US-12625114-B2 - Methods for associating test data for part under test with end item coordinate system and systems associated therewith

Abstract

A method for associating test data for a part under test with an end item coordinate system includes acquiring scan data during a plurality of scans of at least a portion of the part of an end item along a predetermined path plan using an ultrasonic scanning device of a robot. Robot location information associated with the scan data acquired during the plurality of scans is recorded. The robot location information is based on a robot coordinate system. The robot location information is translated to end item location information within the end item coordinate system based on at least three common reference points in the predetermined path plan, an electronic design model of the end item within the end item coordinate system, and the part. A non-destructive inspection (NDI) system for associating the test data with the end item coordinate system is also provided.

Inventors

• Samuel R. Goertz
• Barry A. Fetzer

Assignees

• THE BOEING COMPANY

Dates

Publication Date

20260512

Application Date

20230220

Claims (20)

1. 1 . A method for associating test data for a part under test with an end item coordinate system, the method comprising: acquiring scan data during a plurality of scans of at least a portion of the part of an end item along a predetermined path plan using an ultrasonic scanning device of a robot, wherein the ultrasonic scanning device is controlled by a robot computing system; recording robot location information associated with the scan data acquired during the plurality of scans, wherein the robot location information is expressed in x, y, z coordinates and based at least in part on a robot coordinate system associated with the robot; and translating the robot location information for the robot coordinate system to end item location information within the end item coordinate system based on common reference points in the predetermined path plan, an electronic design model of the end item within the end item coordinate system, and the part.
2. 2 . The method of claim 1 , wherein the electronic design model comprises a three-dimensional computer-aided design model.
3. 3 . The method of claim 1 , wherein the scan data comprises waveform data from each scan of the plurality of scans.
4. 4 . The method of claim 1 , wherein each scan of the plurality of scans comprises a measurement of an echo off a back wall of an emitted sound wave from the ultrasonic scanning device.
5. 5 . The method of claim 1 , wherein the predetermined path plan comprises a contiguous path for traversal of the part by the ultrasonic scanning device.
6. 6 . The method of claim 1 , wherein the x, y, z coordinates for the robot location information are based on an x-axis extending along a horizontal plane from an origin associated with a central point of the ultrasonic scanning device, a y-axis perpendicular to the origin of the x-axis in the horizontal plane, and a z-axis perpendicular to the origin of the x-axis in a vertical plane.
7. 7 . The method of claim 1 , wherein the end item location information within the end item coordinate system is expressed as x, y, z coordinates with an x-axis extending along a horizontal plane from an origin at a central front point of the end item to a central aft point, a y-axis perpendicular to the origin of the x-axis in the horizontal plane, and a z-axis perpendicular to the origin of the x-axis in a vertical plane.
8. 8 . The method of claim 1 , wherein each common reference point comprises at least one of a determinate assembly hole within the part, a pilot hole within the part, a stringer within the part, and a key visible feature associated with the part.
9. 9 . The method of claim 1 , further comprising: obtaining at least a portion of the electronic design model of the end item associated with the part; aligning the electronic design model of the part to the robot coordinate system; generating the path plan for the plurality of scans within the robot coordinate system based on the electronic design model, a predetermined test pattern grid for the part, and a predetermined distance between the ultrasonic scanning device and a surface of the part; and aligning the path plan to the robot coordinate system.
10. 10 . The method of claim 9 , further comprising: identifying the common reference points for the part in the electronic design model; aligning the common reference points to the robot coordinate system to obtain corresponding robot reference coordinates in the robot coordinate system; positioning the part in relation to the robot prior to the acquiring of the scan data; moving the ultrasonic scanning device to each of the robot reference coordinates; for each robot reference coordinate, scanning the part in a vicinity of the corresponding robot reference coordinate to detect as-built reference coordinates relating to the robot reference coordinates and to acquire location information in the robot coordinate system for the as-built reference coordinates; and adjusting alignment of the path plan within the robot coordinate system to obtain the predetermined path plan based on offsets between the as-built reference coordinates and the robot reference coordinates.
11. 11 . The method of claim 1 , further comprising: obtaining at least a portion of the electronic design model of the end item associated with the part; identifying the common reference points for the part in the electronic design model; aligning the common reference points to the robot coordinate system to obtain corresponding robot reference coordinates in the robot coordinate system; positioning the part in relation to the robot prior to the acquiring of the scan data; moving the ultrasonic scanning device to each of the robot reference coordinates; for each robot reference coordinate, scanning the part in a vicinity of the corresponding robot reference coordinate to detect as-built reference coordinates relating to the robot reference coordinates and to acquire location information in the robot coordinate system for the as-built reference coordinates; and comparing the as-built reference coordinates to the robot reference coordinates to determine if there is an offset requiring adjustment of the predetermined path plan.
12. 12 . The method of claim 1 , further comprising: obtaining at least a portion of the electronic design model of the end item associated with the part; identifying the common reference points for the part in the electronic design model; aligning the common reference points to the robot coordinate system to obtain corresponding robot reference coordinates in the robot coordinate system; positioning the part in relation to the robot prior to the acquiring of the scan data; moving the ultrasonic scanning device to each of the robot reference coordinates; for each robot reference coordinate, scanning the part in a vicinity of the corresponding robot reference coordinate to detect as-built reference coordinates relating to the robot reference coordinates and to acquire location information in the robot coordinate system for the as-built reference coordinates; and adjusting the robot reference coordinates based on the as-built reference coordinates to obtain at least three adjusted reference coordinates in the robot coordinate system.
13. 13 . The method of claim 1 , wherein the translating the robot location information comprises: obtaining the electronic design model of the end item; identifying the common reference points for the part in the electronic design model; aligning the common reference points to the robot coordinate system to obtain corresponding robot reference coordinates in the robot coordinate system; for each robot location information associated with the scan data, determining relationships between the corresponding robot location information in the robot coordinate system and the robot reference coordinates; obtaining end item reference coordinates in the end item coordinate system for the common reference points from the electronic design model; and for each robot location information associated with the scan data, translating the corresponding robot location information to the end item location information in the end item coordinate system based on the end item reference coordinates and an inverse of the relationships between the corresponding robot location information and the robot reference coordinates.
14. 14 . The method of claim 13 , wherein the robot reference coordinates are expressed as x, y, z coordinates with an x-axis extending along a horizontal plane from an origin associated with a central point of the ultrasonic scanning device, a y-axis perpendicular to the origin of the x-axis in the horizontal plane, and a z-axis perpendicular to the origin of the x-axis in a vertical plane.
15. 15 . The method of claim 13 , wherein the relationships between the corresponding robot location information and the robot reference coordinates and the inverse thereof for the end item reference coordinates and the end item location information comprise the end item reference coordinates relative to the end item location information multiplied by the robot location information relative to the robot reference coordinates.
16. 16 . The method of claim 13 , wherein the end item reference coordinates are expressed as x, y, z coordinates with an x-axis extending along a horizontal plane from an origin at a central front point of the end item to a central aft point, a y-axis perpendicular to the origin of the x-axis in the horizontal plane, and a z-axis perpendicular to the origin of the x-axis in a vertical plane.
17. 17 . The method of claim 1 , further comprising: linking the scan data from the plurality of scans with the corresponding end item location information within the end item coordinate system based on the translating such that each scan data is associated with an end item location coordinate.
18. 18 . The method of claim 17 , further comprising: receiving a scan data query for at least one of an individual end item location coordinate, a plurality of end item location coordinates, and a range of end item location coordinates; processing the scan data in response to the scan data query to identify query results; and providing the query results to at least one of a display device, a messaging system, a storage device, and a rendering device.
19. 19 . The method of claim 18 , wherein the query results form a visual overlay for the part within the electronic design model representative of at least defective locations based on the scan data.
20. 20 . The method of claim 19 , wherein the electronic design model is rendered in three-dimensions and the visual overlay comprises a solid three-dimensional overlay rendered in multiple colors representing predetermined ranges of the scan data.

Description

FIELD The present disclosure relates generally to associating test data for a part under test with an end item coordinate system and, particularly, to translating location information for ultrasonic scan data from a coordinate system in the testing environment with the end item coordinate system. Various examples of methods and systems for associating the test data with the ends item coordinate system are disclosed. For example, applications of the disclosed methods and systems to non-destructive inspection (NDI) of parts constructed of composite materials for use in aircraft are disclosed herein. Applications to various other types of parts, other types of testing, and other types of end items are also contemplated. BACKGROUND For current testing environments, location information associated with test data for a part under test is based on a point of origin in the testing environment and a corresponding testing coordinate system. Moreover, for certain test data, such as ultrasonic scan data, the location information captured by the testing instrument may only be in two dimensions (e.g., x, y) regardless of whether the part is contoured or shaped in three-dimensions. One technique for translating test data to an end item coordinate system uses pixel data based on the two-dimensional test data. The pixel data is then mapped on a three-dimensional model of the part. This technique is not efficient and not particularly accurate. Accordingly, those skilled in the art continue with research and development efforts to streamline translation of test data from a testing environment to design environments and in-service environments to improve various product lifecycle management processes. SUMMARY Disclosed are examples of a method for associating test data for a part under test with an end item coordinate system and a non-destructive inspection (NDI) system associated therewith. Examples of a method for integrating adjacent sets of test data for a part under test in an electronic design model are also disclosed. The following is a non-exhaustive list of examples, which may or may not be claimed, of the subject matter according to the present disclosure. In an example, the disclosed method for associating test data for a part under test with an end item coordinate system includes: (1) acquiring scan data during a plurality of scans of at least a portion of the part of an end item along a predetermined path plan using an ultrasonic scanning device of a robot, wherein the ultrasonic scanning device is controlled by a robot computing system; (2) recording robot location information associated with the scan data acquired during the plurality of scans, wherein the robot location information is based at least in part on a robot coordinate system associated with the robot; and (3) translating the robot location information for the robot coordinate system to end item location information within the end item coordinate system based on at least three common reference points in the predetermined path plan, an electronic design model of the end item within the end item coordinate system, and the part. In an example, the disclosed NDI system for associating test data for a part under test with an end item coordinate system includes a robot and a robot computing system. The robot includes a base, a mechanical arm with a proximal end secured to the base and a distal end, a flange movably secured to the distal end of the mechanical arm, and an ultrasonic scanning device secured to the flange. The robot computing system is in operative communication with the robot and configured to control movement of the mechanical arm and operation of the ultrasonic scanning device. The robot computing system includes at least one processor and associated memory and at least one storage device storing at least one application program and robot data. The robot computing system and the robot, in conjunction with the at least one processor running first application programs and accessing first robot data, is configured to acquire scan data during a plurality of scans of at least a portion of the part of an end item along a predetermined path plan using the ultrasonic scanning device. The robot computing system and the robot, in conjunction with the at least one processor running second application programs and accessing second robot data, is configured to record robot location information associated with the scan data acquired during the plurality of scans. The robot location information is based at least in part on a robot coordinate system associated with the robot. The robot computing system, in conjunction with the at least one processor running third application programs and accessing third robot data, is configured to translate the robot location information for the robot coordinate system to end item location information within the end item coordinate system based on at least three common reference points in the predetermined path plan, an el