Large area wireless fuselage dimple inspection apparatus and method

Abstract

A large area wireless fuselage dimple inspection apparatus and method. The present disclosure provides an inspection vehicle for inspecting a large area object, such as an aircraft fuselage. In one aspect, an inspection car includes a tower that supports a track. The inspection vehicle further comprises a bracket capable of moving along the track. The carriage supports a 3D scanner having at least two cameras and a projector. The inspection vehicle also includes an integrated optical reference arranged relative to the track such that the optical reference is within the field of view of the 3D scanner during scanning of the object. In other aspects, an inspection system including at least one inspection vehicle is provided. In further aspects, a method of inspecting large area objects using the inspection vehicle is provided.

Description

Technical Field

[0001] Aspects of the present disclosure relate to apparatus, systems, and methods for inspecting large area objects, such as aircraft fuselages. Background Art

[0002] Traditionally, inspecting aircraft fuselages for defects has been a manual process involving flashing lights and bump caps, and dependent on human vision and meticulousness. As a result, inspecting aircraft fuselages for defects has traditionally been quite time-consuming. Furthermore, aircraft fuselages are typically inspected during final assembly while being coated with a green temporary protective coating (TPC), which obstructs the view of many defects. As a result, some defects go undetected until a later stage, such as after a glossy final paint job has been applied to the fuselage of the aircraft. Reworking at this stage to repair these undetected defects can be costly. In some cases, for example, it may be necessary to remove the cockpit or lavatory from the fuselage in order to reveal dents that were not detected during final assembly. Currently available scanners and vision systems offer little help in automating the inspection process because they are relatively small, localized, and take too long to process images. Summary of the Invention

[0003] The present disclosure provides, in one aspect, a method comprising: translating a 3D scanner relative to a target object, the 3D scanner being disposed in an inspection vehicle; scanning the target object with the 3D scanner as the 3D scanner translates to capture an image of at least one slice of the target object, wherein an optical fiducial integrated into the inspection vehicle is disposed in a field of view of the 3D scanner during the scanning; stitching the captured images of the target object obtained during the scanning to create a slice image, the captured images being stitched together based on positional targets provided by the optical fiducial; and detecting one or more defects on the target object based on the slice image.

[0004] In one aspect, in combination with any of the above or below example methods, the method includes projecting, by a 3D scanner, one or more defect indicators onto the target object to indicate corresponding defects among the one or more defects detected on the target object.

[0005] In one aspect, in combination with any of the above or below example methods, at least one of the one or more defect indicators is projected onto the target object outlining a defect of the one or more defects detected on the target object.

[0006] In one aspect, in combination with any of the above or below example methods, the 3D scanner translates along a linear path oriented at an angle relative to vertical.

[0007] In one aspect, in combination with any of the above or below example methods, the optical reference includes first and second reference rails spaced apart from each other and arranged parallel to the linear path.

[0008] In one aspect, in combination with any of the above or below example methods, the position targets are arranged on first fingers extending from a first reference rail and on second fingers extending from a second reference rail, the first fingers being spaced apart from one another along the first reference rail and the second fingers being spaced apart from one another along the second reference rail.

[0009] In one aspect, in combination with any of the above or below example methods, the method includes masking the optical fiducial in the slice image so that the optical fiducial does not appear on the slice image.

[0010] In one aspect, in combination with any of the above or below example methods, the slice of the target object is a first slice, and wherein the method further comprises: a) moving the inspection vehicle so that the inspection vehicle is aligned with a subsequent slice of the target object; b) translating the 3D scanner relative to the target object with the inspection vehicle aligned with the subsequent slice; c) scanning the target object with the 3D scanner as the 3D scanner translates with the inspection vehicle aligned with the subsequent slice to capture images of subsequent slices of the target object, wherein the optical reference is arranged in a field of view of the 3D scanner during the scanning of the subsequent slice; d) stitching the captured images of the subsequent slices of the target object together to create a subsequent slice image, the captured images of the subsequent slices being stitched together according to position targets provided by the optical reference; and e) detecting one or more defects on the subsequent slice of the target object based on the subsequent slice image.

[0011] In one aspect, in combination with any of the above or below example methods, the method further comprises: iterating a) to e) for a predetermined length of the target object; and stitching the slice image of the first slice and the subsequent slice images of each subsequent slice into a combined slice image.

[0012] In one aspect, in combination with any of the above or below example methods, the combined slice image is a first combined slice image associated with a first side of the target object, and wherein the method further comprises creating a second combined slice image associated with a second side of the target object.

[0013] In one aspect, in combination with any of the example methods above or below, the method includes creating a digital twin of the target object based at least in part on the first combined slice image and the second combined slice image.

[0014] In one aspect, in combination with any of the example methods above or below, the inspection vehicle autonomously moves from one slice to another of a target object.

[0015] In one aspect, in combination with any of the above or below example methods, the target object is a fuselage, and wherein the fuselage is scanned such that the captured image of the slice extends from a midline of the lower abdomen of the fuselage to a window line of the fuselage.

[0016] In one aspect, in combination with any of the above or below example methods, the target object is a fuselage, and wherein the fuselage is scanned such that the captured image of the slice extends from a midline of the lower abdomen of the fuselage to a midline of the top of the fuselage.

[0017] In another aspect, the present disclosure provides an inspection system. The inspection system includes an inspection vehicle. The vehicle includes a tower supporting a track. The vehicle also includes a carriage movable along the track, the carriage supporting a 3D scanner having at least two cameras and a projector. Furthermore, the vehicle includes an optical fiducial positioned relative to the track such that the optical fiducial is within the field of view of the 3D scanner during scanning of a target object.

[0018] In one aspect, in combination with any of the above or below example inspection systems, the inspection system further comprises one or more processors and one or more non-transitory memory devices storing a program that, when executed by any combination of the one or more processors, causes the one or more processors to perform operations including: moving the carriage along a track to move the 3D scanner relative to a target object; causing the 3D scanner to scan the target object as the 3D scanner translates to capture an image of at least one slice of the target object; stitching the captured images of the slices of the target object together to create a slice image, the captured images being stitched together according to positional targets provided by the optical fiducials; and detecting one or more defects on the target object based on the slice image.

[0019] In one aspect, in combination with any of the example inspection systems above or below, the operations further include causing a projector of the 3D scanner to project one or more defect indicators onto the target object to indicate corresponding defects among the one or more defects detected on the target object.

[0020] In one aspect, in combination with any of the example inspection systems above or below, the track is a linear track, and the optical reference includes a first reference rail and a second reference rail spaced apart from each other and arranged parallel to the linear track.

[0021] In one aspect, in combination with any of the above or below example inspection systems, the target object is a fuselage, and wherein the track is a curved track extending above and below the fuselage.

[0022] The present disclosure provides, in another aspect, an inspection vehicle. The inspection vehicle includes: a tower supporting a track; a carriage movable along the track, the carriage supporting a 3D scanner having at least two cameras and a projector; and an optical fiducial positioned relative to the track such that the optical fiducial is within a field of view of the 3D scanner during scanning of a target object. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order that the features recited above can be understood in detail, a more particular description, briefly summarized above, may be had by reference to example aspects, some of which are illustrated in the accompanying drawings.

[0024] Figure 1 is a front-to-rear perspective view of an inspection vehicle according to an example aspect of the present disclosure.

[0025] Figure 2 yes Figure 1 A perspective view of the inspection vehicle from the rear to the front.

[0026] Figure 3 yes Figure 1 Side view of the inspection car.

[0027] Figure 4 is a system diagram of an inspection system according to an example aspect of the present disclosure.

[0028] Figure 5 is a flow chart of an example method of inspecting a target object using an inspection system according to an example aspect of the present disclosure.

[0029] Figure 6 is a schematic side view of an aircraft fuselage, illustrating one example manner in which the fuselage may be divided into slices.

[0030] Figure 7 and Figure 8 Depicted is the inspection vehicle positioned relative to a slice of the port side of the fuselage and performing its scan.

[0031] Figure 9 Depicted in Figure 7 and Figure 8 Multiple images of a slice of the fuselage captured during the scan are depicted.

[0032] Figure 10 Shown from Figure 9 The images of the slices depicted in the figure are stitched together into a combined slice image.

[0033] Figure 11 Shows defect indicators projected onto the fuselage by a projector of a 3D scanner.

[0034] Figure 12A plurality of slice images are shown, each associated with one of the predefined slices of the fuselage, wherein the slice images are stitched together into a combined slice image.

[0035] Figure 13 A front-to-back view of a fuselage is depicted and shows a first inspection vehicle and a second inspection vehicle scanning and capturing images of respective sides of the fuselage according to example aspects of the present disclosure.

[0036] Figure 14 is a perspective view of an inspection vehicle with a siegetower in a scanner / manipulator configuration according to example aspects of the present disclosure.

[0037] Figure 15 is a perspective view of another inspection vehicle having an enclosing tower in a roller coaster conveyor configuration according to example aspects of the present disclosure. DETAILED DESCRIPTION

[0038] The present disclosure relates to improved aircraft fuselage inspection equipment, systems, and methods. In particular, the equipment, systems, and methods disclosed herein facilitate, for example, real-time detection of defects on an aircraft fuselage. The equipment and methods disclosed herein can be used to inspect an aircraft fuselage at various lifecycle stages, such as at final assembly, at delivery, or even after the aircraft has been placed in service (e.g., performing an inspection after a hailstorm). Although the inspection equipment, systems, and methods are described herein in the context of inspecting an aircraft fuselage, aspects of the present disclosure are also applicable to inspecting other large-area objects, such as other areas of an aircraft (e.g., wings, cockpit, tail, etc.), ships, spacecraft, trains, industrial pipelines, and the like.

[0039] In one exemplary aspect, an inspection vehicle of an inspection system is provided that facilitates inspection of an aircraft fuselage, for example, by detecting skin defects in real time. The inspection vehicle is mobile and includes a tower supporting a track. The inspection vehicle also includes a carriage movable along the track. The carriage supports a 3D scanner having at least two cameras and a projector. The inspection vehicle also includes an integrated optical fiducial positioned relative to the track such that the optical fiducial is within the field of view of the 3D scanner during scanning of the fuselage. In this aspect, the optical fiducial is integrated into the inspection vehicle. During inspection of the fuselage, the 3D scanner can translate along the track. As the 3D scanner translates, it captures images of at least one slice of the fuselage. During scanning, the integrated optical fiducial is positioned within the field of view of the 3D scanner. The captured images can be stitched together to create a slice image. The captured images are stitched together based on positional targets provided by the optical fiducial. One or more defects on the fuselage can be detected based on the slice image. The detected defects can be presented to an operator during or immediately after the slice is scanned. In particular, one or more defect indicators can be projected onto the fuselage to indicate the location of the defects. This allows the operator to immediately understand the defect and its corresponding location on the fuselage. Other alerts or reports of the identified defect are also possible, such as real-time presentation of the identified defect on a display, audio alerts, automatically generated reports, etc. This process can be repeated for other slices of the fuselage, and the slice images can be stitched together to form a combined slice image. In some aspects, multiple inspection vehicles can be utilized to simultaneously scan different sections of the fuselage.

[0040] The inspection vehicles, inspection systems and methods disclosed herein may provide certain advantages, benefits and / or technical effects. For example, the apparatus and methods provided herein may eliminate or largely replace manual fuselage inspections for detecting defects (e.g., dents, missing parts, unacceptable tolerances, etc.). Eliminating or reducing the need for manual inspections may allow for fewer escapes, lower costs, higher repeatability, precision and accuracy of defects detected, improved quality and safety, reduced inspection time, elimination or reduction of ergonomic challenges for operators (e.g., head injuries under the fuselage, repetitive strain injuries (harmful postures), eye fatigue and noise. Additionally, optical fiducials are integrated into the inspection vehicle, which allows for contactless fuselage inspection. Thus, there is no need to touch or contact the fuselage to arrange optical targets thereon. Optical fiducials are traditionally placed on the target part or on a fixture that holds the target part (e.g., with stickers in known locations). For large target parts (e.g., aircraft fuselages), setup and cleanup of such traditional techniques would be time consuming and costly.

[0041] In addition, defects can be detected and their location made immediately known to the operator, for example, by projecting defect indicators onto the fuselage of the aircraft. The operator can use the indicators to mark the aircraft as needed (e.g., using tape, etc.). In addition, the carriage carrying the 3D scanner can be driven in a controlled motion with the optical reference at a known distance and within the field of view of the camera. The 3D scanner can use "fingers" and / or position targets on the reference guide to determine its relative position, which helps to stitch the captured images together into slice images of the fuselage. In addition, the inspection vehicle is mobile and can therefore be moved (e.g., manually or autonomously) from one capture location to the next to capture different slices of the fuselage. The slice images can be stitched together to create, for example, a combined slice image of the length of the aircraft fuselage. The slice images and / or combined slice images can be used to generate a digital twin of the fuselage, which can be used as a baseline for comparison with future scans of the fuselage, as well as other possible uses. Additionally, the predictive assembly system may use the slice images and / or combined slice images to make assembly predictions, such as predictions about how to address one or more detected defects (eg, by adding shims, machining a surface, etc.).

[0042] Turning now to the accompanying drawings, Figure 1 、 Figure 2 、 Figure 3 Various views of an inspection vehicle 100 according to example aspects of the present disclosure are provided. For reference, the inspection vehicle 100 defines a transverse direction T, a lateral direction L, and a vertical direction V, which are mutually perpendicular and form an orthogonal directional system. The inspection vehicle 100 has a front end 102 and a rear end 104. The front end 102 and the rear end 104 are spaced apart from each other along the transverse direction T. The inspection vehicle 100 also has a first side 106 and a second side 108. The first side 106 is spaced apart from the second side 108 along the lateral direction L.

[0043] The inspection cart 100 has a chassis 110 mounted with a plurality of casters 112. The casters 112 enable the inspection cart 100 to be mobile. The chassis 110 is generally formed from a plurality of frame members and has a rectangular configuration. The inspection cart 100 also has a first side support 114 and a second side support 116, both of which are connected to and supported by the chassis 110. The first side support 114 includes a first side rail 118, a first front post 120, and a first intermediate post 122. Similarly, the second side support 116 includes a second side rail 124, a second front post 126, and a second intermediate post 128. The first side rail 118 and the second side rail 124 are each arranged at an ergonomically friendly height, wherein an adult of average height can easily grasp, and if necessary, the inspection cart 100 can be manually moved by pushing or pulling one or both of the first side rail 118 and the second side rail 124.

[0044] Inspection vehicle 100 also includes a tower 130, which structurally supports a translation carriage 132 carrying a 3D scanner 134. Tower 130 includes, among other things, a first tower column 136, a second tower column 138, and a tower beam 140 extending between and connecting the first and second tower columns 136, 138 at their top ends. Tower 130 also includes a first tilt frame 141 and a second tilt frame 142. The first and second tilt frames 141, 142 are coupled to tower beam 140 at the top of tower 130 and to chassis beam 144 at the bottom of tower 130. Tower 130 also includes first and second intermediate tower columns 146, 148, which support the mid-span points of the first and second tilt frames 141, 142. The first and second side rails 118, 124 are connected to the first and second tower columns 136, 138, respectively. A rear handle bar 150 is connected to the first tower column 136 and the second tower column 138 and provides an ergonomic handle for a user to grasp and manually move the inspection vehicle 100. The rear handle bar 150 also advantageously extends outwardly above a control cabinet 152 to, for example, provide protection for the control cabinet 152. The control cabinet 152 may store various power, communication, and computing devices associated with operating the inspection vehicle 100.

[0045] Tower 130 also includes a track 154 and a drive system 156 for translating or moving carriage 132 along track 154. Track 154 includes a first side rail 158 and a second side rail 160 coupled to first tilt frame 141 and second tilt frame 142, respectively. In this example, track 154 is a linear track. In this regard, first side rail 158 and second side rail 160 are linear. In some exemplary aspects, first side rail 158 and second side rail 160 may include end stops at their respective top and / or bottom ends, for example, to provide failsafe protection for carriage and / or 3D scanner 134 carried therein. As one example, the end stops may be shock absorbers positioned at the bottom of first side rail 158 and / or second side rail 160. As another example, the end stops may be compression springs positioned at the bottom of first side rail 158 and / or second side rail 160. As another example, the end stops may be elastomeric stop bumpers placed on top of the first side rail 158 and / or the second side rail 160 . Figure 1 An elastomeric stop bumper 162 is shown disposed on top of the second side rail 160 .

[0046] The drive system 156 is a belt drive system in this example and includes, among other things, an electric motor 164, a gear box 166 mechanically coupled to the electric motor 164, and a pulley system 168 mechanically coupled to the gear box 166. Generally, the carriage 132 is slidably received within the track 154, and the drive system 156 can be controlled to translate the carriage 132, and therefore the 3D scanner 134, along the track 154. The carriage 132 translates along the track 154 between a first position (e.g., a bottom position) and a second position (e.g., a top position). Figure 1 and Figure 3 The middle bracket 132 is shown in the bottom or first position and in Figure 2 The middle bracket 132 is shown in the top or second position. Thus, the 3D scanner 134 can move along the translation path TP ( Figure 3 ) translation, in this example the translation path TP is a straight path oriented at an angle relative to a vertical direction V. In some example aspects, the translation path TP can be oriented at a forty-five degree angle (45°) relative to the vertical direction V. However, in other example aspects, the translation path TP can be oriented at other angles, such as thirty degrees (30°) or sixty degrees (60°).

[0047] Inspection vehicle 100 also includes optical fiducials that are positioned within the field of view (FOV) of 3D scanner 134 during scanning of a target object (e.g., an aircraft fuselage). In this example, the optical fiducials include a first optical fiducial 170 and a second optical fiducial 172. First optical fiducial 170 includes a first fiducial rail 174, and second optical fiducial 172 includes a second fiducial rail 176. First and second fiducial rails 174, 176 are spaced apart from one another, for example, along a lateral direction L, and are arranged parallel to translation path TP, or more specifically, parallel to the translation angle of 3D scanner 134. Both first and second fiducial rails 174, 176 are spaced apart from rail 154, for example, along a direction perpendicular to translation path TP. The bottom end of first fiducial rail 174 is supported by a first front support post 178, which is connected to first side bracket 114 and extends longitudinally along vertical direction V. The top end of the first reference rail 174 is connected to a first rear support column 180, which is connected to the tower beam 140 and extends longitudinally in a direction perpendicular to the translation path TP. Similarly, the bottom end of the second reference rail 176 is supported by a second front support column 182, which is connected to the second side bracket 116 and extends longitudinally in the vertical direction V. The top end of the second reference rail 176 is connected to a second rear support column 184, which is connected to the tower beam 140 and extends longitudinally in a direction perpendicular to the translation path TP.

[0048] like Figure 2As shown, first optical fiducial 170 and second optical fiducial 172 may include position targets 186. Generally, position targets 186 are used to assist 3D scanner 134 in determining its position as the target object is translated during scanning, and also to enable captured images to be stitched together to form a combined image. In some aspects, position targets 186 may be located on first and second fiducial rails 174, 176. Additionally or alternatively, position targets 186 may be located on fingers of first and second fiducial rails 174, 176. In some aspects, for example, position targets 186 may be arranged on first fingers 188 extending from first fiducial rail 174 and second fingers 190 extending from second fiducial rail 176. First fingers 188 are spaced apart from one another along first fiducial rail 174, and second fingers 190 are spaced apart from one another along second fiducial rail 176. The first finger 188 and the second finger 190 each extend from their respective first reference rail 174 and second reference rail 176 toward each other along the lateral direction L. Figure 2 In the depicted example, position targets 186 are provided on each first finger 188 and along the entire length of first reference rail 174. Additionally, position targets 186 are provided on each second finger 190 and along the entire length of second reference rail 176. Figure 2 The corresponding close-up view in , depicts a position target 186 on the feature. The position target 186 is arranged to face or otherwise be within the FOV of the 3D scanner 134.

[0049] Position targets 186 can be arranged in different patterns along first and second reference rails 174, 176, and along first and second fingers 188, 190. The pattern and location of position targets 186 (e.g., coordinates relative to 3D scanner 134) can be known to 3D scanner 134 and / or a computing system associated with inspection vehicle 100, such that position targets 186 can be used to assist 3D scanner 134 in determining its position as the target object is translated during scanning, and also for stitching captured images together. Advantageously, first and second optical fiducials 170, 172 are integrated into inspection vehicle 100 and have position targets 186 arranged within the FOV of 3D scanner 134. In this way, 3D scanner 134 can know or determine its position relative to position targets 186—without requiring any targets or markers on the target object itself. This provides non-contact scanning capabilities.

[0050] Figure 1 、 Figure 2 and Figure 3 An inspection vehicle according to example aspects of the present disclosure is provided. In some alternative aspects, Figure 1 、 Figure 2 and Figure 3The inspection vehicle 100 may have other configurations. For example, in some aspects, the inspection vehicle 100 may be arranged on wheels locked into a track, for example, where the track extends along at least a portion of the target object (e.g., the entire longitudinal length of the fuselage). The inspection vehicle 100 can move along the track to capture images of various "slices" of the fuselage. In other aspects, the inspection vehicle 100 may be arranged with one or more steerable wheels and, optionally, one or more non-steerable wheels. In these aspects, the inspection vehicle 100 may include a steering mechanism (e.g., a steering wheel, a pull rod for zero-turn capability, etc.) and may have a motor or engine to propel the inspection vehicle 100. In this regard, the inspection vehicle 100 can be driven to a desired location for scanning. In some further aspects, the inspection vehicle 100 may include a self-driving or autonomous driving feature that allows the inspection vehicle to be autonomously moved to various locations, for example, along the longitudinal length of the fuselage. In other aspects, as will be described in more detail herein, the inspection vehicle 100 may include a "wraparound turret" that, for example, enables scanning of the top quadrant of the fuselage in addition to the bottom quadrant.

[0051] Now refer to Figure 4 , in some respects, Figure 1 、 Figure 2 、 Figure 3 The inspection vehicle 100 may be part of an inspection system 200. The inspection system 200 may include the inspection vehicle 100 ( Figures 1 to 3 ) and computing system 210, and in some aspects may also include a data repository 238 and / or a predictive assembly system 240. Other systems may also be communicatively coupled to the inspection system 200, for example, via a communication bus 244.

[0052] like Figure 4 As depicted in FIG. 1 , the inspection vehicle 100 ( Figures 1 to 3 ) includes a track 154 ( Figure 1) 3D scanner 134 that translates. 3D scanner 134 includes, among other things, at least two cameras and a projector 191. In this example, the cameras include a first camera 192 and a second camera 193 positioned on opposite sides of projector 191. As 3D scanner 134 translates along track 154, first camera 192 and second camera 193 capture images of a target object. As will be described in greater detail herein, during scanning, projector 191 can project light onto the target object to enhance the images captured by first camera 192 and second camera 193. Additionally, projector 191 can be used to project defect indicators onto the target object to indicate corresponding detected defects. 3D scanner 134 also includes first and second laser emitters 194 and 195 spaced apart from each other. First and second laser emitters 194 and 195 can emit laser light onto the target object, for example, to ensure that the focal distance between first and second cameras 192 and 193 and the target object is within a predetermined range or specification. For example, when the lasers emitted from the first laser emitter 194 and the second laser emitter 195 meet at a point, the focal length can be determined to be within a predetermined range or specification. In this regard, the first laser emitter 194 and the second laser emitter 195 can be used to determine that the inspection vehicle 100 has a suitable "standoff" relative to the target object.

[0053] The 3D scanner 134 can be used with the inspection vehicle 100 ( Figures 1 to 3 ) on other systems (e.g., control cabinet 152 ( Figure 1 ) and / or onboard components of the computing system 210, and is also communicatively coupled to one or more off-board systems (e.g., off-board components of the computing system 210, data repository 238, predictive assembly system 240, etc.). In some aspects, the computing system 210 may be partially located on the inspection vehicle 100 and partially located off the inspection vehicle 100. In other example aspects, the computing system 210 may be completely located on the inspection vehicle 100.

[0054] The computing system 210 may include one or more processors 212 and one or more non-transitory memory devices 214 that may store computer-readable instructions 216 or code. These instructions or code are executable by the processor 212 to perform operations such as causing the first camera 192 and the second camera 193 to capture images of the target object as the 3D scanner 134 moves along the track 154, stitching the captured images together, and / or causing the projector 191 to project defect indicators corresponding to detected defects onto the target object. The instructions 216 may be software written in any suitable programming language or may be implemented in hardware. For example, the one or more processors 212 and the one or more non-transitory memory devices 214 may be embodied in one or more computing devices.

[0055] The one or more processors 212 may include any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, a logic device, or other suitable processing device. The one or more memory devices 214 may include one or more computer-readable media, including but not limited to non-transitory computer-readable media, RAM, ROM, a hard drive, a flash drive, and other memory devices. The one or more memory devices 214 may store information accessible by the one or more processors 212, including instructions 216 executable by the one or more processors 212. The memory device 214 may also store data 218 accessible by the processor 212. For example, the data 218 may include images captured by the 3D scanner 134, position targets 186 ( Figure 2 ), known coordinates of the target object, data related to the target object, etc. According to example aspects of the present disclosure, the data 218 may include one or more tables, functions, algorithms, models, equations, etc.

[0056] Computing system 210 also includes a communication interface 220 for communicating, for example, with other components of inspection system 200. Communication interface 220 may include any suitable components for interfacing with one or more networks, including, for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.

[0057] like Figure 4 As further shown in FIG. 2 , in some example aspects, instructions 216 may include an image analysis module 222 including an image stitching container 224 and a defect detection container 226. One or more processors 212 of computing system 210 may receive multiple captured images 228 from 3D scanner 134 and stitch the captured images together to create slice images representing "slices" of a large area of ​​a target object. The slice images may be merged or stitched together with other slice images of the target object to ultimately render a combined slice image of the target object. When one or more processors 212 of computing system 210 execute defect detection container 226, one or more defects on the target object may be detected in the slice images and / or combined slice images and / or merged images. In at least some examples, the coordinates of the defects may be determined, and a defect indicator 230 may be generated corresponding to the coordinates of the detected defects. Computing system 210 may cause projector 191 of 3D scanner 134 to project defect indicator 230 onto the target object (e.g., in the form of a crosshair, arrow, circle, etc.). In some aspects, at least one defect indicator can be projected onto the target object to outline the defect. That is, the projected defect indicator can outline the perimeter of the defect, which can make the defect area clear to an operator viewing the defect on the target object.

[0058] In addition, in some aspects, the instructions 216 may include a digital twin creator 232. When one or more processors of the computing system 210 execute the digital twin creator 232, a digital twin 234 of the target object may be created, which, for example, marks defects on the target object. The digital twin 234 may digitally represent a portion of the target object (e.g., the lower quadrant of the aircraft fuselage) or the entire target object (e.g., the entire aircraft fuselage). The digital twin 234 may be used for a variety of purposes, such as providing a baseline assessment of the target object at the time of final assembly, which can be compared with future scans of the target object (e.g., after rework, at delivery, after being put into service, etc.). In addition, the digital twin 234 may be used for a variety of other reasons.

[0059] In some additional aspects, the instructions 216 may include an autonomous movement module 236. In these aspects, the inspection vehicle 100 ( Figures 1 to 3 ) can be an autonomous vehicle. As an example, the inspection vehicle 100 can be a self-driving vehicle that can be driven autonomously or without human intervention. As another example, the inspection vehicle 100 can be a self-guided vehicle that can move autonomously along a track, for example, from one location to another. The autonomous movement module 236 may include, for example, the logic required to move the inspection vehicle 100 from one scanning location to another based on sensor feedback disposed on the inspection vehicle 100 (e.g., sensor feedback from a camera located on the inspection vehicle 100).

[0060] The data repository 238 may store various captured images and / or stitched images, digital twins 234, etc. of the target object. These features may be stored in memory for future use and analysis. The predictive assembly system 240 may be communicatively coupled to the other elements of the inspection system 200. The predictive assembly system 240 may call or receive captured images and / or stitched images, digital twins 234, etc., and based on detected defects, the predictive assembly system 240 may provide an assembly prediction 242, such as the 3D geometry of a gasket that may be placed at a joint between two docking components to provide enhanced mechanical properties to the joint. In this regard, an integrated approach to inspection and assembly may be achieved.

[0061] In a general description Figure 4 In the context of inspection system 200 , an example manner in which inspection system 200 may be used to inspect an aircraft fuselage for defects is provided below.

[0062] Figure 5 is a flow chart of an example method 300 for inspecting a target object using an inspection system. Figure 4 The method 300 is described in the context of the inspection system 200 for inspecting an aircraft fuselage. Figure 5 In addition, you can also refer to Figures 1 to 4However, as will be appreciated, method 300 may be configured with Figures 1 to 4 The inspection system 200 and the inspection vehicle 100 are implemented as different inspection systems and inspection vehicles.

[0063] At 302, method 300 may include starting to scan at least one slice of a target object (in this example, an aircraft fuselage). Some aircraft fuselages may be very large relative to the FOV of the 3D scanner 134, and therefore, the longitudinal length of the aircraft fuselage may be scanned slice by slice. That is, the aircraft fuselage may be divided into a plurality of slices along its longitudinal length. For example, Figure 6 is a schematic side view of an aircraft fuselage 400 illustrating one example manner in which the fuselage 400 may be divided into slices. The fuselage 400 has a front end 402 and a rear end 404 and extends along a longitudinal direction L1. As shown, the fuselage 400 is divided into a plurality of slices 406, or in this example, slices S1-S14 representing fourteen (14) slices. The slices 406 are divided along the longitudinal direction L1. The slices 406 may cover the entire longitudinal length of the fuselage 400 or a portion thereof. However, in other example aspects, the slices 406 may be divided along a portion of the longitudinal length of the fuselage 400.

[0064] Generally, the inspection vehicle 100 may be positioned relative to a given slice of the fuselage 400, the 3D scanner 134 may scan the given slice to capture an image of the given slice of the fuselage 400, and then the inspection vehicle 100 may be moved or repositioned relative to a subsequent slice (e.g., an adjacent slice) of the fuselage 400. While the inspection vehicle 100 is positioned relative to the subsequent slice, the 3D scanner 134 may scan the subsequent slice to capture an image of the subsequent slice and then be repositioned relative to another subsequent slice. This process may be iterated until, for example, the entire longitudinal length of the fuselage 400 has been scanned, e.g., slice by slice. In at least some example aspects, the slice 406 is defined to have a width less than the FOV of the 3D scanner 134, e.g., so that the captured images (or slice images) of the slice overlap, which may facilitate stitching the slice images together into a combined slice image. Because at least a portion of the method 300 may be iterative (e.g., in terms of scanning), scanning of subsequent slices of the target object may also be initiated at 302.

[0065] At 304, method 300 may include positioning an inspection vehicle of the inspection system relative to a target object. For example, the inspection vehicle 100 may be positioned relative to a given slice of fuselage 400 to be scanned. The inspection vehicle may be moved manually, or the inspection vehicle 100 may move autonomously. In some example aspects, the inspection vehicle 100 may be positioned relative to fuselage 400 by performing a "standoff process" to ensure that the inspection vehicle 100 is at an appropriate distance from fuselage 400. In an example standoff process, lasers may be emitted by first and second laser emitters 194 and 195 of the 3D scanner 134, and when the lasers meet at a point or are within a predetermined distance of each other, the focal length between the first and second cameras 192 and 193 and fuselage 400 may be determined to be within a predetermined range or specification. This ensures that the cameras are positioned satisfactorily to capture images of fuselage 400 during scanning. In at least some aspects, the standoff process is performed for each slice of fuselage 400 while the 3D scanner is located at the same position (e.g., top or bottom) along the track 154. This may facilitate continuity of the captured images and may facilitate stitching of the slice images together into a combined slice image.Once the inspection vehicle 100 is arranged relative to the slice of the fuselage 400, for example in a suitable standoff, scanning of the slice may begin.

[0066] At 306 , method 300 may include translating the 3D scanner relative to the target object. For example, once inspection vehicle 100 is positioned relative to the slice of fuselage 400 at 304 , 3D scanner 134 may be translated, for example, along translation path TP. Specifically, electric motor 164 may be activated to drive gearbox 166 , which in turn drives the belt of pulley system 168 . When the belt is driven, carriage 132 carrying 3D scanner 134 may move along track 154 , or more specifically, along translation path TP. Thus, 3D scanner 134 translates. For example, 3D scanner 134 may begin at one end of track 154 and translate to the other end of the track. Alternatively, 3D scanner 134 may move along translation path TP from a predetermined starting position to a predetermined ending position.

[0067] At 308, method 300 may include scanning the target object using the 3D scanner to capture an image of at least one slice of the target object as the 3D scanner translates at 306, wherein during the scanning, an optical fiducial integrated into the inspection vehicle is positioned within the FOV of the 3D scanner. For example, projector 191 of 3D scanner 134 may project light onto fuselage 400. While the light is projected onto fuselage 400, first camera 192 and second camera 193 may capture an image of at least one slice of fuselage 400 as 3D scanner 134 translates. Multiple images may be captured for a given slice. Furthermore, as first camera 192 and second camera 193 capture images, first fiducial rail 174 and second fiducial rail 176, as well as first finger 188 and second finger 190, are positioned within the FOV of 3D scanner 134, resulting in these items appearing in the captured images.

[0068] As an example, Figure 7 A slice relative to the port side of the fuselage 400 is depicted (eg, Figure 6 The inspection vehicle 100 is positioned in the third slice S3 of the fuselage 400. Figure 7 As shown, the projector 191 of the 3D scanner 134 projects light onto the lower abdomen of the fuselage 400, and the 3D scanner 134 moves along the track 154 ( Figure 1 ) is positioned at the bottom. The FOV of the first camera 192 and the second camera 193 are Figure 7 It is noted that the optical fiducials 170, 172 are arranged within the FOV, and therefore, the position target 186 ( Figure 2 ) is also within the FOV. As the 3D scanner 134 moves along the track 154 or more precisely the translation path TP ( Figure 3 ) pans, the first camera 192 and the second camera 193 can capture images of the body 400. The 3D scanner 134 can capture images of the body 400 at predefined intervals when sensing a given position target, etc. Eventually, the 3D scanner 134 reaches the end of the track 154 or a predefined position. Figure 8 As shown, the 3D scanner 134 is shown in a top position along the track 154. In this regard, the 3D scanner 134 moves along the translation path TP from the bottom position ( Figure 7 ) traverse to the top position ( Figure 8 ), capturing images along the way. Figure 8 , the FOV is at or just above the window line WL of the body 400, which extends along the longitudinal direction L1 defined by the body 400. Figure 7 and Figure 8The slice scan of the fuselage 400 in FIG. 4 is performed so that the captured image of the slice extends from the center line of the lower belly of the fuselage 400 to the window line WL of the fuselage 400. In this regard, the scanned slice is a slice of the port bottom quadrant of the fuselage 400.

[0069] With the 3D scanner 134 Figure 7 and Figure 8 As shown translating along track 154, first camera 192 and second camera 193 capture images of fuselage 400. The captured image 228 is depicted in FIG. Figure 9 In particular, when the 3D scanner 134 is in a first position (e.g., Figure 7 154), a first image C1 of the fuselage 400 may be captured. Then, with the 3D scanner 134 in a second position (different from the first position) along the track 154, a second image C2 of the fuselage 400 may be captured. Next, with the 3D scanner 134 in a third position (different from the first and second positions) along the track 154, a third image C3 of the fuselage 400 may be captured. This process may continue for subsequent image captures, such as a fourth image C4, a fifth image C5, a sixth image C6, a seventh image C7, an eighth image C8, and a ninth image C9. When the 3D scanner 134 is positioned at the top of the track 154 (e.g., as shown in FIG. 154), the second image C2 of the fuselage 400 may be captured. Figure 8 ), first camera 192 and second camera 193 may capture a ninth image C9. In captured images C1-C9, first and second reference rails 174 and 176 and their first and second fingers 188 and 190 are depicted, and as a result, position target 186 is also in captured images C1-C9. Position target 186 may be used to stitch captured images 228 together at 310. In other aspects, more or fewer than nine (9) images may be captured during a slice scan of fuselage 400.

[0070] At 310, method 300 may include stitching together captured images of the target object obtained during the scan to create a sliced ​​image, the captured images being stitched together based on the positional targets provided by the optical fiducials. For example, one or more processors 212 of computing system 210 may execute image stitching container 224 to cause captured images 228 (e.g., Figure 9The arrangement of the position targets 186 within the captured images 228 can be identified so that the position of the 3D scanner 134 can be determined. As previously described, the position targets 186 can be uniquely (e.g., in a unique pattern) arranged on the first and second reference rails 174, 176 and / or the first and second fingers 188, 190 so that their positions can be easily identified, which can facilitate rapid processing of the position of the 3D scanner 134. Based on the known position of the 3D scanner 134, the captured images 228 can be stitched together to form a 3D scanner 134. Figure 10 Slice image SL3 is shown. For example, slice image SL3 may represent a complete image of third slice S3. It is noteworthy that first and second optical fiducials 170, 172, and first and second fingers 188, 190 may be removed or masked from slice image SL3. For example, when stereoscopic vision is obtained from multiple positions, first and second optical fiducials 170, 172, and first and second fingers 188, 190 may be filtered out from slice image SL3.

[0071] At 312, method 300 may include detecting one or more defects on the target object based on the slice image. For example, one or more processors 212 of computing system 210 may execute defect detection container 226 to analyze the defect image. Figure 10 The defects of the slice of the fuselage 400 in the slice image SL3 are shown. Figure 10 As shown, for this example, defects 246 are detected for this slice of fuselage 400, including a first defect 246A and a second defect 246B. When executing defect detection container 226, one or more processors 212 may ignore known features so as not to identify them as defects. For example, when executing defect detection container 226, one or more processors 212 may receive data indicating the locations of known features in fuselage 400 that may appear to be defects (e.g., window cutouts, door cutouts, rivets, etc.). This data may be processed to ensure that these known features are not identified as defects.

[0072] At 314, method 300 may include projecting, via the 3D scanner, one or more defect indicators onto the target object to indicate a corresponding defect from the one or more defects detected on the target object. In at least some examples, the coordinates of detected defect 246 may be determined, and defect indicator 230 may be generated corresponding to the coordinates of detected defect 246. Computing system 210 may cause projector 191 of 3D scanner 134 to project defect indicator 230 onto the target object (e.g., in the form of a crosshair, arrow, circle, etc.). In some aspects, defect 246 may be classified as one of a plurality of defect types (e.g., defect type 1, defect type 2, etc.), and the defect indicator projected onto fuselage 400 may be projected in a color associated with the defect type into which the defect is classified. In some aspects, at least one defect indicator may be projected onto fuselage 400 to outline the defect. In other words, the projected defect indicator may outline the perimeter of the defect, which may make the defect area readily apparent to an operator viewing the defect on fuselage 400. As an example, Figure 11 The projector 191 of the 3D scanner 134 is shown projecting the first defect indicator 230A onto the fuselage 400. The first defect indicator 230A projected onto the fuselage 400 corresponds to Figure 10 1 . First defect indicator 230A outlines the perimeter of first detected defect 246A, making the area of ​​first detected defect 246A readily apparent to the operator. 3D scanner 134 can translate along track 154 so that defect indicator 230 corresponding to each detected defect 246 can be projected onto fuselage 400.

[0073] In some aspects, operations 312 and 314 may be completed at a later stage, such as after the individual slices of fuselage 400 have been scanned and the slice images have been stitched together into a combined slice image.

[0074] At 316, the method 300 may include determining whether the respective relevant slices of the target object have been scanned, for example, according to operations 302 to 314. When the respective relevant slices have not been scanned, the method 300 may iterate to 302 so that subsequent slices are scanned. When the respective relevant slices have been scanned, the method 300 may proceed to 318. For example, when slices S1-S14 ( Figure 6 ) (or from beginning to end), method 300 may proceed to 318. Thus, operations 302 through 314 may be iterated for a predetermined length of the target object (eg, the complete longitudinal length of fuselage 400).

[0075] At 318, the method 300 may include stitching the slice images together into a combined slice image. For example, one or more processors 212 of the computing system 210 may stitch the slice images together into a combined slice image. As an example, Figure 12 A plurality of slice images 252 are shown, each associated with one of the predefined slices of the fuselage 400 . Figure 12 2 , slice images SL1, SL3, SL4, SL5, and SL14 are shown associated with slices S1, S3, S4, S5, and S14, but it will be understood that the slice images SL1 through SL14 may be stitched together to form the combined slice image 254. In at least some example aspects, a slice is defined as having a width that is less than the FOV of the 3D scanner 134, such as to cause the slice images to overlap, which may facilitate stitching the slice images together into the combined slice image.

[0076] At 320, method 300 may include creating a second combined slice image associated with a second side of the target object, wherein the combined slice image created at 318 is the first combined slice image associated with the first side of the target object. For example, the combined slice image 254 may be the first combined slice image 254 associated with the first side (e.g., the port side) of the fuselage 400. The second combined slice image associated with the second side (e.g., the starboard side) of the fuselage 400 may be created, for example, using operations 302 through 318. In addition to identifying defects, if any, associated with the second side of the fuselage 400, the second combined slice image may be generated to have the same Figure 12 The shape of the fuselage 400 is the same or similar to that in the first combined slice image 254 presented in FIG.

[0077] At 322, method 300 may include storing the combined slice image in a data repository. For example, the first combined slice image 254 (and in some cases, the second combined slice image, etc.) may be stored in the data repository (e.g., on one or more non-transitory memory devices thereof). The images may be stored for analysis. For example, the predictive assembly system 240 may call or receive the captured and / or stitched images, and in the event that a defect is identified, the predictive assembly system 240 may provide one or more assembly predictions 242. The assembly prediction may provide guidance on how to repair the detected defect, such as by providing guidance on how to machine a surface, construct a gasket to strengthen a joint, tighten a rivet according to specifications, rework a specific area to remove a dent, etc. In this regard, an integrated approach to inspection and assembly may be achieved.

[0078] At 324, method 300 may include creating a digital twin of the target object based at least in part on the first combined slice image and, in some cases, one or more other combined slice images. For example, one or more processors 212 of computing system 210 may execute digital twin creator 232 to create digital twin 234 of fuselage 400. Created digital twin 234 may identify defects detected on fuselage 400. Digital twin 234 may be used for a variety of purposes, such as providing a baseline assessment of fuselage 400 at the time of final assembly, which may be compared with future scans of fuselage 400 (e.g., after rework, upon delivery, after entry into service, etc.). For example, the combined slice image may be retrieved from data repository 238 or memory device 214.

[0079] In some implementations, to facilitate additional efficiency in inspecting the fuselage, the inspection system 200 may include at least one inspection vehicle associated with a first side (e.g., port) of the fuselage 400 and at least one inspection vehicle associated with a second side (e.g., starboard) of the fuselage 400. For example, Figure 13 A front-to-back view of the fuselage 400 is depicted, and shows a first inspection vehicle 100A scanning and capturing images of various slices of the port side of the fuselage 400 to detect defects thereon, while a second inspection vehicle 100B is scanning and capturing images of various slices of the starboard side of the fuselage 400 to detect defects thereon. The first inspection vehicle 100A and the second inspection vehicle 100B can be configured and operated in a manner similar to the inspection vehicle 100 described herein. In some aspects, the first inspection vehicle 100A and the second inspection vehicle 100B can perform aspects of the method 300 simultaneously, which can provide additional efficiency in inspecting the fuselage 400 for defects.

[0080] In other implementations, the inspection vehicle of inspection system 200 may have a "wraparound turret" that enables scanning of the fuselage so that the captured image of a given slice extends at least from the centerline of the fuselage underbelly to the centerline of the fuselage top.

[0081] As an example, Figure 14 is a perspective view of an inspection vehicle 100C having an enclosing tower in a scanner / manipulator configuration. The inspection vehicle 100C includes a tower 130C supporting a track 154C along which a 3D scanner 134C can translate. The 3D scanner 134C can be supported, for example, by a bracket. The track 154C is non-linear or, in this example, curved to complement the shape of the fuselage 400. In this regard, the translation path of the 3D scanner 134C is also curved or non-linear. The track 154C is connected at its top end by a roof 111. The roof 111 is supported by rear columns 113. Although Figure 14 Not shown in FIG, a curved optical reference rail may be provided having a shape complementary to track 154C so that the position target is within the FOV of 3D scanner 134C.

[0082] exist Figure 14 , a sequence illustrating one example manner in which 3D scanner 134C may translate is shown. At a first position P1, 3D scanner 134C has a first field of view (FOV1) and captures images of a portion of the underbelly of fuselage 400. At a second position P2, 3D scanner 134C has a second field of view (FOV2) and captures images of the lower quadrant of fuselage 400. At a third position P3, 3D scanner 134C has a third field of view (FOV3) and captures images of the side of fuselage 400. At a fourth position P4, 3D scanner 134C has a fourth field of view (FOV4) and captures images of the upper quadrant of fuselage 400. At a fifth position P5, 3D scanner 134C has a fifth field of view (FOV5) and captures images of the top side of fuselage 400. Thus, inspection vehicle 100C is arranged to capture images of a given slice of fuselage 400, at least from the midline of the underbelly of fuselage 400 to the midline of the top of fuselage 400. In this regard, the slice images created from the images may represent the lower and upper quadrants of a side of fuselage 400. This scanning range may facilitate additional efficiency in inspecting the fuselage and may allow for detection of defects on both the lower and upper quadrants of the fuselage.

[0083] Figure 15 is a perspective view of an inspection vehicle 100D having an enclosure tower in a roller coaster conveyor configuration. The inspection vehicle 100D includes a tower 130D supporting a track 154D along which a 3D scanner 134D can translate. Figure 15 3D scanner 134D is shown in various positions along track 154D. 3D scanner 134D may be carried, for example, by a carriage. Track 154D is non-linear, or in this example, curved to complement the shape of fuselage 400. In this regard, the translation path of 3D scanner 134D is also curved or non-linear. Track 154D is supported by front and rear struts 115, 117. Front and rear struts 115, 117 are supported by chassis 110D. Track 154D includes a backbone 119, first and second load rails 121, 123 along which the carriage or 3D scanner 134D translates, and load rail supports 125 connecting and supporting first and second load rails 121, 123 to backbone 119. Track 154D is uniquely arranged to accommodate a relatively large fuselage, such that when inspection vehicle 100D is in position relative to fuselage 400, lower end 127 of track 154D is disposed below fuselage 400 and upper end 129 is disposed above fuselage 400. In this regard, track 154D "wraps" around a portion of fuselage 400. Although Figure 15 Not shown in FIG, a curved optical reference guide may be provided having a shape complementary to track 154D so that the position target is within the FOV of 3D scanner 134D.

[0084] The inspection vehicle 100D is arranged to capture images of a given slice of the fuselage 400 from at least the midline of the underbelly of the fuselage 400 to the midline of the top of the fuselage 400. In this regard, the slice images created from the images can represent the lower and upper quadrants of a side of the fuselage 400. This scanning range can facilitate additional efficiency in inspecting the fuselage and can allow defects to be detected in both the lower and upper quadrants of the fuselage. In at least some aspects, the inspection vehicle 100D can be an autonomous guided vehicle (AGV). In these aspects, the inspection vehicle 100D can autonomously move from one scanning location to the next.

[0085] In the present disclosure, reference is made to various aspects. However, it should be understood that the present disclosure is not limited to the specific aspects described. On the contrary, any combination of the following features and elements, whether or not related to different aspects, is contemplated as implementing and practicing the teachings provided herein. In addition, when the elements of various aspects are described in the form of "at least one of A and B", it will be understood that each aspect is contemplated to include exclusively element A, exclusively element B, and elements A and B. In addition, although some aspects may achieve advantages that are superior to other possible solutions and / or superior to the prior art, whether a particular advantage is achieved by a given aspect is not a limitation of the present disclosure. Therefore, the aspects, features, aspects, and advantages disclosed herein are merely illustrative and are not considered to be elements or limitations of the appended claims unless explicitly stated in the claims.

[0086] Those skilled in the art will appreciate that the aspects described herein may be embodied as a system, method, or computer program product. Thus, the aspects may take the form of all-hardware aspects, all-software aspects (including firmware, resident software, microcode, etc.), or aspects combining software and hardware aspects, which may all generally be referred to herein as "circuits," "modules," or "systems." Additionally, the aspects described herein may take the form of a computer program product embodied in one or more computer-readable storage media embodied with computer-readable program code.

[0087] Program code embodied on a computer-readable storage medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

[0088] The computer program code for implementing the operations of various aspects of the present disclosure can be written in any combination of one or more programming languages, including object-oriented programming languages ​​(e.g., Java, Smalltalk, C++, etc.) and traditional procedural programming languages ​​(e.g., "C" programming language or similar programming languages). The program code can be executed entirely on the user's computer, partially on the user's computer, as a stand-alone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In the latter case, 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 an external computer (e.g., via the Internet using an Internet service provider) can be connected.

[0089] Various aspects of the present disclosure are described herein with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to various aspects of the present disclosure. It will be understood that the individual blocks of the flowcharts and / or block diagrams, and the combination of blocks in the flowcharts and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing device to generate a machine, such that instructions executed by the processor of the computer or other programmable data processing device create a means for implementing the functions / behaviors specified in the blocks of the flowcharts and / or block diagrams.

[0090] These computer program instructions may also be stored in a computer-readable medium, which can direct a computer, other programmable data processing device or other apparatus to function in a specific manner, so that the instructions stored in the computer-readable medium generate an article of manufacture including instructions for implementing the functions / behaviors specified in the blocks of the flowchart and / or block diagram.

[0091] Computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus, or other device to generate a computer-implemented process, such that the instructions executed on the computer, other programmable data processing apparatus, or other device provide a process for implementing the functions / behaviors specified in the flowchart and / or block diagram blocks.

[0092] The flow charts and block diagrams in the accompanying drawings illustrate the architecture, functions and operations of possible implementations of the systems, methods and computer program products according to various aspects of the present disclosure. In this regard, each block in the flow chart or block diagram may represent a module, segment or code portion, which 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 blocks may not occur in the order indicated in the figures. For example, depending on the functions involved, the two blocks shown in succession may actually be performed substantially simultaneously, or the blocks may sometimes be performed in the opposite order or out of order. It will also be noted that the combination of each block in the block diagram and / or flow chart and the blocks in the block diagram and / or flow chart may be implemented by a system based on dedicated hardware that performs a specified function or behavior or a combination of dedicated hardware and computer instructions.

[0093] While the foregoing is directed to various aspects of the disclosure, other and further aspects of the disclosure may be devised without departing from the basic scope thereof, and the scope of which is to be determined by the claims that follow.

Claims

1. A method (300), comprising: translating (306) a 3D scanner (134) relative to a target object (400), the 3D scanner (134) being disposed in an inspection vehicle (100); scanning (308) the target object (400) with the 3D scanner (134) as the 3D scanner (134) translates to capture an image (228) of at least one slice of the target object (400), wherein during the scanning, an optical fiducial (170, 172) integrated into the inspection vehicle (100) is arranged within a field of view (FOV) of the 3D scanner (134); stitching (310) together captured images (228) of the target object (400) obtained during the scan (308) to create a slice image SL3, the captured images (228) being stitched together based on positional targets (186) provided by the optical fiducials (170, 172); and One or more defects (246) on the target object (400) are detected (312) based on the slice image SL3.

2. The method (300) of claim 1, further comprising: One or more defect indicators (230) are projected (314) onto the target object (400) by the 3D scanner (134) to indicate corresponding defects among the one or more defects (246) detected on the target object (400).

3. The method (300) according to claim 2, wherein: At least one defect indicator of the one or more defect indicators (230) is projected onto the target object (400) outlining a defect of the one or more defects (246) detected on the target object (400).

4. The method (300) of claim 1, wherein: The 3D scanner (134) translates along a linear path TP oriented at an angle relative to a vertical direction V.

5. The method (300) according to claim 4, wherein: The optical reference (170, 172) includes a first reference rail (170) and a second reference rail (172) spaced apart from each other and arranged parallel to the linear path TP.

6. The method (300) of claim 5, wherein: The position target (186) is arranged on a first finger (188) extending from the first reference rail (170) and on a second finger (190) extending from the second reference rail (172), the first fingers (188) being spaced apart from each other along the first reference rail (170), and the second fingers (190) being spaced apart from each other along the second reference rail (172).

7. The method (300) of claim 1, further comprising: The optical reference (170, 172) in the slice image SL3 is masked so that the optical reference (170, 172) does not appear on the slice image SL3.

8. The method (300) of claim 1, wherein: The slice of the target object (400) is a first slice, and wherein the method (300) further comprises: a) moving (302) the inspection vehicle (100) so that the inspection vehicle (100) is aligned with subsequent slices of the target object (400); b) translating (306) the 3D scanner (134) relative to the target object (400) with the inspection vehicle (100) aligned with the subsequent slice; c) scanning (308) the target object (400) with the 3D scanner (134) as the 3D scanner (134) translates with the inspection vehicle (100) aligned with the subsequent slice to capture an image (228) of the subsequent slice of the target object (400), wherein the optical fiducials (170, 172) are disposed within the field of view (FOV) of the 3D scanner (134) during the scanning of the subsequent slice; d) stitching (310) together the captured images (228) of the subsequent slices of the target object (400) to create a subsequent slice image SL3, the captured images (228) of the subsequent slices being stitched together based on the position target (186) provided by the optical fiducials (170, 172); and e) detecting (312) one or more defects (246) on the subsequent slice of the target object (400) based on the subsequent slice image SL3.

9. An inspection system (200), comprising: An inspection vehicle (100), comprising: a tower (130) supporting a track (154); a carriage (132) movable along the track (154), the carriage (132) supporting a 3D scanner (134) having at least two cameras (192, 193) and a projector (191); and An optical fiducial (170, 172) is arranged relative to the track (154) such that the optical fiducial (170, 172) is within a field of view (FOV) of the 3D scanner (134) during scanning of a target object (400).

10. An inspection vehicle (100), comprising: a tower (130) supporting a track (154); a carriage (132) movable along the track (154), the carriage (132) supporting a 3D scanner (134) having at least two cameras (192, 193) and a projector (191); and An optical fiducial (170, 172) is arranged relative to the track (154) such that the optical fiducial (170, 172) is within a field of view (FOV) of the 3D scanner (134) during scanning of a target object (400).

Images