Patents by Inventor Roger W. Engelbart

Roger W. Engelbart has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20220146256
    Abstract: Apparatus, systems, and methods for the inspection of holes in transparent materials, the apparatus including a processor, an illumination probe, and a detection probe. The illumination probe includes a laser light source and a reflective surface and is configured to be inserted into a first hole in the transparent material. The detection probe includes a second reflective surface and a photodetector and is configured to be inserted in a second hole in the transparent material. Laser light is directed onto the first reflective surface within the first hole and is reflected through a wall of the first hole, into the transparent material, and reflected by the second reflective surface to the photodetector. The photodetector transmits a measured light intensity value to the processor, which compares the light intensity value to a standard intensity value to determine whether or not a crazing condition exists in the second hole.
    Type: Application
    Filed: November 9, 2021
    Publication date: May 12, 2022
    Applicant: The Boeing Company
    Inventors: Roger W. Engelbart, Elizabeth Ann Paton, Christopher M. Vaccaro
  • Patent number: 11181887
    Abstract: A method and system provide for reducing gaps between two mating parts. Either or both parts may be nondestructively inspected at a plurality of locations on a surface to gather a data set relating to the part thickness. The data set may be used to calculate a set of as-built thickness values for the part and a set of deviations from a design model. A mating area may be determined for mating surfaces of the parts. One or more layers of sacrificial material in the mating area may be prepared for any deviations greater than a design allowance. The system may include a ply cutting device and an additive manufacturing device coupled to a computer to receive the sacrificial material layer data and shim data and to cut the one or more layers of sacrificial material and to construct the shim. A shim may be constructed for any deviations equal to or greater than a minimum shim thickness. The one or more layers of sacrificial material may be applied to the part, cured, and machined to a desired thickness.
    Type: Grant
    Filed: December 14, 2018
    Date of Patent: November 23, 2021
    Assignee: The Boeing Company
    Inventors: Roger W. Engelbart, James L. Scherer, Christopher M. Vaccaro, Brian Stutzman, George E. Bible, Jeffrey J. Kilwin
  • Patent number: 11002697
    Abstract: A system and method for nondestructive inspection of a unitized composite structures is provided. The system includes an infrared thermographic camera and a carriage that can be mounted on, for example, adjacent frames of the unitized composite structure. The carriage can move along the length of the frames while the infrared thermographic camera collects and analyzes thermographic images of the frame, skin, and stiffeners. The carriage can be moved to other frames and the inspection continued until the entire unitized composite structure has be inspected.
    Type: Grant
    Filed: August 17, 2018
    Date of Patent: May 11, 2021
    Assignee: THE BOEING COMPANY
    Inventors: Roger W. Engelbart, Jeffrey G. Thompson
  • Patent number: 10937006
    Abstract: A method, system and computer program product are provided in order to evaluate corrosion loss and to establish maintenance actions based thereupon. In the context of a method, a structure is inspected to generate corrosion information and a corrosion model of the structure is generated based upon the corrosion information. The method also includes generating a combined corrosion model based upon the corrosion model and a baseline model of the structure including material types and thicknesses at respective locations on the structure. The method further includes establishing maintenance actions including modification of an inspection interval based upon the combined corrosion model. Corresponding systems and computer program products are also provided.
    Type: Grant
    Filed: June 9, 2017
    Date of Patent: March 2, 2021
    Assignee: The Boeing Company
    Inventors: Roger W. Engelbart, Taisia Tsukruk Lou
  • Patent number: 10843821
    Abstract: A method and system may be provided for determining a set of parameters for preparing a skin for assembly to a substructure. The skin may be nondestructively inspected to gather a data set relating to the skin thickness. Sets of as-built thickness values for the skin and of deviations from a nominal map of the skin thickness may be calculated. A mating area for the skin and substructure and a set of one or more locations for fastener holes in the mating area may be determined. A set of parameters for the one or more fastener holes and a set of one or more fastener lengths may be generated using the deviations. A tool may cut the one or more fastener holes using the set of parameters and the skin and substructure may be fastened using fasteners selected according to the generated set of one or more fastener lengths.
    Type: Grant
    Filed: January 3, 2019
    Date of Patent: November 24, 2020
    Assignee: The Boeing Company
    Inventors: Roger W. Engelbart, John William Adams, James C. Kennedy
  • Patent number: 10768121
    Abstract: Methods, systems, and apparatus for detection of a condition in a hole defined by a transparent material that is at least partially enclosed by one or more substantially opaque materials. The method may include positioning a light source in a first hole in the transparent material, directing light from the positioned light source through the transparent material and toward a second hole that is adjacent to the first hole. A prism may be positioned so that the light transmitted from the light source through the machined inner surface of the second hole is visible through a viewing face of the prism. By observing the transmitted light, a surface condition of the machined inner surface of the second hole may be determined.
    Type: Grant
    Filed: May 22, 2018
    Date of Patent: September 8, 2020
    Assignee: The Boeing Company
    Inventors: Elizabeth Ann Paton, Roger W. Engelbart, Christopher M. Vaccaro
  • Publication number: 20200216198
    Abstract: A method and system may be provided for determining a set of parameters for preparing a skin for assembly to a substructure. The skin may be nondestructively inspected to gather a data set relating to the skin thickness. Sets of as-built thickness values for the skin and of deviations from a nominal map of the skin thickness may be calculated. A mating area for the skin and substructure and a set of one or more locations for fastener holes in the mating area may be determined. A set of parameters for the one or more fastener holes and a set of one or more fastener lengths may be generated using the deviations. A tool may cut the one or more fastener holes using the set of parameters and the skin and substructure may be fastened using fasteners selected according to the generated set of one or more fastener lengths.
    Type: Application
    Filed: January 3, 2019
    Publication date: July 9, 2020
    Applicant: The Boeing Company
    Inventors: Roger W. Engelbart, John William Adams, James C. Kennedy
  • Publication number: 20200192331
    Abstract: A method and system provide for reducing gaps between two mating parts. Either or both parts may be nondestructively inspected at a plurality of locations on a surface to gather a data set relating to the part thickness. The data set may be used to calculate a set of as-built thickness values for the part and a set of deviations from a design model. A mating area may be determined for mating surfaces of the parts. One or more layers of sacrificial material in the mating area may be prepared for any deviations greater than a design allowance. The system may include a ply cutting device and an additive manufacturing device coupled to a computer to receive the sacrificial material layer data and shim data and to cut the one or more layers of sacrificial material and to construct the shim. A shim may be constructed for any deviations equal to or greater than a minimum shim thickness. The one or more layers of sacrificial material may be applied to the part, cured, and machined to a desired thickness.
    Type: Application
    Filed: December 14, 2018
    Publication date: June 18, 2020
    Applicant: The Boeing Company
    Inventors: Roger W. Engelbart, James L. Scherer, Christopher M. Vaccaro, Brian Stutzman, George E. Bible, Jeffrey J. Kilwin
  • Patent number: 10661512
    Abstract: A system comprises a laser projector, an automated material placement head, and a laser inspection system. The laser projector is configured to project boundary projection line onto a part. The automated material placement head is configured to lay down a course of composite material. The laser inspection system is connected to the automated material placement head and configured to project a laser beam into a laser line parallel to the motion of the automated material placement head in laying the composite material.
    Type: Grant
    Filed: April 25, 2017
    Date of Patent: May 26, 2020
    Assignee: The Boeing Company
    Inventors: Roger W. Engelbart, Reed Hannebaum, Eric Rector
  • Publication number: 20200057012
    Abstract: A system and method for nondestructive inspection of a unitized composite structures is provided. The system includes an infrared thermographic camera and a carriage that can be mounted on, for example, adjacent frames of the unitized composite structure. The carriage can move along the length of the frames while the infrared thermographic camera collects and analyzes thermographic images of the frame, skin, and stiffeners. The carriage can be moved to other frames and the inspection continued until the entire unitized composite structure has be inspected.
    Type: Application
    Filed: August 17, 2018
    Publication date: February 20, 2020
    Inventors: Roger W. Engelbart, Jeffrey G. Thompson
  • Publication number: 20190360945
    Abstract: Methods, systems, and apparatus for detection of a condition in a hole defined by a transparent material that is at least partially enclosed by one or more substantially opaque materials. The method may include positioning a light source in a first hole in the transparent material, directing light from the positioned light source through the transparent material and toward a second hole that is adjacent to the first hole. A prism may be positioned so that the light transmitted from the light source through the machined inner surface of the second hole is visible through a viewing face of the prism. By observing the transmitted light, a surface condition of the machined inner surface of the second hole may be determined.
    Type: Application
    Filed: May 22, 2018
    Publication date: November 28, 2019
    Applicant: The Boeing Company
    Inventors: Elizabeth Ann Paton, Roger W. Engelbart, Christopher M. Vaccaro
  • Patent number: 10260953
    Abstract: A method of thermographic inspection includes absorbing, at an applique applied to a test area of an article, light from a testing light source. The method further includes emitting, by the applique, thermal radiation directed to a capture device, the thermal radiation corresponding to at least a portion of the light absorbed by the applique.
    Type: Grant
    Filed: August 11, 2016
    Date of Patent: April 16, 2019
    Assignee: The Boeing Company
    Inventors: Roger W. Engelbart, Nathan R. Smith, Loyal B. Shawgo
  • Publication number: 20180357613
    Abstract: A method, system and computer program product are provided in order to evaluate corrosion loss and to establish maintenance actions based thereupon. In the context of a method, a structure is inspected to generate corrosion information and a corrosion model of the structure is generated based upon the corrosion information. The method also includes generating a combined corrosion model based upon the corrosion model and a baseline model of the structure including material types and thicknesses at respective locations on the structure. The method further includes establishing maintenance actions including modification of an inspection interval based upon the combined corrosion model. Corresponding systems and computer program products are also provided.
    Type: Application
    Filed: June 9, 2017
    Publication date: December 13, 2018
    Inventors: Roger W. Engelbart, Taisia Tsukruk Lou
  • Patent number: 10139808
    Abstract: A method and a system are provided for predicting and creating a shim for use in a joint where two parts, such as a skin and a substructure, are assembled together. Digital models for the skin and the substructure may be used as nominal maps of the outlines and profiles of the parts. The skin may be inspected, e.g., by nondestructive means, such as ultrasound, to determine as-built thickness profile for comparison to the skin's digital model of the thickness profile. Mating areas of the skin and substructure may be determined from their digital models of their outlines. Deviations in the mating areas of the as-built thickness of the skin from the digital model of the skin may be used to generate a digital model of a shim. The shim may be constructed from its digital model by additive manufacturing techniques that may involving machining or 3D printing.
    Type: Grant
    Filed: September 7, 2016
    Date of Patent: November 27, 2018
    Assignee: The Boeing Company
    Inventors: Roger W. Engelbart, George E. Bible, James Leonard Scherer, Brian Stutzman, Jeffrey J. Kilwin, Christopher M. Vaccaro
  • Publication number: 20180304558
    Abstract: A system comprises a laser projector, an automated material placement head, and a laser inspection system. The laser projector is configured to project boundary projection line onto a part. The automated material placement head is configured to lay down a course of composite material. The laser inspection system is connected to the automated material placement head and configured to project a laser beam into a laser line parallel to the motion of the automated material placement head in laying the composite material.
    Type: Application
    Filed: April 25, 2017
    Publication date: October 25, 2018
    Inventors: Roger W. Engelbart, Reed Hannebaum, Eric Rector
  • Publication number: 20180067476
    Abstract: A method and a system are provided for predicting and creating a shim for use in a joint where two parts, such as a skin and a substructure, are assembled together. Digital models for the skin and the substructure may be used as nominal maps of the outlines and profiles of the parts. The skin may be inspected, e.g., by nondestructive means, such as ultrasound, to determine as-built thickness profile for comparison to the skin's digital model of the thickness profile. Mating areas of the skin and substructure may be determined from their digital models of their outlines. Deviations in the mating areas of the as-built thickness of the skin from the digital model of the skin may be used to generate a digital model of a shim. The shim may be constructed from its digital model by additive manufacturing techniques that may involving machining or 3D printing.
    Type: Application
    Filed: September 7, 2016
    Publication date: March 8, 2018
    Applicant: The Boeing Company
    Inventors: Roger W. Engelbart, George E. Bible, James Leonard Scherer, Brian Stutzman, Jeffrey J. Kilwin, Christopher M. Vaccaro
  • Publication number: 20180045574
    Abstract: A method of thermographic inspection includes absorbing, at an applique applied to a test area of an article, light from a testing light source. The method further includes emitting, by the applique, thermal radiation directed to a capture device, the thermal radiation corresponding to at least a portion of the light absorbed by the applique.
    Type: Application
    Filed: August 11, 2016
    Publication date: February 15, 2018
    Applicant: THE BOEING COMPANY
    Inventors: Roger W. Engelbart, Nathan R. Smith, Loyal B. Shawgo
  • Patent number: 9645095
    Abstract: A method, system and computer-readable storage medium are provided to facilitate inspection of a composite part during manufacture. In the context of a system, a system for inspecting a composite part during manufacture is provided that includes an inspection system configured to detect an in-process anomaly with respect to a ply of the composite part during placement of the ply. The system also includes a computing system configured to determine part location coordinates of the in-process anomaly detected by the inspection system with respect to the ply of the composite part. The computing system is also configured to map the in-process anomaly to a digital part model based upon the part location coordinates. The system additionally includes a display, responsive to the computing system, configured to present a representation of the digital part model including an indication of the in-process anomaly relative thereto.
    Type: Grant
    Filed: October 6, 2014
    Date of Patent: May 9, 2017
    Assignee: The Boeing Company
    Inventors: Roger W. Engelbart, James W. Fonda, Allen Halbritter
  • Patent number: 9610730
    Abstract: A method and apparatus for reworking an inconsistency on a part. Information about the inconsistency on the part may be identified using data generated by a nondestructive evaluation system. A portion of a section of the part in which the inconsistency is located may be removed based on the information about the inconsistency. A profile for the section of the part may be identified. Rework image data may be generated using the profile in which the rework image data comprises a number of patch images. The number of patch images may be projected onto a rework material as a number of patch projections for use in forming a patch to be applied over the section of the part.
    Type: Grant
    Filed: June 10, 2015
    Date of Patent: April 4, 2017
    Assignee: THE BOEING COMPANY
    Inventor: Roger W. Engelbart
  • Patent number: 9595096
    Abstract: Provided are methods, systems, and computer program products for inspecting composite items. Specifically, a method involves analyzing an image of or, more generally, data characterizing condition of a top layer, which is disposed over a bottom layer. The method also involves performing a structural integrity check based on any anomalies detected in the top layer during this analysis as well as based on any anomalies previously detected in the bottom layer. As such, this structural integrity check accounts for characteristics of multiple layers, in some embodiments, all layers applied up to point of this inspection. In addition to the detected anomalies, the structural integrity check may account for previously performed repairs. The structural integrity check may be performed on individual portions of a composite item while, for example, other portions continue receiving a new composite layer, which may be referred to as an inline inspection.
    Type: Grant
    Filed: March 10, 2014
    Date of Patent: March 14, 2017
    Assignee: The Boeing Company
    Inventors: Steven A. Dorris, Arun Ayyagari, Jonathan Blake Vance, David E. Corman, James W. Fonda, Roger W. Engelbart, Philip L. Freeman