip (FWT) physical build.

Preload is used during normal system operation to prevent adverse conditions including, but not limited to, side loading of the latch pin actuators (LPAs) and decreased service life. Rigging under preload and live hydraulics presents other potential safety hazards which prevent shop personnel from gaining close proximity to the wing tip. The remote vision system alleviates this issue by placing cameras in the far fixed lugs facing each latch pin actuator (LPA) pin, centered in the respective near fixed lug. For example, camera438is placed to view through bore432of clevis422and target446of pin416is centered in bore430of clevis422. A scale reticle is centered within the moving lug bushing. For example, scale reticle437is centered within bore428ofFIG. 4.

In some illustrative examples, the scale reticle may instead be referred to as a “bomber sight” reticle. When the wing tip is extended and preloaded, the reticle provides a measure of how well the pins will align with the moving lug bores when pin extension is commanded. Across each of the four latch pin actuator (LPA) locations, there is a diametrical clearance of +/−0.015″. Due to the unique loading characteristics of the folding wing tip, the forward and aft most latch pin actuator (LPA) locations (1 and 4) deflect considerably more than the interior latch pin actuator (LPA) locations (2 and 3), installed directly next to the two structural end stop fittings, when subjected to a given preload. Latch pin actuator (LPA) locations (1 and 4) may be seen at latch pin632and latch pin674ofFIG. 6.

Latch pin actuator (LPA) locations (2 and 3) may be seen at latch pin648and latch pin662ofFIG. 6. This bending deflection pattern is generally referred to as the “banana” effect, given the shape when all points are plotted together. The rigging process utilizes the adjustment of shim stacks installed underneath the two end stop plates, so that “banana” pattern shifts up and down together, with more or less shim thickness installed. The moving lugs at locations 1 and 4 (the end points of the “banana”) deflect within 0.015 inch of the latch pin actuator (LPA) pin center toward the six o'clock position, within the moving lug bore, and the inner locations 2 and 3 deflect toward the 12 o'clock position within the same 0.015 inch allowable.

The Folding Wing Tip (FWT) Vision System was initially used to sight the latch pin actuator (LPA) pins under preload, with the end stop fittings purposely under-shimmed in order to avoid potential overloading to the end stops and surrounding structure. Images are processed in real time to diagnose the appropriate additional shim thickness to install in order to align the latch pin actuator (LPA) pins with the moving lug bores, when under preload. Additional shim thickness was installed and all four locations were sighted with the cameras a second time, after adjustment. After adjustment for reticle error, all locations were found to be within the +/−0.015 inch diametrical tolerance allowable. Cameras are then removed and latch pin actuator (LPA) hydraulic lines reinstalled.

The Folding Wing Tip (FWT) Vision System allows for diagnosable shimming to structurally align the wing tip. If desired, the Folding Wing Tip (FWT) Vision System may be validated using the bluing technique. Findings are in line with the structural deflection model.

The vision system is used to sight and measure the alignment between the latch pin assembly (LPA) pin installed in the aft fixed clevis and the moving lug bore as the system is held under preload (many tens of thousands in-lbs torque, such as 70,000 in-lbs torque). The preload is applied via the Folding Wing Tip (FWT) power drive and stiffens the wing tip hinge to where the target bores will not “bounce” while inserting the latch pins. In service, this preload may be used during taxiing. This large preload and live hydraulic system pressure may make it desirable for personnel to work remotely.

The use of multiple cameras to take measurements at each of the four latch pin actuator (LPA) locations per wing at the same time presents a significant time savings over performing the same sequence four times per wing. Proper alignment between the two bores (clevis and lug) is required to assure minimization of the side loading introduced into the latch pin actuator (LPA) as the pin extends and locks the two surfaces. Side loading on the latch pin actuator (LPA) will reduce actuator life, increase hydraulic leakage, and result in in-service schedule interruptions. Adjustment of the structural end stop shims, in combination with the vision system, is used to assure that pins can extend, without side loading from structural interference or contact, at all four latch pin actuator (LPA) locations. The pins should never be extended while the vision system is installed.

The vision system itself has to meet strict size requirements to meet the minimal space inside of the wing tip latch line. There are multiple equipment installations including hydraulic tubing and whirling torque tubes which are part of the underlying Folding Wing Tip (FWT) actuation system. The Folding Wing Tip (FWT) Vision System is able to maintain a high resolution magnification and focus across a large depth of field. The system allows for measurement down to 0.001/0.002 inch offset between the latch pin and its respective moving lug by overlaying a sharp image of the pin surface and the scale reticle installed in the moving lug.

The vision system consists of a laptop, GigE cameras, 0.001 inch scale printed reticles, tunable drivers, USB hub, Ethernet hub, power over Ethernet (PoE) converters, USB cables, Hirose cables, and LED light packs. The diagram below assumes a two camera set up as used on the CSA-Lite test rig. The production equivalent is planned to utilize four cameras to minimize factory flow time, as opposed to multiple set ups and measuring activity for a single wing tip. Mounting hardware is also required to temporarily install the cameras and the reticles for measurement within the bores of the fixed clevis and moving lug, respectively.

There are two sets of mounting hardware per location. The scale reticle is installed in the bore of the moving lug. The camera mount is installed on the forward fixed lug, looking aft toward its latch pin actuator (LPA).