Patent Application
20080095310
Examples of embodiments of the present invention and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures.
The presence of foreign objects (FOD) in an aircraft may present a substantial hazard to the aircraft, as well as to its cargo, crew, and passengers. Therefore, it is desirable to determine if any FOD is present
Further, the ability to readily locate FOD in an aircraft may eliminate the need for an exhaustive search of the aircraft, such as may be necessitated when a tool or other item is determined to be missing and to likely be somewhere in the aircraft. According to contemporary practice, such a search may involve partial disassembly of the aircraft and may thus cause an undesirable delay in delivery of the aircraft, as well as undesirably increased labor costs that are associated with searching the aircraft.
The output from an X-ray backscatter system may be a projected 2D grayscale image. Differences between an image of an aircraft taken before a modification and an image taken after the modification are generally those caused by the addition of newly installed hardware, and those caused by the elimination of removed hardware. Any other differences in the images may potentially be FOD.
An example of an embodiment of the present invention comprises a process for using pixel subtraction to automatically discern differences between pre-modified aircraft and post-modified aircraft. A resultant image from a pixel subtraction between the two aircraft states may include newly installed hardware, deleted hardware, and FOD. A modification or manufacturing engineer familiar with the subject modification may discern between design hardware and FOD. Alternatively, an automated process may be used to discern between design hardware and FOD, as discussed below.
An exemplary embodiment of this process may comprise taking an x-ray backscatter image of areas of interest prior to aircraft modification. These images may be stored until the modification is complete. In order to supplement the detection process, current best practices of tool inventory and FOD accounting may be retained. After the modification is complete, a second x-ray backscatter image may be taken.
Photo editing software may be used to register the before and after images with respect to one another and to perform any image processing that is required (such as scaling, light balancing, etc.) This process may be either manual (performed by a human operator) or automatic (performed by a computer or the like). Position relaxation on the initial image will allow features to be shifted so that they may be mapped on top of themselves to reduce discrepancies due to minor differences in the two scans. Fiducials may be rigidly located in the aircraft to facilitate image registration. When possible, the fiducials remain in place throughout the modification process, so that their precise positioning is not disturbed.
Once the images are registered, pixel subtraction may be performed wherein each pixel in the before image is subtracted from the corresponding pixel in the after image. The resulting pixel value may be used to represent the brightness for that pixel in a resultant Image. The resultant image may then be analyzed to determine the presence of potential or suspected FOD, such as by using FOD inventory list or database as a reference.
One or more embodiments of the present invention may be used to detect FOD in critical areas such as flight control areas, fuel systems, and life support systems in a new production environment. A scan of a reference assembly, known to be free of FOD, may be used as the before state. An inline production process may then be used to automatically detect any deviation from the reference state.
A significant additional benefit of at least one embodiment of the present invention is the enhanced ability to provide post-modification configuration documentation. Because the resultant image should contain only parts that were changed on the aircraft, the data represent the explicit product of the culmination of all design, planning, and manufacturing definition that defined the modification. This information may be stored to be used for future modification designs, or service bulletin development.
One or more embodiments of the present invention may be used to verify and document modifications that have been performed. This may be accomplished by providing x-ray backscatter images of critical modifications. Before and after images may be provided.
Examples of embodiments of the present invention are shown in
Fiducials 101 are attached to aircraft 100 in a manner that assures that fiducials 101 remain in place throughout modification of aircraft 100. For example, fiducials 101 may be attached to aircraft 100 via adhesive bonding, such as via superglue, dental cement, or epoxy. As a further example, fiducials 101 may be attached to aircraft 100 via fasteners, such as bolts or screws.
Fiducials 101 facilitate alignment of images that are used to detect the presence of FOD, as discussed in detail below. The use of fiducials 101 is optional. Other means for aligning the images may alternatively be used.
A two-dimensional and/or a three-dimensional x-ray backscatter system 102 may be used to provide images that are used to determine the potential presence of FOD in aircraft 100 after modification thereof. Such use of two-dimensional/three-dimensional x-ray backscatter system 102 is discussed in detail below.
An image taken after modification of aircraft 100 is compared to an image taken prior to modification of aircraft 100 by comparator 103. Such comparison may be performed by pixel subtraction, for example. Thus, each pixel of the image taken prior to modification of aircraft 100 may be subtracted from a corresponding pixel of the image taken after modification of aircraft 100 to provide a resultant image. Pixel subtraction may result in a resultant image that contains differences between the two images. Such differences may be due to the presence of FOD in aircraft 100.
Optionally, a database 104 containing geometric characteristics of known (previously identified and characterized) FOD may be used to attempt to identify any potential FOD in the resultant image. Thus, geometric characteristics of potential FOD in the resultant image may be compared to geometric characteristics of known FOD in database 104 to attempt to determine if the potential FOD is actually FOD. Such geometric characteristics may include size (such as largest dimension), shape, volume, key dimensions, ratios of dimensions, and/or the presence of unique structures (such as backscatter targets that may be present in some items such as tools to make them more apparent on backscatter images).
The results of the comparison of the image taken prior to modification and the image taken after modification may be shown on a display 105. Such results may include the resultant image, information representative of that provided by the resultant image (which may be in a graphic or text format), and/or information resulting from use of database 104. For example, the results may indicate that a specific tool that was used during modification of aircraft 100 is still on aircraft 100, hidden in a closed compartment thereof, after modification is complete. As discussed above, the presence of such FOD may present a substantial hazard.
Processor 201 may perform processing tasks such as scaling and light balance. Position relaxer 202 may vary, to some degree, the size, shape, and/or position of geometric structures of the image taken before modification and/or the image taken after modification, so as to better facilitate a match of such structures by comparator 103. In this manner, minor differences between the two images are less likely to result in contributions to the resultant image. Such minor differences may result from thermal expansion, mechanical stress, and/or movement of non-rigid components (cables, wiring, plumbing, etc.). Thus, the use of position relaxer 202 makes it more likely that items that appear in the resultant image will be FOD (it reduces the occurrence of false positives).
As discussed above, pixel substractor 203 performs pixel subtraction to provide the resultant image. Generally, each pixel of one of the images is subtracted from a corresponding pixel of the other image. However, the use of position relaxer 202 may result in pixels being subtracted from other, generally nearby, pixels instead. In any event, position relaxer 202 attempts to cause a structure in one image to be subtracted from the same structure in another image even though the structure is not represented by the same pixels in each image.
Geometry comparator 204 compares the geometric characteristics of items found in the resultant image to geometric characteristics of known FOD using database 104. Items that are suspected to be missing and that are therefore good candidates for FOD may be given priority during this comparison. For example, if a particular tool cannot be located after modification of aircraft 100, then geometry comparator may give preference to that tool as being an item shown in a resultant image if geometric characteristics of the item in the image are generally consistent with those of the missing tool.
Production flow 301 comprises interring the aircraft 100 for modification, as indicated in block 304. The aircraft 100 may be interred at the manufacture's facility or at some other maintenance depot. Indeed the aircraft 100 may be interred anywhere that modification may be performed.
Prior to modification of the aircraft 100, the aircraft 100 is scanned, such as using a two-dimensional and/or three dimensional x-ray backscatter system 102 (
FOD accounting and detection 302 provides a way to determine the likely presences of FOD within aircraft 100 and a way to potentially identify the FOD. The image formed by scanning the aircraft 100 with the x-ray backscatter system per block 305 is registered with respect to the image formed by scanning the aircraft 100 with the x-ray backscatter system per block 307, as indicted in block 311. Such registration is necessary so that the two images may be properly compared to one another, such as via pixel subtraction. Position relaxation may be used, as discussed herein.
The original x-ray image (taken per block 305) may be subtracted from the post modification x-ray image 312 (taken per block 307) to form a resultant or subtracted image, as indicated in block 312. The subtracted image may then be searched for geometric characteristics of identified tools, as indicated in block 313. Such searching may be facilitated by logging of unaccounted FOD, as indicated in block 309, and by assembling geometric tool search parameters, as indicated in block 310. The assembled geometric tool search parameters are defined by geometric characteristics of known FOD and may be the search parameters used to identify the potential presence of FOD in the resultant image.
The location of potential FOD that was identified by comparison of the two images may be facilitated by overlaying unresolved discrepancies between the two images with an existing aircraft definition, such as a computer aided drawing (CAD) drawing of the aircraft, as indicated in block 314. In this manner, a user of the system may be provided with a drawing that identifies the location of any potential FOD within the aircraft 100. That is, a drawing of the aircraft 100 may be provided that has indicia formed thereto to indicate the location and type of FOD. The type of FOD may be indicated via the use of unique icons for each type of FOD (a tool icon for tool FOD, a fastener icon for fastener FOD, etc.).
Existing definitions of geometric characteristic may be used to facilitate FOD location and identification, as indicated in block 303. A catalog of tool, fastener, and other potential FOD geometric characteristics may be compiled, as indicated in block 316. This information may be used to define the geometric tool search parameters per block 310.
Further, nominal aircraft geometric characteristics may be provided, as indicated in block 317, and previously collected configuration data may be provided, as indicated in block 318. The aircraft geometric characteristics of block 317 and the configuration data of 318 may be used to provide the existing aircraft definition data of block 315.
Thus, geometric data of the aircraft and geometric data of potential FOD may be used to facilitate the finding and identification of FOD in the resulting image and to facilitate the determination of the location of such FOD within the aircraft 100.
The two images resulting from the two scans may be aligned using the fiducials as indicated in block 405 and compared as indicated in block 406. Of course, many initial images and many final images may be necessary, depending upon the size of the area modified and the size of the area subject to each scan.
As discussed above, position relaxation may be used to better facilitate such comparison. The geometric characteristics of any structures found in the resultant image(s) may be compared to geometric characteristic in a database to determine if items in the resultant image are FOD (as opposed to desired aircraft structures). The result of the comparison are displayed or otherwise communicated so that a user may check the aircraft to verify the presence of FOD found according to this process and may then remove the FOD.
Embodiments of the present invention are described herein as using x-ray backscatter to facilitate scanning for FOD. However, those skilled in the art will appreciate that other technologies may be used to facilitate scanning for FOD. For example, gamma ray backscatter may similarly be used and can thus be consider equivalent to x-ray backscatter. Thus, the discussion of x-ray backscatter is by way of example only, and not by way of limitation.
Embodiments of the present invention are described herein as having application to the detection of FOD on aircraft. However, those skilled in the art will appreciate that embodiments of the present invention may similarly have application to the detection of FOD in a variety of other vehicles, objects, or areas. For example, embodiments of the present invention may be used to detect FOD in automobiles, ships, submarines, satellites and spacecraft. As a further example, embodiments of the present invention may be used to detect FOD in food products, such as boxed or canned foods. As such, discussion of embodiments of the present invention as having application to the detection of FOD in aircraft is by way of example only, and not by way of limitation.
Thus, methods and systems are provided for locating FOD on an aircraft or the like. After being located, the FOD may be removed such that it does not present a hazard to the aircraft, cargo, crew, or passengers.
Embodiments described above illustrate but do not limit the invention. It should also be understood that numerous modifications and variations are possible in accordance with the principles of the present invention. Accordingly, the scope of the invention is defined only by the following claims.
