General-purpose foreign object debris detection and collection device

Abstract

To increase efficiency of the task of detecting and addressing FOD.SOLUTION: In one embodiment, systems and methods include using an inspection system to remove or seal foreign object debris. An inspection system comprises: a borescope, in which multiple optical fibers are disposed; a mounting system; an articulation system; and a controller, which comprises a display; where a proximal end of the borescope is coupled to the mounting system, the mounting system is configured to secure the inspection system to an external surface, the mounting system is coupled to the articulation system, the articulation system is configured to actuate the borescope, and the articulation system is communicatively coupled to the controller.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates generally to inspection devices, and more particularly to inspection systems for detecting and addressing debris present onboard aircraft. [Background technology]

[0002] Foreign object debris (FOD) is a concern for all aircraft, and if left undetected on board an aircraft, FOD can cause significant damage. Summary of the Invention [Problem to be solved by the invention]

[0003] There are often hard-to-reach locations within an aircraft where FOD may be located during the manufacture or maintenance of each aircraft. Current methods for detecting and responding to FOD include the use of multiple tools. These current methods often require multiple people and a large amount of time, and there is room for improvement in the efficiency of FOD detection and response efforts. [Means for solving the problem]

[0004] In one embodiment, the system and method includes using an inspection system to remove or seal foreign body debris, the inspection system including a borescope having a plurality of optical fibers disposed therein, a mounting system, an articulation system, and a controller with a display, wherein a proximal end of the borescope is coupled to the mounting system, the mounting system configured to secure the inspection system to an exterior surface, the mounting system coupled to the articulation system, the articulation system configured to actuate the borescope, and the articulation system communicatively coupled to the controller.

[0005] For an aid in understanding the present disclosure, reference is made to the following description taken in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0006] [Figure 1] 1 illustrates an example of an inspection system in accordance with certain embodiments. [Figure 2] 2 illustrates an example of a distal end of a borescope of the inspection system of FIG. 1 in accordance with certain embodiments. [Figure 3] 2 illustrates an example of a distal end of a borescope of the inspection system of FIG. 1 in accordance with certain embodiments. [Figure 4] 1 illustrates an example of an inspection system in accordance with certain embodiments. [Figure 5] 1 illustrates an example of an inspection system in accordance with certain embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0007] To facilitate a better understanding of the present disclosure, the following examples of specific embodiments are provided. The following examples should not be read to limit or define the scope of the present disclosure. The embodiments of the present disclosure and their advantages are best understood by referring to Figures 1 to 5, where like numbers are used to indicate like and corresponding parts.

[0008] As discussed, foreign object debris (FOD) may be present on aircraft. Detecting and / or removing FOD from an aircraft to prevent potential damage may be difficult. Described herein are various systems and methods that provide improved detection, removal, sealing, and combinations thereof through the use of inspection systems.

[0009] FIG. 1 is an isometric view of an inspection system 100. The inspection system 100 may be configured to determine the presence of any FOD on an aircraft, remove the FOD, seal the FOD in place, and any combination thereof. In an embodiment, the inspection system 100 may include a borescope 105, a mounting system 110, an articulation system 115, and a controller 120. In one or more embodiments, the borescope 105 may be configured to move near and around small and / or difficult-to-access areas. The borescope 105 may be of any suitable size, height, shape, and combinations thereof. In an embodiment, the borescope 105 may include a tubular body, the tubular body having an elongated cylindrical shape. The borescope 105 may include any suitable material. Without limitation, suitable materials may be metal, non-metal, polymer, composite, and any combination thereof. In an embodiment, the borescope 105 may be rigid, flexible, or a combination thereof. In certain embodiments, a portion of the borescope 105 may be flexible, while the remainder of the borescope may be rigid. In one or more embodiments, the borescope 105 may further comprise an optical device, such as a camera (e.g., camera 210 of FIG. 2), and a plurality of optical fibers. In these embodiments, the plurality of optical fibers may be disposed within the tubular body and may connect the distal end 125 of the borescope 105 to the controller 120, and the optical device may be disposed at the distal end 125 of the borescope 105.

[0010] As shown, the proximal end 130 of the borescope 105 can be coupled to a mounting system 110. In embodiments, the mounting system 110 can be configured to secure the inspection system 100 to an exterior surface. The mounting system 110 can include any suitable components, such as, but not limited to, a tubular body, a rod, a clamp, a hinge, a fastener, or the like. In embodiments, the mounting system 110 can be adjustable to secure the inspection system 100 at any suitable distance and / or angle relative to the exterior surface. The mounting system 110 can be any suitable size, height, shape, and combinations thereof. The mounting system 110 can further include any suitable material. Suitable materials can be, but are not limited to, metals, non-metals, polymers, composites, and any combinations thereof. In embodiments, the mounting system 110 can be coupled to an articulation system 115.

[0011] The articulation system 115 can be configured to actuate the borescope 105. In one or more embodiments, the articulation system 115 can include a first rotary lever 135, a second rotary lever 140, and a handle 145. The first rotary lever 135 can be configured to actuate a portion of the borescope 105 near the distal end 125 to bend along a horizontal plane relative to the distal end 125. In embodiments, the second rotary lever 140 can be configured to actuate a portion of the borescope 105 near the distal end 125 to bend along a vertical plane relative to the distal end 125. In one or more embodiments, the portion of the borescope 105 near the distal end 125 can have any suitable length necessary to operate in a small area within or near the aircraft. Without limitation, the length of the portion of borescope 105 proximate distal tip 125 can be from about 1 inch (25.4 mm) to about 3 inches (76.2 mm), from about 3 inches (76.2 mm) to about 5 inches (127 mm), from about 5 inches (127 mm) to about 10 inches (254 mm), and any combination thereof. In embodiments, the portion of borescope 105 proximate distal tip 125 can have a length of about 5 inches (127 mm). The portion of borescope 105 proximate distal tip 125 can bend to form an angle of about 120 degrees or less relative to an initial position of distal tip 125. Without limitation, the portion of borescope 105 near distal tip 125 may form an angle between about 0.5 degrees and about 45 degrees, about 45 degrees and about 90 degrees, about 90 degrees and about 120 degrees, or any combination thereof, with the initial position of the distal tip.

[0012] In one or more embodiments, the first rotary lever 135 and / or the second rotary lever 140 may be manually or automatically actuated via the controller 120. In embodiments, the first rotary lever 135 and the second rotary lever 140 may be actuated simultaneously and / or at different times to move a portion of the borescope 105 near the distal end 125. The first rotary lever 135 and the second rotary lever 140 may be any suitable size, height, shape, and combinations thereof. In embodiments, the first rotary lever 135 and the second rotary lever 140 may have the same dimensions. In other embodiments, the first rotary lever 135 and the second rotary lever 140 may have different dimensions.

[0013] In one or more embodiments, the first rotary lever 135 and the second rotary lever 140 may be disposed adjacent to a handle 145. In these embodiments, the proximal end 130 of the borescope 105 may be attached to the handle 145, and the first rotary lever 135 and the second rotary lever 140 may be disposed on the handle 145 opposite the proximal end 130. In embodiments, the handle 145 may be configured to be physically manipulated by an operator when operating the inspection system 100. The handle 145 may be any suitable size, height, shape, and combinations thereof. The handle 145 may comprise any suitable material. Suitable materials may be, but are not limited to, metals, non-metals, polymers, composites, and any combinations thereof.

[0014] As shown, the handle 145 may be communicatively coupled to the controller 120. In one or more embodiments, the controller 120 may be configured to operate the inspection system 100 or individual components within the inspection system 100. During operation, the controller 120 may control the movement and operation of the borescope 105. In one or more embodiments, the controller 120 may include one or more interfaces, processing circuitry, memory, and / or other suitable elements. In embodiments, an interface may receive input, send output, process the input and / or output, and / or perform other suitable operations. The interface may comprise hardware and / or software. In embodiments, the controller 120 may further include a display 122, which may be configured to display information obtained by the inspection system 100 to an operator, via which the operator may control certain functions of the inspection system 100. Without limitation, via the display 122, the operator may take photographs or record videos, control lights positioned near the borescope 105 (e.g., light 205 in FIG. 2), access stored photographs and / or videos, control connections to a communications network, and any combination thereof.

[0015] A processing circuit performs or manages the operations of a component. The processing circuit may include hardware and / or software. Examples of processing circuits include one or more computers, one or more microprocessors, one or more applications, etc. In certain embodiments, the processing circuit executes logic (e.g., instructions) to perform actions (e.g., operations), such as generating output from input. The logic performed by the processing circuit may be encoded in one or more tangible, non-transitory computer-readable media (e.g., memory). For example, the logic may include computer programs, software, computer-executable instructions, and / or computer-executable instructions. In certain embodiments, the operations of the embodiments may be performed by one or more computer-readable media storing, embodied in, and / or encoded in, and / or having a computer program stored and / or encoded thereon.

[0016] Information is stored in a memory (or memory unit). A memory may include one or more non-transitory, tangible, computer-readable, and / or computer-executable storage media. Examples of memory include computer memory (e.g., RAM and ROM), mass storage media (e.g., hard disks), removable storage media (e.g., compact discs (CDs) and digital video discs (DVDs)), databases and / or network storage devices (e.g., servers), and / or other computer-readable media.

[0017] Here, a computer-readable non-transitory storage medium may include one or more semiconductor-based or other integrated circuits (ICs) (such as field programmable gate arrays (FPGAs) or application-specific ICs (ASICs)), hard disk drives (HDDs), hybrid hard drives (HHDs), optical disks, optical disk drives (ODDs), magneto-optical disks, magneto-optical drives, floppy disks, floppy disk drives (FDDs), magnetic tapes, solid-state drives (SSDs), RAM drives, SECURE DIGITAL cards or drives, any other suitable computer-readable non-transitory storage medium, or any suitable combination of two or more thereof. A computer-readable non-volatile storage medium may be volatile, non-volatile, or a combination of volatile and non-volatile, as appropriate.

[0018] FIG. 2 illustrates an embodiment of the distal end 125 of the borescope 105. As shown, a cover plate 200 may be disposed on the distal end 125. The cover plate 200 may seal the interior of the borescope 105 and secure additional components to the distal end 125. The cover plate 200 may be of any suitable size, height, shape, and configuration. In an embodiment, the cover plate 200 may have a circular cross-section with a diameter slightly larger than the outer diameter of the borescope 105, where there is a tolerance of at least 1% to about 5% between the cover plate 200 and the borescope 105. The cover plate 200 may be attached to the distal end 125 by any suitable means, including, but not limited to, suitable fasteners, adhesives, threading, welding, brazing, and any combination thereof.

[0019] As shown, the cover plate 200 may include a first light 205A, a second light 205B (both the first light 205A and the second light 205B are collectively referred to herein as lights 205), a camera 210, and a working channel 215. In embodiments, any suitable light may be used for the light 205. In one or more embodiments, the light 205 may be configured to project and provide light to an area designated for inspection through the borescope 105. In embodiments, the light 205 may be any suitable size, height, shape, and combination thereof. As shown, both the first light 205A and the second light 205B may be disposed within the cover plate 200. In certain embodiments, at least one of the lights 205 may be disposed within the cover plate 200. The first light 205A and / or the second light 205B may be disposed adjacent any suitable location and configuration within the cover plate 200. As shown, the first light 205A and the second light 205B may generally be located near opposite portions of the cover plate 200. In an embodiment, the lights 205 may be electrically coupled to the controller 120 (see FIG. 1 ) using any suitable wiring, which may be located inside the borescope 105.

[0020] The camera 210 may be positioned within the cover plate 200 near the light 205. In embodiments, the camera 210 may be positioned near any suitable location within the cover plate 200. As shown, the camera 210 may be positioned generally between the lights 205, but offset by a distance. In embodiments, the camera 210 may be any suitable size, height, shape, and combination thereof. In embodiments, any suitable camera may be used for the camera 210. In one or more embodiments, the camera 210 may be configured to record, capture, visually display, and combinations thereof, information within a designated area for inspection via the borescope 105. In embodiments, the camera 210 may be electrically coupled to the controller 120 using any suitable wiring (e.g., fiber optic cable), which may be located inside the borescope 105. In operation, the display 122 (see FIG. 1 ) may visually display information, images, video, etc. to an operator as the camera 210 operates. In one or more embodiments, the operator can further utilize the working channel 215 to address any potential FODs discovered by the camera 210.

[0021] As shown, the working channel 215 may be positioned near the light 205 within the cover plate 200. In embodiments, the working channel 215 may be positioned near any suitable location within the cover plate 200. As shown, the working channel 215 may be generally positioned between the lights 205, but offset a certain distance, on the opposite side of the camera 210. In other embodiments, the working channel 215 may be positioned near the center of the cover plate 200, and the light 205 and / or camera 210 may be positioned in a suitable configuration near the working channel 215. In embodiments, the working channel 215 may be any suitable size, height, shape, and combinations thereof. As shown, the working channel 215 may have a circular cross-section. In one or more embodiments, the cross-section of the working channel 215 may be uniform along its length. In alternative embodiments, the cross-section of the working channel 215 may vary along its length. In embodiments, working channel 215 may be a hollow channel extending along the length of borescope 105. Without limitation, working channel 215 may be configured to allow introduction of a tool or component through handle 145 (see FIG. 1 ) for operation at or near distal end 125 of borescope 105. In other embodiments, working channel 215 may provide a flow path from a designated area near distal end 125 through borescope 105 to handle 145.

[0022] FIG. 3 illustrates one embodiment of the distal end 125 of the borescope 105 in operation. In one or more embodiments, the tubular body 300 can be disposed within the working channel 215 (see FIG. 2) of the borescope 105. In these embodiments, the tubular body 300 can line the interior of the length of the working channel 215. The tubular body 300 can be any suitable size, height, shape, and combinations thereof. The tubular body 300 can also comprise any suitable material. Suitable materials can be, but are not limited to, metals, non-metals, polymers, composites, and any combinations thereof. In one or more embodiments, a heat-shrink material such as polyolefins can be used for the tubular body 300. In other embodiments, polyethylene and other similar polymers can be used for the tubular body 300. In embodiments, a piston plunger 305 can be disposed within the tubular body 300.

[0023] The piston plunger 305 may include a piston head 310 disposed at a distal end 315 of the piston plunger 305. The piston plunger 305 and piston head 310 may be any suitable size, height, shape, and combinations thereof. In one or more embodiments, the piston head 310 may generally have the same diameter as the inner circumference of the tubular body 300. The piston plunger 305 and piston head 310 may comprise any suitable material. Suitable materials may include, but are not limited to, metals, non-metals, polymers, composites, and any combination thereof. In embodiments, the piston plunger 305 may be configured to translate the piston head 310 out through the tubular body 300. During operation, a seal (not shown) may be disposed within the distal portion of the tubular body 300. In embodiments, the piston plunger 305 can be actuated to translate or displace the piston head 310 toward and into the sealing material, causing the sealing material to be expelled from the distal end 320 of the tubular body 300. The combination of the piston plunger 305 and sealing material can be used to seal any potential FOD in place within a designated area when the operator is unable to remove the FOD.

[0024] FIG. 4 illustrates an embodiment of the inspection system 100 having a piston plunger 305. As shown, the handle 145 can include a port 400, which can provide access to the working channel 215 (see FIG. 2). In one or more embodiments, the piston plunger 305 can be introduced into the working channel 215 through the port 400. In operation, an operator can insert the distal end 315 (see FIG. 3) of the piston plunger 305 into the port 400 and feed the length of the piston plunger 305 through the working channel 215. In embodiments, a portion of the length of the piston plunger 305 can be positioned within the working channel 215, up to the proximal end 405 of the piston plunger 305. As shown, a knob 410 can be positioned at the proximal end 405 of the piston plunger 305 for use by the operator. Knob 410 may be used to push and / or pull piston plunger 305, translating or displacing piston head 310 (see FIG. 3) an equivalent distance. While not limiting, piston plunger 305 is shown to be inserted into working channel 215, any other suitable tool may be used with working channel 215. In embodiments, mechanical and / or magnetic tools used to physically obtain FOD may be inserted into working channel 215. In other embodiments, a measurement tool may be inserted into working channel 215.

[0025] 2-4 , during operation, an operator may insert the piston plunger 305 through the port 400 into the working channel 215 and at least partially out of the cover plate 200. In embodiments, the tubular body 300 may be disposed over and around at least a portion of the piston plunger 305. Heat may be applied to the tubular body 300 to heat-shrink the tubular body 300 onto the piston plunger 305. In embodiments, any suitable method of applying heat to the tubular body 300 may be used, such as, but not limited to, a hot air gun. The operator may use the tubular body 300 to retract the piston plunger 305 into the working channel 215 so that the tubular body 300 covers at least a portion of the interior of the working channel 215. In one or more embodiments, a sealant may be injected into the distal end 320 of the tubular body 300. Any suitable sealant may be used, including, but not limited to, the tubular body 300. In embodiments, the sealing material may be thick and / or viscous. Once the sealing material is positioned within a portion of the tubular body 300, the operator may move the piston plunger 305 through the working channel 215, thereby dispensing the sealing material onto any potential FOD within the designated area. In embodiments, the FOD may be completely surrounded by the sealing material and may be fixed in its current position. In other embodiments, the sealing material may at least partially cover the FOD as long as the FOD is fixed in its current position. In one or more embodiments, the operator manually actuates the piston plunger 305. In other embodiments, actuation of the piston plunger 305 may be automatic via the controller 120 (see FIG. 1 ).

[0026] FIG. 5 illustrates an embodiment of the inspection system 100 including a vacuum attachment 500. As shown, the vacuum attachment 500 may be positioned between the handle 145 and the first rotary lever 135. The vacuum attachment 500 may be configured to couple a vacuum (e.g., an air supply) to the inspection system 100, which may be capable of evacuating any potential FOD within a designated area via the borescope 105. The vacuum attachment 500 may be any suitable size, height, shape, and combinations thereof. The vacuum attachment 500 may comprise any suitable material. Suitable materials may be, but are not limited to, metals, non-metals, polymers, composites, and any combinations thereof.

[0027] As shown, the vacuum attachment 500 may include a port coupling 505, an air supply coupling 510, and a containment coupling 515. The port coupling 505 may be configured to indirectly couple the port 400 to the vacuum attachment 500. In embodiments, a conduit 520 may be attached to both the port 400 and the port coupling 505 to couple the port 400 to the port coupling 505. The port coupling 505 may be located on a bottom surface of the vacuum attachment 500. In embodiments, the containment coupling 515 may be located on a top surface of the vacuum attachment 500. The containment coupling 515 may be configured to couple an external container (not shown) to the vacuum attachment 500, which may receive any potential FOD removed from the designated area by the vacuuming means. The air supply coupling 510 may be located on a side of the vacuum attachment 500. The air supply coupling 510 may be configured to couple any suitable air supply to the inspection system 100 via the vacuum attachment 500. In one or more embodiments, any suitable and / or standard couplings may be used for both the port coupling 505, the air supply coupling 510, and the containment coupling 515. In embodiments, although the port coupling 505, the air supply coupling 510, and the containment coupling 515 are shown in a particular configuration in FIG. 5, each of the port coupling 505, the air supply coupling 510, and the containment coupling 515 may be located in any suitable location near the vacuum attachment 500. Without limitation, each of the port coupling 505, the air supply coupling 510, and the containment coupling 515 may be a male or female coupling.

[0028] Technical advantages of the present disclosure may include one or more of the following: The inspection system 100 described herein may reduce the amount of time and / or tooling required to inspect designated areas, remove FOD, seal FOD, and any combination thereof. The borescope 105 may be configured to access hard-to-reach areas around the aircraft, and while the borescope 105 is in place, any potential FOD may be addressed by any of the following means: vacuuming, sealing, mechanical and / or magnetic gripping, and any combination thereof.

[0029] The present disclosure may provide many advantages, including various technical advantages described for each of the various embodiments and examples disclosed herein. Other technical advantages will be readily apparent to those skilled in the art from the following figures, description, and claims. Moreover, although certain advantages are recited in this disclosure, various embodiments may not include all, some, or any of the recited advantages.

[0030] As used herein, "or" is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Thus, as used herein, "A or B" means "A, B, or both," unless expressly indicated otherwise or indicated otherwise by context. Furthermore, "and" means both jointly and individually, unless expressly indicated otherwise or indicated otherwise by context. Thus, as used herein, "A and B" means "A and B, jointly or individually," unless expressly indicated otherwise or indicated otherwise by context.

[0031] The scope of the present disclosure includes all changes, substitutions, variations, alterations, and modifications to the exemplary embodiments described or illustrated herein that would be understood by a person skilled in the art. The scope of the present disclosure is not limited to the exemplary embodiments described or illustrated herein. Furthermore, although the present disclosure describes and illustrates each embodiment herein as including particular components, elements, features, functions, operations, or steps, any of these embodiments may include any combination or permutation of any components, elements, features, functions, operations, or steps described or illustrated anywhere herein that would be understood by a person skilled in the art. Furthermore, a reference in the appended claims to an apparatus or system component that is adapted, arranged, capable, configured, enabled, operable, or operates to perform a particular function encompasses the apparatus, system, or component, so long as the apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operates, regardless of whether the apparatus, system, or component, or its particular function, is activated, turned on, or unlocked. Furthermore, although this disclosure describes or illustrates particular embodiments that provide certain advantages, a particular embodiment may provide none, some, or all of these advantages. [Explanation of symbols]

[0032] 100 Inspection Systems 105 Borescope 110 Mounting System 115 Joint System 120 Controller 125 proximal end 130 distal end

Claims

1. a borescope having a plurality of optical fibers disposed therein; The mounting system, The joint system and a hollow working channel extending along the length of said borescope; a tubular body disposed within the working channel so as to cover at least a portion of the inner surface of the working channel; a piston plunger including a piston head configured to translate through the tubular body and exit the tubular body at a distal end of the borescope; a seal disposed within the distal portion of the tubular body adjacent to the piston head; a controller having a display, a proximal end of the borescope coupled to the mounting system, the mounting system configured to secure the inspection system to an exterior surface of an inspection object, the mounting system coupled to the articulation system, the articulation system configured to actuate the borescope, the articulation system communicatively coupled to the controller; the controller is configured to actuate the piston plunger to expel the sealing material from the distal end of the tubular body and secure foreign object debris with the sealing material. The inspection system.

2. The inspection system of claim 1 , wherein the mounting system comprises a tubular body, a rod, a clamp, a hinge, a fastener, and any combination thereof.

3. The inspection system of claim 1 , wherein the mounting system is configured to adjust the distance and angle of the inspection system relative to the exterior surface.

4. The articulation system comprises: a first rotary lever; a second rotary lever; a handle; The inspection system of claim 1 .

5. The inspection system of claim 4 , wherein the first rotary lever is configured to actuate a portion of the borescope proximate the distal end to bend along a horizontal plane relative to the distal end.

6. The inspection system of claim 4 , wherein the second rotary lever is configured to actuate a portion of the borescope proximate the distal end to bend along a plane perpendicular to the distal end.

7. 5. The inspection system of claim 4, wherein the proximal end of the borescope is attached to the handle, and the first and second rotary levers are located on opposite sides of the handle from the proximal end of the borescope.

8. The inspection system of claim 1 , further comprising a cover plate disposed at a distal end of the borescope.

9. A camera and The first light, A second light, The inspection system of claim 8 further comprising:

10. 10. The inspection system of claim 9, wherein both the first light and the second light are disposed within the cover plate, the first light being disposed on an opposite portion of the cover plate from the second light.

11. 10. The inspection system of claim 9, wherein the camera is positioned between the first light and the second light and offset by a distance, the camera being electrically coupled to the controller.

12. The inspection system of claim 11 , wherein the working channel is disposed between the first light and the second light and offset a distance opposite the camera.

13. The inspection system of claim 1 , further comprising a vacuum attachment, the vacuum attachment comprising a port coupling, an air supply coupling, and a containment coupling.

14. The inspection system of claim 1 , further comprising a tool selected from the group consisting of a mechanical tool, a magnetic tool, a measurement tool, and combinations thereof.

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