Methods and scan systems for analyzing an object
Methods and scan systems for analyzing an object. The methods include obtaining a local operation dataset that includes a plurality of operation data points obtained from an object and a corresponding location, within the operation coordinate system, for each operation data point of the plurality of operation data points. The methods also include mapping the plurality of operation data points from the operation coordinate system to a global coordinate system for the object. The mapping includes mapping to generate a global operation dataset that includes the plurality of operation data points and a corresponding global location, within the global coordinate system, for each operation data point. The scan systems include a robot that performs a plurality of operations on an object within an operation coordinate system and a computing device that maps the plurality of operation data points from the operation coordinate system to a global coordinate system.
1. A method of analyzing an object that includes at least a region of an aircraft, the method comprising:
obtaining a local operation dataset that includes a plurality of operation data points obtained from the object and a corresponding local location, within an operation coordinate system, for each operation data point of the plurality of operation data points, wherein the obtaining the local operation dataset includes performing an operation on the object with a robot to generate the local operation dataset, and further wherein the performing the operation includes:
(i) moving the robot relative to the object and to a plurality of distinct local locations within the operation coordinate system; and
(ii) collecting a corresponding test result at each distinct local location; and
mapping the plurality of operation data points from the operation coordinate system to a global coordinate system for the object, which differs from the operation coordinate system, to generate a global operation dataset that includes the plurality of operation data points and a corresponding global location, within the global coordinate system for the object, for each operation data point;
wherein the method further includes utilizing the global operation dataset to determine a location of a defect within the object;
wherein the method includes comparing the defect to a predetermined defect tolerance, wherein the predetermined defect tolerance is a location-specific predetermined defect tolerance that varies with location within the operation coordinate system; and
further wherein the method includes at least one of:
(i) scrapping the object when the defect is outside the predetermined defect tolerance;
(ii) reworking the object when the defect is outside the predetermined defect tolerance; and
(iii) approving the object for utilization when the defect is within the predetermined defect tolerance.
2. The method of claim 1 , wherein the obtaining the local operation dataset includes:
(i) obtaining a first local operation dataset that includes a first plurality of operation data points, in the form of a plurality of test results generated from nondestructive testing of the object, and a corresponding first-local-operation-dataset location, within the operation coordinate system, for each test result of the plurality of test results; and
(ii) obtaining a second local operation dataset that includes a second plurality of operation data points, in the form of a plurality of laser profiler dimensions of the object, and a corresponding second-location-operation-dataset location, within the operation coordinate system, for each laser profiler dimension of the plurality of laser profiler dimensions of the object.
3. The method of claim 2 , wherein the corresponding local location for each operation data point includes a location of the robot within a 2-dimensional grid that defines the operation coordinate system, and further wherein the mapping the plurality of operation data points includes determining a local spatial relationship between the location of the robot within the 2-dimensional grid and a location, on the object, at which each operation data point is obtained by the robot.
4. The method of claim 3 , wherein the mapping the plurality of operation data points from the operation coordinate system to the global coordinate system for the object includes mapping based, at least in part, on the operation coordinate system, the global coordinate system for the object, and the local spatial relationship.
5. The method of claim 2 , wherein the method further includes determining a local location of a reference feature of the object within the operation coordinate system, as identified in the plurality of laser profiler dimensions, and also determining a global location of the reference feature of the object within the global coordinate system for the object, wherein the mapping the plurality of operation data points from the operation coordinate system to the global coordinate system for the object includes mapping based, at least in part, on the local location of the reference feature and the global location of the reference feature.
6. The method of claim 1 , wherein the obtaining the local operation dataset includes obtaining the local operation dataset from a database that includes the local operation dataset.
7. The method of claim 1 , wherein the performing the operation includes performing the operation with a spatial resolution of at least 0.01 millimeter and at most 20 mm.
8. The method of claim 1 , wherein the operation includes at least one of:
(i) a non-destructive inspection of the object;
(ii) a non-contact inspection of the object;
(iii) an ultrasound inspection of the object;
(iv) an infrared inspection of the object;
(v) an optical inspection of the object;
(vi) a dimensional inspection of the object; and
(vii) a laser dimensional inspection of the object.
9. The method of claim 1 , wherein the mapping the plurality of operation data points from the operation coordinate system to the global coordinate system for the object includes utilizing a spatial relationship between the operation coordinate system and the global coordinate system for the object to map the plurality of operation data points from the operation coordinate system to the global coordinate system for the object.
10. The method of claim 9 , wherein the method further includes determining the spatial relationship between the operation coordinate system and the global coordinate system for the object.
11. The method of claim 10 , wherein the determining the spatial relationship includes establishing at least one reference location within both the operation coordinate system and the global coordinate system for the object, and further wherein the determining the spatial relationship includes determining based, at least in part, on at least one of:
(i) an operation coordinate system position of the at least one reference location within the operation coordinate system;
(ii) a global coordinate system position of the at least one reference location within the global coordinate system for the object; and
(iii) a comparison between the operation coordinate system position and the global coordinate system position.
12. The method of claim 1 , wherein the method further includes utilizing the global operation dataset during construction of the object to at least one of:
(i) determine a rework location where rework is to be performed on the object, wherein the method further includes performing the rework on the object;
(ii) determine a repair location where a repair is to be performed on the object, wherein the method further include performing the repair;
(iii) determine a deviation in at least one geometric property of the object from an expected geometric property, wherein the method includes utilizing a shim to adjust for the deviation in the at least one geometric property of the object; and
(iv) estimate tool wear of a tool utilized to construct the object, wherein the method further includes dispositioning the tool based, at least in part, on the tool wear.
13. The method of claim 1 , wherein the method further includes utilizing the global operation dataset during in-service repair of the object to at least one of:
(i) correlate a location of the operation data points with a location of a repair; and
(ii) predict the location of the repair based, at least in part, on the location of the operation data points.
14. The method of claim 1 , wherein:
(i) the operation coordinate system is a 2-dimensional coordinate system; and
(ii) the global coordinate system for the object is a 3-dimensional coordinate system.
15. A scan system for analyzing an object, the scan system comprising:
a robot including a sensor configured to perform a plurality of operations at a plurality of corresponding operation locations on an object to generate a local operation dataset that includes a plurality of operation data points and a corresponding location, within an operation coordinate system, for each operation data point of the plurality of operation data points by:
(i) moving the robot relative to the object and to a plurality of distinct local locations within the operation coordinate system; and
(ii) collecting a corresponding test result at each distinct local location; and
a computing device programmed to map the plurality of operation data points from the operation coordinate system to a global coordinate system for the object, which differs from the operation coordinate system, to generate a global operation dataset that includes the plurality of operation data points and a corresponding global location, within the global coordinate system for the object, for each operation data point; wherein the computing device further is programmed to utilize the global operation dataset to determine a location of a defect within the object by comparing the defect to a predetermined defect tolerance, wherein the predetermined defect tolerance is a location-specific predetermined defect tolerance that varies with location within the operation coordinate system; and wherein the computing device further is programmed to direct at least one of:
(i) scrapping the object when the defect is outside the predetermined defect tolerance;
(ii) reworking the object when the defect is outside the predetermined defect tolerance; and
(iii) approving the object for utilization when the defect is within the predetermined defect tolerance.
16. The scan system of claim 15 , wherein the plurality of operations includes at least one of:
(i) a non-destructive inspection of the object;
(ii) a non-contact inspection of the object;
(iii) an ultrasound inspection of the object;
(iv) an infrared inspection of the object;
(v) an optical inspection of the object;
(vi) a dimensional inspection of the object; and
(vii) a laser dimensional inspection of the object.
17. The scan system of claim 15 , wherein the computing device is programmed to utilize a spatial relationship between the operation coordinate system and the global coordinate system for the object to map the plurality of operation data points from the operation coordinate system to the global coordinate system for the object.
18. The scan system of claim 17 , wherein the computing device also is programed to determine the spatial relationship between the operation coordinate system and the global coordinate system for the object.
19. The scan system of claim 15 , wherein the global coordinate system for the object describes a location of the plurality of operation data points relative to a reference structure of an aircraft.
20. The method of claim 1 , wherein the global coordinate system for the object describes a location of the plurality of operation data points relative to a reference structure of the aircraft.