Systems and methods for determining serviceability and remaining life of in-service structures

Abstract

The present disclosure relates to a method for determining serviceability and remaining life of an in-service structure. According to an example, three-dimensional (3D) scan data representative of an in-service structure captured by a scanning device is accessed by a processor circuit. Based on the 3D scan data, in-service computer-aided design (CAD) data representative of an in-service surface corresponding to the in-service structure is generated by the processor circuit. Based on the in-service CAD data representative of the in-service surface, at least one of a serviceability level or a remaining life estimate of the in-service structure is determined.

Description

TECHNICAL FIELD

[0001] Examples described herein relate to analyzing in-service structures, and more specifically, to determining serviceability and remaining life of in-service structures using three-dimensional scan data. BACKGROUND

[0002] During structural inspection and maintenance of an aircraft, aircraft components are inspected, measured, and compared to predetermined (e.g., original or as-designed) allowable limits, such as design tolerances. For example, a component is manually measured by a maintenance technician using a measurement tool (e.g., calipers, micrometer, ruler, boat gauge, etc.). The measured value is compared to the design tolerance for the component (e.g., as indicated by a 3D model or 2D blueprint). If the measured value is not within the design tolerance, the measured value is sent to a structural engineer (possibly not on-site) for analysis. The analysis can indicate that the component should be reused, repaired, or scrapped. Additionally, due to the complexity of the analysis, the structural engineer can require more measurements to complete the analysis, thereby extending the inspection and maintenance cycle. This structural inspection and maintenance process is time consuming and complex analyses performed for a component or similar components of the same type cannot be reused. SUMMARY

[0003] According to an example, a system for determining serviceability and remaining life of an in-service structure is disclosed. The system includes a processor circuit and a memory coupled to the processor circuit. The memory includes machine-readable instructions that, when executed by the processor circuit, access three-dimensional (3D) scan data representative of the in-service structure captured by a scanning device. The machine-readable instructions further cause the processor circuit to generate, based on the 3D scan data, in-service computer-aided design (CAD) data representative of an in-service surface corresponding to the in-service structure. The machine-readable instructions further cause the processor circuit to determine at least one of a serviceability level or a remaining life estimate for the in-service structure based on the in-service CAD data representative of the in-service surface.

[0004] According to an example and any of the previous examples, the machine-readable instructions further cause the processor circuit to access nominal CAD data representative of a nominal volume including a nominal surface, wherein the nominal volume corresponds to a nominal structure, and wherein a portion of the nominal surface corresponds to the in-service surface. The machine-readable instructions further cause the processor circuit to replace the portion of the nominal surface with the in-service surface to generate altered in-service CAD data, the altered in-service CAD data representative of an altered in-service volume including the in-service surface. Determining at least one of the serviceability level or the remaining life estimate for the in-service structure is further based on the altered nominal CAD data.

[0005] According to any of the examples and previous examples, replacing the portion of the nominal surface further includes removing a trimmed volume defined by the portion of the nominal surface and the as-built surface from the nominal volume.

[0006] According to any of the examples and previous examples, replacing the portion of the nominal surface further includes adding an added volume defined by the portion of the nominal surface and the as-built surface in the nominal volume.

[0007] According to any of the examples and previous examples, replacing the portion of the nominal surface further includes: raising the nominal surface relative to the nominal volume to generate an increased nominal volume; and removing a trimmed volume defined by the raised nominal surface and the as-built surface from the increased nominal volume.

[0008] According to any of the examples and previous examples, the machine-readable instructions further cause the processor circuit to compare the as-built surface of the altered nominal volume to the 3D scan data. The machine-readable instructions further cause the processor circuit to determine, based on the comparison, whether the as-built surface of the altered nominal CAD data corresponds to the as-built surface of the as-built structure within a predetermined tolerance. The machine-readable instructions further cause the processor circuit to generate, in response to the determination, an indication of whether the as-built surface of the altered nominal CAD data corresponds to the as-built surface of the as-built structure within the predetermined tolerance.

[0009] According to any of the examples and previous examples, the machine-readable instructions further cause the processor circuit to access second 3D scan data representative of the as-built structure captured by the scanning device. The machine-readable instructions further cause the processor circuit to compare the as-built surface of the altered nominal CAD data to the second 3D scan data. The machine-readable instructions further cause the processor circuit to determine, based on the comparison, whether the as-built surface of the altered nominal CAD data corresponds to the as-built surface of the as-built structure within a predetermined tolerance. The machine-readable instructions further cause the processor circuit to generate, in response to the determination, an indication of whether the as-built surface of the altered nominal CAD data corresponds to the as-built surface of the as-built structure within the predetermined tolerance.

[0010] According to any of the examples and previous examples, the 3D scan data includes a 3D mesh data structure. Generating the as-built CAD data further includes converting the 3D mesh data structure to an as-built CAD data structure that includes the as-built surface.

[0011] According to any of the examples and previous examples, determining at least one of a serviceability level or a remaining life estimate for the in-service structure based on the in-service CAD data further comprises performing a strength analysis on the in-service CAD data.

[0012] According to any of the examples and previous examples, performing the strength analysis comprises performing a finite element analysis (FEA) to determine a condition of the in-service structure.

[0013] According to any of the examples and previous examples, the in-service structure comprises an in-service vehicle structure.

[0014] According to any of the examples and previous examples, the in-service structure comprises an in-service aircraft structure.

[0015] According to any of the examples and previous examples, a method for determining serviceability and remaining life of an in-service structure is disclosed. The method comprises accessing, by a processor circuit, three-dimensional (3D) scan data representative of an in-service structure captured by a scanning device. The method further comprises generating, by the processor circuit, in-service CAD data representative of an in-service surface corresponding to the in-service structure based on the 3D scan data. The method further comprises determining at least one of a serviceability level or a remaining life estimate for the in-service structure based on the in-service CAD data representative of the in-service surface.

[0016] According to any of the examples and previous examples, the method further comprises accessing nominal CAD data representative of a nominal volume comprising a nominal surface, wherein the nominal volume corresponds to a nominal structure, and wherein a portion of the nominal surface corresponds to the in-service surface. The method further comprises replacing the portion of the nominal surface with the in-service surface to generate altered in-service CAD data representative of an altered in-service volume comprising the in-service surface. Determining at least one of a serviceability level or a remaining life estimate for the in-service structure is further based on the altered nominal CAD data.

[0017] According to any of the examples and previous examples, replacing the portion of the nominal surface further comprises removing a trimmed volume defined by the portion of the nominal surface and the in-service surface from the nominal volume.

[0018] According to any of the examples and previous examples, replacing the portion of the nominal surface further comprises adding an added volume defined by the portion of the nominal surface and the in-service surface in the nominal volume.

[0019] According to any of the examples and previous examples, replacing the portion of the nominal surface further includes elevating the nominal surface relative to the nominal volume to create an increased nominal volume; and removing a trimmed volume defined by the elevated nominal surface and the in-service surface from the increased nominal volume.

[0020] According to any of the examples and previous examples, the method further includes comparing, by the processor circuit, the in-service surface of the altered nominal volume to the 3D scan data. The method further includes determining, by the processor circuit, based on the comparison, whether the in-service surface of the altered nominal CAD data corresponds to the in-service surface of the in-service structure within a predetermined tolerance. The method further includes generating, by the processor circuit, responsive to the determination, an indication of whether the in-service surface of the altered nominal CAD data corresponds to the in-service surface of the in-service structure within the predetermined tolerance.

[0021] According to any of the examples and previous examples, the method further includes performing a strength analysis on the altered nominal CAD data to determine a condition of the in-service structure.

[0022] According to any of the examples and previous examples, a system for determining serviceability and remaining life of an in-service structure is disclosed. The system includes a processor circuit and a memory coupled to the processor circuit. The memory includes machine-readable instructions that, when executed by the processor circuit, access nominal computer-aided design (CAD) data representative of a nominal volume including a nominal surface, wherein the nominal volume corresponds to a nominal structure. The machine-readable instructions further cause the processor circuit to access three-dimensional (3D) scan data representative of an in-service structure corresponding to a portion of the nominal structure, captured by a scanning device. The machine-readable instructions further cause the processor circuit to generate, based on the 3D scan data, in-service CAD data representative of an in-service surface of the in-service structure corresponding to a portion of the nominal surface. The machine-readable instructions further cause the processor circuit to replace the portion of the nominal surface with the in-service surface to generate altered in-service CAD data representative of an altered in-service volume including the in-service surface. BRIEF DESCRIPTION OF DRAWINGS

[0023] FIG. 1A is a flowchart of operations to generate computer-aided design (CAD) data for strength analysis of an in-service component according to an example;

[0024] FIG. 1B is a flowchart of operations to replace a portion of a nominal surface with an in-service surface according to an example, including adding or removing a volume defined by the nominal surface and the portion of the in-service surface in a nominal volume;

[0025] FIG. 1C is a flowchart of operations to replace a portion of a nominal surface with an in-service surface according to an example, the operations including removing a volume defined by the raised portion of the nominal surface and the in-service surface in an enlarged nominal volume;

[0026] FIG. 1D is a flowchart of operations to verify accuracy and precision of the altered nominal volume according to an example;

[0027] FIG. 2A illustrates capturing 3D scan data of an in-service structure by a scanning device according to an example;

[0028] FIG. 2B illustrates generating in-service CAD data from the 3D scan data captured in FIG. 2A

[0029] FIG. 2C illustrates altering the nominal CAD data to generate an altered nominal volume by replacing a portion of the nominal surface with the in-service surface of FIG. 2B

[0030] FIG. 2D illustrates altered nominal CAD data including the altered nominal volume altered in FIG. 2C

[0031] FIG. 3A illustrates raising the nominal surface relative to a nominal volume proximate to the nominal volume of FIG. 2C to generate an enlarged nominal volume according to an alternative example;

[0032] FIG. 3B illustrates removing a trimmed volume defined by the raised nominal surface of FIG. 3A and the in-service surface from the enlarged nominal volume to generate an altered nominal volume according to an example;

[0033] FIG. 4A illustrates comparing the 3D scan data to an in-service surface of an altered nominal volume proximate to the altered nominal volume of FIG. 2D according to an example;

[0034] FIG. 4B illustrates a graphical indication of how the in-service surface of the altered nominal CAD data based on the comparison corresponds to or deviates from the in-service surface of the in-service structure; and

[0035] FIG. 5 illustrates a computing system for performing operations of any of the systems, devices, or methods disclosed herein according to an example. DETAILED DESCRIPTION

[0036] ​​​Examples or embodiments described herein relate to analyzing in-service structures, and more particularly, to determining serviceability and remaining life of in-service structures using three-dimensional scan data. According to some examples, three-dimensional (3D) scan data representative of an in-service structure, such as a vehicle (e.g., an airplane) or other structure, is captured by a scanning device. Based on the 3D scan data, in-service computer-aided design (CAD) data representative of an in-service surface corresponding to the in-service structure is generated. Based on the in-service CAD data, at least one of a serviceability level or a remaining life estimate of the in-service structure is determined. In some examples, nominal CAD data representative of a nominal volume having a nominal surface is accessed. The nominal volume corresponds to a nominal structure, and a portion of the nominal surface corresponds to the in-service surface. In this example, the portion of the nominal surface is replaced with the in-service surface to generate altered nominal CAD data representative of an altered nominal volume having the in-service surface. In this example, at least one of the serviceability level or the remaining life estimate of the in-service structure is determined based also on the altered nominal CAD data.

[0037] One advantage of this and other arrangements is that a model for performing strength analysis, such as finite element analysis (FEA) models, can be created more quickly and efficiently in an in-service condition compared to existing methods such as, for example, manual measurements and meshing. Instead of manually taking measurements and creating and altering CAD models, such as FEA meshes, a high-definition scan can generate a 3D surface that more closely represents the in-service condition and can be used to generate a CAD model for FEA analysis, which can save many hours in the measurement and generation cycle and can improve the accuracy of the resulting FEA analysis over traditional methods.

[0038] In this regard, FIG. 1A is a flowchart of operations 100 for generating CAD data for strength analysis of an in-service part according to examples. Operations 100 include accessing nominal CAD data representative of a nominal volume corresponding to a nominal structure including a nominal surface (block 102). In one example, the nominal structure is an airplane or other vehicle structure design. Operations 100 also include accessing 3D scan data captured by a scanning device (block 104). The 3D scan data is representative of an in-service structure corresponding to a portion of the nominal structure. In an airplane example, the in-service structure is an in-service example of an airplane corresponding to the nominal airplane design. Operations 100 also include generating in-service CAD data representative of an in-service surface corresponding to the in-service structure based on the 3D scan data (block 106). In some examples, the 3D scan data includes a 3D mesh data structure, and generating the in-service CAD data further includes converting the 3D mesh data structure into an in-service CAD data structure including the in-service surface.

[0039] In some examples, the in-service surface includes wear or damage that causes the in-service surface to deviate from the corresponding nominal surface of the nominal structure. Operation 100 also includes modifying the nominal CAD data based on the in-service CAD data (box 108). In one example, this includes replacing a portion of the nominal surface of the nominal CAD data with the in-service surface of the in-service CAD data to generate modified nominal CAD data (box 110). The portion of the nominal surface of the nominal CAD data corresponds to the portion of the nominal structure as defined above. Operation 100 also includes determining at least one of the serviceability level or remaining service life estimate of the in-service structure based on the in-service CAD data representing the in-service surface (box 112). In some examples, this determination includes storing the modified nominal CAD data in memory (box 113) and performing a strength analysis (such as, for example, FEA strength analysis) using the modified nominal CAD data (box 114). For example, FEA strength analysis can be used to analyze the modified nominal CAD data to produce FEA results corresponding to at least one of the actual condition or serviceability of the in-service structure within predetermined tolerances.

[0040] FIG. 1B This is an example operation 110' of replacing a portion of the nominal surface with an in-service surface (as...). FIG. 1A The flowchart is an alternative to box 110. Operation 110' includes defining a modification volume based on the portion of the nominal surface and the in-service surface (box 116). In one example, defining the modification volume includes locating the nominal surface and the in-service surface in a common coordinate system and defining the modification volume as the volume between the nominal surface and the in-service surface in one or more dimensions of the coordinate system. Operation 110' also includes adding or deleting the modification volume in the nominal volume (box 118) to generate modified nominal CAD data. In the example of adding the modification volume in the nominal volume, the modification volume may alternatively be referred to as increasing the volume.

[0041] FIG. 1C This is another example of operation 110, which involves replacing a portion of the nominal surface with an in-service surface (as...). FIG. 1A The flowchart of another alternative to box 110 in the diagram. Operation 110" includes raising said portion of the nominal surface to increase the nominal volume (box 120). Operation 110" also includes removing from the nominal volume the modified volume defined by said raised portion of the nominal surface and the in-service surface (box 122).

[0042] FIG. 1Dis a flowchart of operations 150 for verifying accuracy and precision of the post-change nominal volume according to an example. The operations 150 include accessing the as-built surface of the post-change nominal volume and comparing it to the 3D scan data or second 3D scan data captured by a scanning device representative of the as-built structure (block 152). The operations 150 also include determining whether the as-built surface of the post-change nominal CAD data corresponds to the as-built surface of the as-built structure within a predetermined tolerance based on the comparison (block 154). The operations 150 also include generating an indication as to whether the as-built surface of the post-change nominal CAD data corresponds to the as-built surface of the as-built structure within the predetermined tolerance in response to the determination (block 156).

[0043] Reference is now made to FIG. 2A to FIG. 2D , FIG. 2A Example 1 illustrates capturing 3D scan data of an as-built structure 200 by an image capture device 202 according to an example. In this example, the as-built structure 200 is an as-built aircraft structure, e.g., an aircraft component, having real-world dimensions, i.e., depth (x) 204, length (y) 206, and height (z) 208 dimensions. However, it should be understood that the as-built structure 200 can be another type of as-built vehicle structure or other structure as desired. In this example, the as-built structure 200 has a plurality of physical damage features 210 that can be due to wear or damage of the as-built structure 200. These damage features 210 cause the dimensions of the as-built structure 200 to deviate from the original design or original condition of the as-built structure 200. As discussed above, conventional manual measurement methods, such as by using manual measurement tools, gridding, etc., are time consuming and cannot produce measurement values that are accuracy or precision qualified for strength analysis or other types of analysis for determining at least one of serviceability or remaining life of the as-built structure 200.

[0044] Reference is now made to FIG. 2B , FIG. 2A The 3D scan data of the as-built structure 200 is used to generate as-built CAD data. FIG. 2B The 3D scan data shown includes an as-built surface 212 positioned and oriented within a scanner coordinate system 214. In this example, the scanner coordinate system 214 is a Cartesian coordinate system having depth (x) 216, length (y) 218, and height (z) 220 dimensions, although it should be understood that other types of coordinate systems, such as cylindrical coordinate systems, spherical coordinate systems, etc., can be used. The as-built surface 212 includes damage features 222 corresponding to the physical damage features 210 of the as-built structure 200. FIG. 2A The 3D scan data shown includes an as-built surface 212 positioned and oriented within a scanner coordinate system 214. In this example, the scanner coordinate system 214 is a Cartesian coordinate system having depth (x) 216, length (y) 218, and height (z) 220 dimensions, although it should be understood that other types of coordinate systems, such as cylindrical coordinate systems, spherical coordinate systems, etc., can be used. The as-built surface 212 includes damage features 222 corresponding to the physical damage features 210 of the as-built structure 200.

[0045] Reference is now made to FIG. 2Ccorresponding to the as-built surface 212. The as-built surface 212 is positioned and aligned relative to the corresponding nominal surface 226 of the nominal volume 224. The nominal volume 224 is positioned and oriented in a CAD coordinate system 228 having depth (x) 230, length (y) 232, and height (z) 234 dimensions. Coordinates of the as-built surface 212 are converted from the scanner coordinate system 214 to the CAD coordinate system 228 so that the as-built surface 212 is positioned and aligned relative to the corresponding nominal surface 226 of the nominal volume 224.

[0046] Referring now to FIG. 2D , the as-built surface 212 replaces FIG. 2C the nominal surface 226 to generate an altered nominal CAD volume 236. In this example, the replacing function is implemented by operations similar to the operations 110’ discussed above with respect to FIG. 1A and FIG. 1B . In FIG. 2D , it can be seen that the altered nominal CAD volume 236 generally corresponds to the nominal CAD volume (i.e., the representation of the original design or original condition of the as-built structure 200). However, the altered nominal CAD volume 236 also includes the as-built surface 212, which includes the damaged features 222 corresponding to the scanned physical damage features 210 of the as-built structure 200. FIG. 2A FIG. 2A

[0047] Referring now to FIG. 3A and FIG. 3B , FIG. 3A an example is illustrated of raising a nominal surface 326 relative to a nominal volume 324 proximate to the nominal volume 224 of FIG. 2C to generate an enlarged nominal volume 340 according to an alternative example. The nominal volume 324 is positioned and oriented in a CAD coordinate system 328 having depth (x) 330, length (y) 332, and height (z) 334 dimensions. In this example, the nominal surface 326 is moved in the height (z) 334 dimension to form a raised surface 338 for the enlarged nominal volume 340.

[0048] Referring now to FIG. 3B , a trimmed volume 342 is defined by the raised surface 338 of FIG. 3A and the as-built surface 312 proximate to the as-built surface 212 of FIG. 2A to FIG. 2D . The trimmed volume 342 is removed from the enlarged nominal volume 340 to generate an altered nominal volume 336. In this example, the removing function is implemented by operations similar to the operations 110” discussed above with respect to FIG. 1A and FIG. 1C .

[0049] ​​It is also desirable to compare the altered nominal volume to the original 3D scan data to verify accuracy or precision of the altered nominal volume, e.g., to confirm that FEA strength analysis will yield results corresponding to at least one of actual condition or serviceability of the in-service structure within predetermined tolerances. In this regard, FIG. 4A and FIG. 4B comparing 3D scan data to in-service surfaces of the altered nominal volume and providing graphical indications as to how the in-service surfaces of the altered nominal CAD data correspond to or deviate from in-service surfaces of the in-service structure.

[0050] In FIG. 4A , the 3D scan data is transformed into a verification surface 444 within a CAD coordinate system 428 having depth (x) 430, length (y) 432, and height (z) 434 dimensions. The verification surface 444 is compared to in-service surfaces 412 of the altered nominal volume 436 including damage features 422 corresponding to the measured in-service volume, whereby the altered nominal volume 436 is compared to the 3D scan data. In another example, new 3D scan data can be captured, such as by the image capture device 202 of FIG. 2A , and transformed into a verification surface 444 to provide independent comparison and verification of accuracy or precision of the altered nominal volume 436 in addition to the original 3D scan data. Based on the comparison, it is determined whether the in-service surfaces 412 of the altered nominal volume 436 correspond to in-service surfaces of the in-service structure, such as the in-service structure 200 in this example, within predetermined tolerances. FIG. 2A

[0051] Reference is now made to FIG. 4B ​, responsive to the determination, a indication 446 is generated, the indication 446 indicating whether the in-service surface 412 of the altered nominal volume 436 corresponds to the in-service surface of the in-service structure within a predetermined tolerance. In this example, the indication 446 is a graphical indication corresponding to a graphical scale 448. In this example, the graphical scale 448 is color-coded or pattern-coded, illustrating different colors or patterns corresponding to different tolerances or tolerance ranges 452, 453. Based on the graphical scale 448, portions of the in-service surface 412 corresponding to the 3D scan data within a particular tolerance or tolerance range are indicated with a corresponding pattern or color. For example, a particular portion 450 of the in-service surface 412 that is within an out-of-tolerance range 453 (i.e., outside of a predetermined in-tolerance or tolerance range 452) can be indicated with a high-contrast pattern 454, color, etc. that is different from a base pattern or base color of the altered nominal volume 426 or a different associated pattern 455 or color of the in-tolerance range 452, to visually attract the attention of an observer to the portion 450 that deviates from the 3D scan data by an out-of-tolerance degree. In this way, the accuracy or precision of the altered nominal volume 436 can be verified, for example, before or after the FEA analysis.

[0052] FIG. 5 is a schematic block diagram of a computing system 500 for performing the operations of any of the systems, apparatuses, or methods disclosed herein, according to an example. According to an example, FIG. 1A to FIG. 1C The operations 100 of the example are implemented in and performed by the system 500, and aspects of the examples described herein are performed, generated, and presented by the system 500. The system 500 includes a processor apparatus 502. According to an example, the processor apparatus 502 is a server or similar processor circuit. The processor apparatus 502 includes a processor circuit 504 for controlling the operation of the processor apparatus 502 and for performing functions such as the functions described herein with respect to the operations 100 of the example. FIG. 1A to FIG. 1C The processor apparatus 502 also includes a memory 506, e.g., a file system. An operating system 508, application programs, and other programs are stored in the memory 506 for running or operating on the processor circuit 504. One or more CAD modules 510 or systems are also stored on the memory 506 and compiled and run on the processor circuit 504 to perform the functions or operations described herein. The CAD modules 510 are any type of software, hardware, or combination of hardware and software for performing 3D data processing, transformations, CAD operations, or other features described herein.

[0053] An image capture module 512 is also stored on the memory 506. For example, when the image capture module 512 is compiled and run on the processor circuit 504, FIG. 1A to FIG. 1COperation 100 (such as capturing 3D scan data) is implemented in image capture module 512 and executed by processor circuitry 504. Image capture module 512 operates in conjunction with CAD module 510. In one example, image capture module 512 is a separate component from CAD module 510. In another example, image capture module 512 is a component of CAD module 510.

[0054] Processor device 502 also includes one or more input devices, output devices, or combined input / output devices collectively referred to as I / O devices 520. I / O devices 520 include, but are not limited to, a keyboard or keypad, pointing devices (such as a mouse), disk drives, and any other means that allow a user to interact with processor device 502 and control its operation and access CAD module 510 or the system and image capture module 512. As an example, at least one of the I / O devices 520 is a means for reading a computer program product (such as computer program product 522). Computer program product 522 is similar to the product described in more detail herein. CAD module 510 and image capture module 512 are loaded from the computer program product (such as computer program product 522) onto memory 506.

[0055] Network members or users 523 of system 500 can use computer system 524 or communication devices to access processor device 502 or server, as well as CAD module 510 and image capture module 512. Computer system 524 or communication device is any type of communication device, including mobile or handheld computers or communication devices. Computer system 524 includes processor 526 for controlling the operation of computer system 524 and memory 528 (e.g., file system or similar data storage device). Operating system 530, application programs 532, and other programs are stored on memory 528 for execution or operation on processor 526. A network or internet browser 534 is also stored on memory 528 for access to processor device 502 or server via network 536. Network 536 can be the Internet, intranet, or other private or proprietary network.

[0056] The CAD application 538 is also stored on memory 528. As an example, FIG. 1A to FIG. 1C Operation 100 is implemented and executed by CAD application 538. For example, CAD application 538 is compiled and run on processor 526 to perform functions similar to those described relative to operation 100.

[0057] One or more image capture applications 540 are also stored on the memory 528 (e.g., a file system). The one or more image capture applications 540 are any type of software application for performing 3D data processing, transformations, CAD operations, or other features described herein. By way of example, the CAD application 538 is a separate component from the image capture application 540, as shown in the example of FIG. 5. In another example, the image capture application 540 is an integral part of the CAD application 538. FIG. 5

[0058] The CAD application 538 and the image capture application 540 operating on the computer system 524 interact with or in conjunction with the CAD module 510 and the image capture module 512 on the processor device 502 or server to perform the functions and operations described herein. Thus, the CAD application 538 and the image capture application 540 operating on the computer system 524 perform some of the functions and operations of the operations 100 of FIG. 1A to FIG. 1C and the CAD module 510 or the image capture module 512 operating on the processor or server perform other functions of the operations 100 of FIG. 1A to FIG. 1C Some examples include only the CAD module 510 and the image capture module 512 on the processor device 502 or server, and other examples include only the CAD module 510 and the image capture module 512 operating on the client computer system 524 or the communication device.

[0059] By way of example, the client computer system 524 or the communication device also includes a display 548, a speaker system 550, and a microphone 552 for voice communications. Commands are presented on the display 548 for controlling the operation of the CAD module 510 and the image capture module 512 or the CAD application 538 and the image capture application 540 and for performing the operations and functions described herein. By way of example, a graphical user interface (GUI) is presented on the display 548 for displaying some aspects of the above examples.

[0060] By way of example, the computer system 524 also includes one or more input devices, output devices, or combined input / output devices, collectively referred to as I / O devices 554. Examples of I / O devices 554 include, but are not necessarily limited to, a keyboard or keypad, a pointing device such as a mouse, a disk drive, and any other device that permits a user, such as the user 523, to interact with the computer system 524 and control the operation of the computer system 524 and access the components of the system 500. The I / O devices 554 also include an image capture device, such as the image capture device 202 of FIG. 2A or a device configured to read computer code from a computer program product, such as the computer program product 522.​

[0061] Additionally, the present disclosure includes examples in accordance with the following clauses:

[0062] Clause 1. A system for determining serviceability and remaining life of an in-service structure, the system comprising:

[0063] a processor circuit; and

[0064] a memory coupled to the processor circuit, the memory comprising machine-readable instructions that, when executed by the processor circuit:

[0065] accessing three-dimensional (3D) scan data representative of the in-service structure captured by a scanning device;

[0066] generating, based on the 3D scan data, in-service computer-aided design (CAD) data representative of an in-service surface corresponding to the in-service structure; and

[0067] determining at least one of a serviceability level or a remaining life estimate for the in-service structure based on the in-service CAD data representative of the in-service surface.

[0068] Clause 2. The system of Clause 1, wherein the machine-readable instructions further cause the processor circuit to:

[0069] accessing nominal CAD data representative of a nominal volume comprising a nominal surface, wherein the nominal volume corresponds to a nominal structure, and wherein a portion of the nominal surface corresponds to the in-service surface; and

[0070] replacing the portion of the nominal surface with the in-service surface to generate altered nominal CAD data representative of an altered nominal volume comprising the in-service surface,

[0071] wherein determining at least one of a serviceability level or a remaining life estimate for the in-service structure is further based on the altered nominal CAD data.

[0072] Clause 3. The system of Clause 2, wherein replacing the portion of the nominal surface further comprises removing a trimmed volume defined by the portion of the nominal surface and the in-service surface from the nominal volume.

[0073] Clause 4. The system of Clause 2, wherein replacing the portion of the nominal surface further comprises adding an added volume defined by the portion of the nominal surface and the in-service surface in the nominal volume.

[0074] Clause 5. The system of clause 2, wherein replacing the portion of the nominal surface further comprises:

[0075] elevating the nominal surface relative to the nominal volume to generate an increased nominal volume; and

[0076] removing a trimmed volume defined by the elevated nominal surface and the in-service surface from the increased nominal volume.

[0077] Clause 6. The system of clause 2, wherein the machine-readable instructions further cause the processor circuit to:

[0078] compare the in-service surface of the altered nominal volume to the 3D scan data;

[0079] determine, based on the comparison, whether the in-service surface of the altered nominal CAD data corresponds to the in-service surface of the in-service structure within a predetermined tolerance; and

[0080] generate, in response to the determination, an indication of whether the in-service surface of the altered nominal CAD data corresponds to the in-service surface of the in-service structure within the predetermined tolerance.

[0081] Clause 7. The system of clause 2, wherein the machine-readable instructions further cause the processor circuit to:

[0082] access second 3D scan data representative of the in-service structure captured by the scanning device;

[0083] compare the in-service surface of the altered nominal CAD data to the second 3D scan data;

[0084] determine, based on the comparison, whether the in-service surface of the altered nominal CAD data corresponds to the in-service surface of the in-service structure within a predetermined tolerance; and

[0085] generate, in response to the determination, an indication of whether the in-service surface of the altered nominal CAD data corresponds to the in-service surface of the in-service structure within the predetermined tolerance.

[0086] Clause 8. The system of clause 1, wherein the 3D scan data comprises a 3D mesh data structure, and wherein generating the in-service CAD data further comprises converting the 3D mesh data structure to an in-service CAD data structure comprising the in-service surface.

[0087] Clause 9. The system of clause 1, wherein determining at least one of a serviceability level or a remaining life estimate of the in-service structure based on the in-service CAD data further comprises: performing a strength analysis on the in-service CAD data to determine a condition of the in-service structure.

[0088] Clause 10. The system of clause 9, wherein performing the strength analysis comprises performing a finite element analysis to determine the condition of the in-service structure.

[0089] Clause 11. The system of clause 1, wherein the in-service structure comprises an in-service vehicle structure.

[0090] Clause 12. The system of clause 11, wherein the in-service structure comprises an in-service aircraft structure.

[0091] Clause 13. A method for determining serviceability and remaining life of an in-service structure comprising:

[0092] accessing, by a processor circuit, three-dimensional (3D) scan data representative of an in-service structure captured by a scanning device;

[0093] generating, by the processor circuit, in-service computer-aided design (CAD) data representative of an in-service surface corresponding to the in-service structure based on the 3D scan data; and

[0094] determining at least one of a serviceability level or a remaining life estimate of the in-service structure based on the in-service CAD data representative of the in-service surface.

[0095] Clause 14. The system of clause 13, the method further comprising:

[0096] accessing nominal CAD data representative of a nominal volume comprising a nominal surface, wherein the nominal volume corresponds to a nominal structure, and wherein a portion of the nominal surface corresponds to the in-service surface; and

[0097] replacing the portion of the nominal surface with the in-service surface to generate altered nominal CAD data representative of an altered nominal volume comprising the in-service surface,

[0098] wherein determining at least one of a serviceability level or a remaining life estimate of the in-service structure is further based on the altered nominal CAD data.

[0099] Clause 15. The method of clause 14, wherein replacing the portion of the nominal surface further comprises removing a trimmed volume defined by the portion of the nominal surface and the in-service surface from the nominal volume.

[0100] Clause 16. The method of clause 14, wherein replacing the portion of the nominal surface further comprises adding an added volume defined by the portion of the nominal surface and the in-service surface in the nominal volume.

[0101] Clause 17. The method of clause 14, wherein replacing the portion of the nominal surface further comprises:

[0102] elevating the nominal surface relative to the nominal volume to generate an increased nominal volume; and

[0103] removing a trimmed volume defined by the elevated nominal surface and the in-service surface from the increased nominal volume.

[0104] Clause 18. The method of clause 14, further comprising:

[0105] comparing, by the processor circuit, the in-service surface of the altered nominal volume to the 3D scan data;

[0106] determining, by the processor circuit, based on the comparison, whether the in-service surface of the altered nominal CAD data corresponds to the in-service surface of the in-service structure within a predetermined tolerance; and

[0107] generating, by the processor circuit, responsive to the determination, an indication as to whether the in-service surface of the altered nominal CAD data corresponds to the in-service surface of the in-service structure within the predetermined tolerance.

[0108] Clause 19. The method of clause 14, further comprising performing a strength analysis on the corrected nominal CAD data.

[0109] Clause 20. A system for determining serviceability and remaining life of an in-service structure, the system comprising:

[0110] a processor circuit; and

[0111] a memory coupled to the processor circuit, the memory comprising machine-readable instructions which, when executed by the processor circuit:

[0112] accessing nominal computer-aided design (CAD) data representative of a nominal volume comprising a nominal surface, wherein the nominal volume corresponds to a nominal structure;

[0113] accessing three-dimensional (3D) scan data representative of an in-service structure corresponding to a portion of the nominal structure, captured by a scanning device;

[0114] generating, based on the 3D scan data, as-built CAD data representative of an as-built surface of the as-built structure corresponding to a portion of the nominal surface; and

[0115] replacing the portion of the nominal surface with the as-built surface to generate as-altered nominal CAD data representative of an as-altered nominal volume including the as-built surface.

[0116] As will be appreciated by those skilled in the art, some aspects of the present disclosure can be exemplified and described herein in any of a number of patentable classes or contexts or any new useful improvements thereto, including any new useful processes, machines, manufacture or compositions of matter. Accordingly, aspects of the present invention can be realized by hardware, software, entire software (including firmware, resident software, microcode, etc.) or combined software and hardware implementations all of which can be generally referred to herein as a "circuit," "module," "component" or "system." Furthermore, aspects of the present disclosure can take the form of a computer program product implemented in one or more computer-readable media having computer readable program code embodied thereon.

[0117] Any combination of one or more computer readable medium can be utilized. The computer readable medium can be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium can be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an appropriate optical fiber with a relay, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium can be any tangible medium that can contain or store a program for use by or in connection with an instruction execution system, apparatus, or device.

[0118] A computer readable signal medium can include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal can take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium can be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device. Program code embodied on a computer readable signal medium can be transmitted using any suitable medium, including, but not limited to, wireless, wired, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

[0119] Computer program code for carrying out operations of aspects of the present disclosure can be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Scala, Smalltalk, Eiffel, JADE, Emerald, C++, C#, VB.NET, Python, and the like, conventional procedural programming languages, such as the "C" programming language, Visual Basic, Fortran 2003, Perl, COBOL 2002, PHP, ABAP, dynamic programming languages, such as Python, Ruby, and Groovy, or other programming languages. The program code can execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer can be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection can be made to an external computer (for example, through the Internet using an Internet Service Provider) or within a cloud computing environment or as a service (such as Software as a Service (SaaS)).

[0120] Herein, aspects of the disclosure are described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems) and computer program products according to examples of the present disclosure. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer readable instructions (e.g., computer program instructions). The machine readable instructions can be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable instruction execution apparatus, create means for implementing the functions or acts specified in the flowchart and / or block diagram block or blocks.

[0121] These machine-readable instructions can also be stored in transient or non-transitory computer-readable media, and when executed, can instruct a computer, other programmable data processing apparatus, or other means to function in a particular manner, causing the instructions stored in the computer-readable medium to produce an article of writing that, when executed, causes the computer to perform the functions or actions specified in one or more boxes of a flowchart or block diagram. The computer-readable instructions can also be loaded onto a computer, other programmable instruction execution device, or other means to cause a series of operational steps to be performed on the computer, other programmable device, or other means to produce a process implemented by the computer, such that the instructions, which execute on the computer or other programmable device, provide a process for implementing the functions or actions specified in one or more boxes of a flowchart or block diagram. The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various aspects of this disclosure. In this regard, each box in a flowchart or block diagram may represent a portion of a module, segment, or code that includes one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the boxes may occur in a different order than that shown in the accompanying drawings. For example, depending on the functions involved, two boxes shown consecutively may actually be executed substantially simultaneously, or these boxes may sometimes be executed in reverse order. It will also be noted that each box in a block diagram or flowchart, and combinations of boxes in a block diagram or flowchart, may be implemented by a system based on dedicated hardware or a combination of dedicated hardware and computer instructions that performs the specified functions or actions.

[0122] The terminology used herein is for descriptive purposes only and is not intended to be limiting of this disclosure. As used herein, the singular forms “a,” “an,” and “the” are also intended to include the plural forms unless the context clearly indicates otherwise. It will be further understood that, when used in this specification, the terms “comprises” and “comprising” specify the presence of the stated feature, step, operation, element, or component, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, or groups thereof. Throughout the description of the accompanying drawings, similar reference numerals denote similar elements.

[0123] In conjunction with the foregoing description and accompanying drawings, numerous different examples have been disclosed herein. It will be understood that describing and illustrating each combination and sub-combination of these examples verbatim would be unnecessarily repetitive and confusing. Therefore, all examples can be combined in any manner or combination, and this specification (including the accompanying drawings) should be construed as a complete written description of all combinations and sub-combinations constituting the examples described herein, the ways and processes of making and using them, and should support any claims for such combinations or sub-combinations.

Claims

1. A system (500) for determining serviceability and remaining life of an in-service structure (200), the system (500) comprising: a processor circuit (504); and a memory (506) coupled to the processor circuit, the memory comprising machine readable instructions (530, 532, 534, 536, 538, 540) that, when executed by the processor circuit: access three-dimensional scan data representative of an in-service structure (200) captured by a scanning device (202); generate (106) in-service computer aided design data representative of an in-service surface (212) corresponding to the in-service structure based on the three-dimensional scan data; and determine (112) at least one of a serviceability level or a remaining life estimate of the in-service structure based on the in-service computer aided design data representative of the in-service surface, wherein the machine readable instructions further cause the processor circuit to: access nominal computer aided design data representative of a nominal volume (224) including a nominal surface (226), wherein the nominal volume corresponds to a nominal structure (225), and wherein a portion of the nominal surface corresponds to the in-service surface; and replace (110) the portion of the nominal surface with the in-service surface to generate altered nominal computer aided design data representative of an altered nominal volume (236) including the in-service surface, wherein determining at least one of a serviceability level or a remaining life estimate of the in-service structure is further based on the altered nominal computer aided design data.

2. The system of claim 1, wherein, Replacing the portion of the nominal surface further comprises at least one of: removing a trimmed volume (342) defined by the portion of the nominal surface and the in-service surface from the nominal volume; and adding an added volume (342) defined by the portion of the nominal surface and the in-service surface in the nominal volume. Replacing the portion of the nominal surface further comprises:

3. The system of claim 1, wherein, raising (120) the nominal surface relative to the nominal volume to generate an enlarged nominal volume (340); and removing (122) a trimmed volume (342) defined by the raised nominal surface and the in-service surface from the enlarged nominal volume. The machine readable instructions further cause the processor circuit to:

4. The system of claim 1, wherein, compare (152) the in-service surface of the altered nominal volume to the three-dimensional scan data; determine (154) based on the comparison whether the in-service surface of the altered nominal computer aided design data corresponds to the in-service surface of the in-service structure within a predetermined tolerance (452); and generate (156) an indication (446) as to whether the in-service surface of the altered nominal computer aided design data corresponds to the in-service surface of the in-service structure within the predetermined tolerance in response to the determination. The machine readable instructions further cause the processor circuit to:

5. The system of claim 1, wherein, ​ accessing second three-dimensional scan data representative of the in-service structure captured by the scanning device; comparing (152) the in-service surfaces of the altered nominal computer-aided design data to the second three-dimensional scan data; determining (154), based on the comparison, whether the in-service surfaces of the altered nominal computer-aided design data correspond to the in-service surfaces of the in-service structure within a predetermined tolerance (452); and generating (156), in response to the determination, an indication (446) as to whether the in-service surfaces of the altered nominal computer-aided design data correspond to the in-service surfaces of the in-service structure within the predetermined tolerance.

6. The system of claim 1, wherein, the three-dimensional scan data comprises a three-dimensional mesh data structure, and wherein generating the in-service computer-aided design data further comprises converting the three-dimensional mesh data structure to an in-service computer-aided design data structure comprising the in-service surfaces.

7. The system of claim 1, wherein, determining at least one of a serviceability level or a remaining life estimate for the in-service structure based on the in-service computer-aided design data further comprises: performing (114) a strength analysis on the in-service computer-aided design data to determine a condition of the in-service structure, wherein performing a strength analysis comprises performing a finite element analysis to determine the condition of the in-service structure.

8. The system of claim 1, wherein, the in-service structure comprises an in-service vehicle structure, and wherein the in-service vehicle structure comprises an in-service aircraft structure.

9. A method (100) for determining serviceability and remaining life of an in-service structure, the method (100) comprising: accessing, by a processor circuit (504), three-dimensional scan data representative of an in-service structure (200) captured by a scanning device (202); generating (106), by the processor circuit based on the three-dimensional scan data, in-service computer-aided design data representative of in-service surfaces (212) corresponding to the in-service structure; and determining (112) at least one of a serviceability level or a remaining life estimate for the in-service structure based on the in-service computer-aided design data representative of the in-service surfaces, the method further comprising: accessing nominal computer-aided design data representative of a nominal volume (224) comprising a nominal surface, wherein the nominal volume corresponds to a nominal structure (225), and wherein a portion of the nominal surface (226) corresponds to the in-service surfaces; and replacing (110) the portion of the nominal surface with the in-service surfaces to generate altered nominal computer-aided design data representative of an altered nominal volume (236) comprising the in-service surfaces, wherein determining at least one of a serviceability level or a remaining life estimate for the in-service structure is further based on the altered nominal computer-aided design data.

10. The method of claim 9, wherein, replacing the portion of the nominal surface further comprises removing a trimmed volume (342) defined by the portion of the nominal surface and the in-service surfaces from the nominal volume.

11. The method of claim 9, wherein, The replacing the portion of the nominal surface further includes adding an added volume (342) defined by the portion of the nominal surface and the in-service surface in the nominal volume.

12. The method of claim 9, wherein, The replacing the portion of the nominal surface further includes: lifting (120) the nominal surface relative to the nominal volume to generate an increased nominal volume (340); removing (122) a trimmed volume (342) defined by the lifted nominal surface and the in-service surface from the increased nominal volume; and performing (114) a strength analysis on the altered nominal computer aided design data.

13. The method of claim 9, the method further comprising: comparing (152), by the processor circuit, the in-service surface of the altered nominal volume to the three-dimensional scan data; determining (154), by the processor circuit, based on the comparison, whether the in-service surface of the altered nominal computer aided design data corresponds to the in-service surface of the in-service structure within a predetermined tolerance (452); and generating (156), by the processor circuit, responsive to the determination, an indication (446) as to whether the in-service surface of the altered nominal computer aided design data corresponds to the in-service surface of the in-service structure within the predetermined tolerance.

14. The method of claim 9, the method further comprising: receiving (150), by the processor circuit, three-dimensional scan data of the in-service structure; and generating (152), by the processor circuit, the in-service surface of the altered nominal volume based on the three-dimensional scan data.

15. The method of claim 9, the method further comprising: receiving (150), by the processor circuit, three-dimensional scan data of the in-service structure; and generating (152), by the processor circuit, the in-service surface of the altered nominal volume based on the three-dimensional scan data.

16. The method of claim 9, the method further comprising: receiving (150), by the processor circuit, three-dimensional scan data of the in-service structure; and generating (152), by the processor circuit, the in-service surface of the altered nominal volume based on the three-dimensional scan data.

17. The method of claim 9, the method further comprising: receiving (150), by the processor circuit, three-dimensional scan data of the in-service structure; and generating (152), by the processor circuit, the in-service surface of the altered nominal volume based on the three-dimensional scan data.

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