Methods and systems for inspecting aircraft fuselage frames

This invention relates generally to aircraft fuselage frames, and more particularly to methods and systems for non-destructive inspection of aircraft fuselage frames.

In order to facilitate performing high-speed digital radiography for defect detection on passenger aircraft fuselage frames in both a timely and cost efficient manner, speed of data collection is primary. Speed can be addressed by rapid image acquisition, which can be accomplished through the synchronous motion of the energy source and the detector. In order to achieve adequate image quality, the detector must be located close to and along the outside of the aircraft fuselage to reduce the effects of magnification.

The proximity of the inspection system to the aircraft fuselage increases the potential for collision and damage to both the aircraft and the inspection system. To facilitate preventing collision and damage, at least some method of avoidance and protection is required.

In one aspect, a method for inspecting an aircraft fuselage using an inspection system that includes a movable detector is provided. The method includes coupling a collision avoidance system to the inspection system detector, monitoring the collision avoidance system during operation of the inspection system, and controlling operation of the inspection system with the collision avoidance system.

In another aspect, an apparatus for inspecting an aircraft fuselage is provided. The apparatus includes a movable detector, and a collision avoidance system in electrical communication with the movable detector to control the movable detector for inspecting the aircraft fuselage.

In another aspect, an inspection system for inspecting an aircraft fuselage is provided. The system includes a movable detector, at least one proximity sensor electrically coupled to the movable detector, and a collision avoidance system in electrical communication with the movable detector and the at least one proximity sensor for controlling the movable detector during the inspection of the aircraft fuselage.

FIG. 1 is an illustration of an aircraft fuselage; and

FIG. 2 is a block diagram of a collision avoidance system coupled to an inspection system for use with an aircraft fuselage.

FIG. 1 is an illustration of an aircraft fuselage 10 of a passenger jet. FIG. 2 is block diagram of an inspection system 12 for use with an aircraft fuselage, such as, aircraft fuselage 10 in FIG. 1 . Inspection system 12 can detect defects in the aircraft fuselage, such as cracks, corrosion, delaminations, disbonds, etc. Inspection system 12 may also be used with other types of aircraft fuselages, structural components, and materials that include these types of defects. More specifically, inspection system 12 includes a movable detector 14 coupled in synchronous motion with an energy source (not shown). In one embodiment, inspection system 12 is a high-speed digital radiography system, such as the DXR-500 available from General Electric Inspection Technology, Cincinnati, Ohio. However, as will be appreciated by those in the art, other systems can be used within the scope of the present invention.

In operation, inspection system 12 rapidly passes close to and along fuselage 10 . A collision avoidance system (CAS) 20 is coupled to inspection system 12 in order to prevent contact between inspection system 12 and fuselage 10 during the inspection process. CAS 20 includes at least one proximity sensor 22 , at least one protection device 24 , and a collision monitor 26 . Proximity sensor 22 is electrically coupled to detector 14 . In one embodiment, proximity sensor 22 is remotely coupled to detector 14 . In one embodiment, proximity sensor 22 is a single sensor that includes at least an infrared sensor, an air-filled bladder sensor, or an accelerometer. In another embodiment, proximity sensor 22 is a group of sensors that includes a combination of at least an infrared sensor, an air-filled bladder sensor, or an accelerometer. An infrared sensor allows for measuring distance between detector 14 and fuselage 10 . An air-filled bladder allows for monitoring changes in pressure and provides damage prevention. An accelerometer allows for measuring detector speed In operation, proximity sensor 22 generates signals during the operation of detector 14 and transmits those signals to collision monitor 26 . If during the inspection process proximity sensor 22 detects an imminent collision, then a signal is transmitted to collision monitor 26 . Monitor 26 is configured to send an imminent collision signal to an inspection system stopping mechanism 28 . Stopping mechanism 28 is configured to immediately halt the motion of detector 14 and facilitate preventing a collision between detector 14 and fuselage 10 . In one embodiment, stopping mechanism 28 is a manipulator that moves detector 14 away from fuselage 10 .

A protection device 24 is coupled to inspection system 12 . In one embodiment, protection device 24 includes, but is not limited to, one or a combination of at least an air-filled bladder, a balloon, or an airbag system. In another embodiment, protection device 24 includes other devices capable of protecting detector 14 as described herein.

Protection device 24 is in electrical communication with stopping mechanism 28 such that during operation, when stopping mechanism 28 receives an imminent collision signal from monitor 26 , protection device 24 is deployed. Accordingly, detector 14 does not contact fuselage 10 . In an alternative embodiment, protection device 24 is in electrical communication with proximity sensor 22 such that when proximity sensor 22 detects an imminent collision, protection device 24 is deployed and prevents contact between detector 14 and fuselage 10 .

The above-described collision avoidance system 22 for an aircraft fuselage inspection system 12 is both cost-effective and highly reliable. The inspection system receives input from at least one proximity sensor coupled to the collision avoidance system to facilitate the prevention of contact between the movable detector and the aircraft fuselage. Furthermore, the collision avoidance system allows non-destructive inspections of aircraft fuselage frames. As a result, the inspection system can perform high-speed digital radiography on aircraft fuselages in close proximity without concern of damage to the detector or the fuselage or loss of image quality.

While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.