EP1154928A1 - Inspection device for aircraft - Google Patents

Inspection device for aircraft

Info

Publication number
EP1154928A1
EP1154928A1 EP00911992A EP00911992A EP1154928A1 EP 1154928 A1 EP1154928 A1 EP 1154928A1 EP 00911992 A EP00911992 A EP 00911992A EP 00911992 A EP00911992 A EP 00911992A EP 1154928 A1 EP1154928 A1 EP 1154928A1
Authority
EP
European Patent Office
Prior art keywords
camera
support
aircraft
distal end
ofthe
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP00911992A
Other languages
German (de)
French (fr)
Inventor
Robert Lee Thompson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Pinotage LLC
Original Assignee
Pinotage LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pinotage LLC filed Critical Pinotage LLC
Publication of EP1154928A1 publication Critical patent/EP1154928A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B64AIRCRAFT; AVIATION; COSMONAUTICS
    • B64FGROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
    • B64F5/00Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
    • B64F5/60Testing or inspecting aircraft components or systems

Definitions

  • the present invention is directed to an imaging system, and more particularly, to an imaging system for visualizing relatively inaccessible regions of an aircraft or other inaccessible areas.
  • many regions of an aircraft are relatively inaccessible and direct visual inspection is difficult if not impossible. These regions include, but are not limited to. the aircraft ' s engines, the aircraft " s structural airframe. the aircraft ' s rudder, stabilizers, ilaps. and other steering controls, the aircraft ' s fuel cells, the aircraft ' s instrumentation panels, cockpit wiring harnesses, etc.
  • the aircraft ' s engines are confined within an engine housing with only the inlet and exhaust portions of the engine being externally visible, specialized visual inspection equipment is necessary to view the interior regions of the aircraft ' s engines.
  • portions of the aircraft engine housing and portions of the aircraft engine typically include a number of small openings by which specialized viewing instruments can be inserted to inspect the interior of the aircraft ' s engine.
  • specialized visual inspection equipment that is used to inspect aircraft has been taken directly from the medical industry with little or no modification.
  • laparoscopes. colonoscopes. arthroscopes. and other forms of endoscopes were originally designed for use in performing minimally invasive surgical and diagnostic procedures, these instruments are now being used in a number of other applications. including the visual inspection of aircraft. When used in non-medical applications, these visual inspection instruments are commonly called borescopes.
  • Rigid borescopes generally include a rigid, typically cylindrical, hollow tube or borescope body with an objective lens disposed at a distal po ⁇ ion of the body and an eyepiece disposed at a proximal end o the body.
  • the objective lens may be disposed in line with a longitudinal axis of the body for viewing objects that are straight ahead, or disposed at an angle to the longitudinal axis of the body for viewing objects that are disposed at a fixed angle obliquely ahead.
  • Flexible borescopes generally include a flexible, typically cylindrical, hollow tube or borescope body having a distal end and a proximal end. with an objective lens disposed at the distal end and a camera or eyepiece disposed at the proximal end. Enclosed within the body is one or a number of optical fibers that extend from the distal end to the proximal end of the body and transmit images from the objective lens to the camera or eyepiece. Other optical fibers may be enclosed within the body to illuminate the object being viewed. Some flexible borescopes permit an analog image of an object that is transmitted to the camera or the eyepiece to be displayed on an external monitor.
  • Two-way and four way flexible borescopes typically include a mechanism
  • rigid borescopes generally require that the operator be positioned so that his/her eye is aligned with the eyepiece at the end of the borescope. In the area of aircraft inspection, this positioning of the operator can be quite difficult to achieve. Furthermore, even with an angled borescope that is capable of viewing objects that are not aligned along the longitudinal axis of the body of the borescope. when a different direction of view is desired, the repositioning of the distal end of the scope results in a repositioning of the proximal end of the scope.
  • some flexible borescopes permit an image of an object to be displayed on an external monitor, and thus do not require that an operator be physically adjacent the distal end of the scope. Further, because some flexible borescopes permit their distal end to be remotely moved relative to an adjacent portion ofthe scope, certain movements of the distal end may be made without repositioning the proximal end. Nonetheless, for movement in a direction other than those predefined directions, the proximal end of the scope must be moved to reposition the distal end. Moreover, even where the direction of movement is such that it may be remotely performed without repositioning the proximal end of the scope, such movement may not be possible due to the shape and/or dimensions of what may be a confined space in which the distal end is placed.
  • flexible borescopes limits their usefulness in aircraft inspection as the body of the scope must frequently traverse large distances to reach the intended target.
  • Flexible medical laparoscopes are typically incapable of spanning large distances without sagging, absent some additional support structure. Hence when such flexible borescopes are used for aircraft inspection, they are frequently inserted into a pipe for support.
  • an aircraft visualization system is provided that is capable of visualizing relatively inaccessible regions of an aircraft, such as the aircraft ' s engine, the aircraft ' s rudder, stabilizers, flaps, and other steering controls, the aircraft ' s fuel cells, the aircraft ' s cockpit, etc.
  • embodiments of the present invention are described with reference to an airplane, the present invention is not so limited, as embodiments ofthe present invention may be used to inspect helicopters, gliders, and other fixed-wing and non-fixed wing aircraft. Moreover, use ofthe present invention is not limited to the aviation or transportation fields, as embodiments ofthe present invention may be used to inspect any object that can be difficult to access and view directly. Thus, exemplary uses for embodiments of the present invention include inspecting underground storage tanks, inspecting turbines used in electrical generators, military tanks or transports or other land, water, or airborne vehicles, etc.
  • aircraft inspection apparatus includes a support having a proximal end and a distal end and a camera that is mounted to the distal end of the support.
  • the camera is movably mounted to the distal end ofthe support for movement relative to the distal end of the support.
  • a method of inspecting an aircraft for a camera that is mounted at a first position to a distal end of an elongated support.
  • the method includes acts of inserting the camera into a portion of the aircraft and moving the camera to a second position that is spaced apart from the first position without changing a position of a proximal end of the elongated support.
  • another method of inspecting an aircraft includes acts of inserting a camera that is mounted to a distal end of an elongated support into a first portion of the aircraft, the camera being mounted to the distal end ofthe elongated support at a first position, and telescoping the camera to a second position that is spaced apart from the first position.
  • a method of inspecting an aircraft includes acts of inserting a camera that is mounted to a distal end of a support into a portion of the aircraft, the distal end of the support being in a first position inside the po ⁇ ion of he aircraft, and remotely telescoping the support to a second position inside the po ⁇ ion of the aircraft.
  • a method of inspecting an aircraft includes acts of inse ⁇ ing a camera that is mounted to a distal end of a suppo ⁇ into a po ⁇ ion of the aircraft and illuminating the portion of the aircraft with a light source that is disposed adjacent to the camera.
  • a further method of inspecting an aircraft includes acts of inserting a camera that is mounted to a distal end of a suppo ⁇ into a po ⁇ ion ofthe aircraft, generating a digital image of the po ⁇ ion ofthe aircraft, transmitting the digital image ofthe portion ofthe aircraft to a storage device, and storing the digital image on the storage device.
  • a method of inspecting an aircraft includes acts of inserting a camera that is mounted to a distal end of a suppo ⁇ into a portion ofthe aircraft and telescoping the camera in a direction other than along a longitudinal axis of the suppo ⁇ .
  • a method of inspecting an aircraft with a conventional borescope includes acts of inse ⁇ ing the borescope into a po ⁇ ion of the aircraft, the borescope having an eyepiece, coupling a digital camera to the eyepiece ofthe borescope. and generating a digital image of the po ⁇ ion cf the aircraft.
  • Figure 1A is a frontal view of a conventional aircraf jet engine
  • Figure IB is a schematic cross-sectional view of a conventional aircraft jet engine
  • Figure IC is a fragmentary enlarged perspective view of a porrion of the jet engine of Figure IB;
  • Figure 2A is a perspective view of an aircraft visualization system according to one embodiment ofthe present invention.
  • Figure 2B is a perspective view of an aircraft visualization system according to another embodiment ofthe present invention.
  • FIG. 1 is a perspective view of an aircraft visualization svst ⁇ m according to another embodiment ofthe present invention:
  • Figure 3B is a perspective view of an aircraft visuaiizauon system according to another embodiment of the present invention
  • Figure 4 is an enlarged fragmentary perspective view of a telescoping suppo ⁇ and camera assembly that may be used with any ofthe embodiments of Figures 2A. 2B. 3 A. and 3B,
  • Figure 5 is a front elevauonai view of an aircraft visuaiizauon system according to another embodiment ofthe present invention.
  • Figure 6A is a perspecuve view of outwardh visible aspects of a multi-positional camera module that may be used with the visuaiizauon system of Figure 5;
  • Figure 6B is an alternative perspective view of the muiti-Dosmonal camera mo ⁇ ule of Figure 6A;
  • Figure 7A is a cross-secuonal view of some of the internal aspects of a muin-positional camera module of Figures 6 A and 6B;
  • Figure 7B is an alternative cross-secuonal view ofthe internal aspect of he multi- positional camera module of Figure 7A;
  • Figure 8 is a cross-sectional view of internal aspects ofthe aircraft visuaiizauon system of Figure 5;
  • Figure 9 is a perspective view ofthe aircraft visuaiizauon system of Figure 5 in a fully extended position
  • Figure 10 is a funcuonal block diagram of an opucai imaging system accordmg to one aspect ofthe present invention.
  • Figure 11 is an exploded front view of an imaging device in accordance with one embodiment ofthe present invention
  • Figure 12 is a partially cutaway side elevational view of the imaging device of Figure 1 1;
  • Figure 13 is a cutaway top view taken through plane 1 -13 in Figure 1 1 , of a sheath cap in the imaging device of Figure 11;
  • Figure 14 is an enlarged cutaway side view of the upper housing and the lower po ⁇ ion of the imaging device of Figure 11;
  • Figure 15 is a cutaway top view of he upper housing of he imaging device of Figure 11 taken through plane 15-15 in Figure 14;
  • Figure 16 is a cutaway top view of the lower po ⁇ ion of the imaging device of Figure 1 1 taken through piane 16-16 in Figure 14;
  • Figure 17 is a funcuonal block diagram of a system for controlling the imaging device of Figure 1 1 and for displaying the images transmitted by the imaging device;
  • Figure 18 is a functional block diagram of an alternate control and display system for the imaging device of Figure 1 1;
  • Figure 19 is an exploded cutaway side view of an alternate embodiment of a surgical/diagnostic imaging device in accordance with the present invention.
  • Figure 20 is a front view of the camera housing ofthe image device of Figure 19; and Figure 21 is a cutaway side view of the camera housing taken through plane 21-21 in Figure 20.
  • Figure 1A is a frontal view of a conventional aircraft jet engine 100 looking toward the turbine blades 140 of the jet engine 100.
  • the engine 100 is disposed within an engine housing 110.
  • the engine 100 can be accessed via a small opening 120 in the engine housing 1 10.
  • Interior regions ofthe engine 100 can be examined via a small opening 130 in the engine 100 that is aligned with the opening 120 in the engine housing 110.
  • Figure IB is a cross-sectional view ofthe aircraft jet engine 100 shown in Figure 1A.
  • the engine 100 includes a plurality of small openings or viewing holes 130 through which various interior regions and pa ⁇ s ofthe engine 100 may be inspected.
  • these opemngs 130 are labeled with reference indicators A-H.
  • Some of these openings e.g., openings A and F
  • a rigid borescope e.g., openings B - E, G, and H.
  • many of the interior portions of the engine 100 can only be viewed from a
  • TIFIED SHEET RULE 91 direction that is perpendicular to the direction in which the borescope is i ⁇ se ⁇ ed in the engine 100. It should be appreciated that depending on the size of the aircraft engine 100 (e.g., an engine of a Boeing 757 or an engine of a Lear jet), the distance between the opening 130 in the engine through which the borescope is inse ⁇ ed and the intended object to be view can be quite large, on the order of several feet.
  • Figure IC is a fragmentary enlarged perspective view of various internal components of the aircraft jet engine of Figure IB showing some of the internal components that are conventionally subject to periodic visual inspection.
  • FIG. 2A illustrates an aircraft visualization system according to one embodiment ofthe present invention.
  • the aircraft visualization system 200 includes an imaging component attached to a telescoping suppo ⁇ 221.
  • the imaging component is a charged coupled device (CCD), but it should be appreciated that the invention is not limited in this respect as other imaging devices can be employed.
  • the aircraft visualization system 200 also includes a light 235 attached to the telescoping suppo ⁇ 221, to illuminate the area viewed by the imaging device.
  • the light is a light source (e.g., a light bulb) that generates light.
  • the present invention is not limited in this respect and the light can alternatively be a fiber optic bundle that carries light, generated from an external light source, to the viewing area.
  • the use of a light source mounted to the telescoping suppo ⁇ 221 is advantageous, in that it can be cheaper than using a fiber optic system, and also enables the system to be used without a light source for a fiber optic bundle which can be rather large and inconvenient to transpo ⁇ .
  • Telescoping suppo ⁇ 221 is attached to a distal end of an elongated suppo ⁇ 21 1, with the proximal end ofthe elongated support 211 being attached to a handle 240.
  • the telescoping support 221 is disposed at an angle that is perpendicular to the elongated support 211. This peimits the hand held po ⁇ ion of the aircraft visualization system 200 to be inse ⁇ ed into a small opening and then extended in a direction perpendicular to the direction of insertion.
  • the present invention is not limited to a telescoping support 221 that is disposed perpendicular to a longitudinal axis ofthe elongated support 211 , as other orientations may be used.
  • the handle 240 includes a number of controls 260 that control the operation of the CCD camera 230, the light source 235, and the telescoping support 221. Images observed by
  • the CCD camera 230 are relayed to a monitor and/or a storage device (not shown) via cable 250.
  • the telescoping support 221 is capable of retracting into a position that is flush with the outer surface o the elongated support 21 1 to permit easy insertion through the openings 120. 130 in the engine housing 1 10 and the engine 100 ( Figure 1).
  • the telescoping support 221 is capable of retracting into a position that extends beyond the outer surface ofthe elongated support 21 1. but is still capable of insertion through openings having a small diameter, for example four millimeters.
  • controls 260 are used to extend the telescoping support 221, and thus, the CCD camera 230 and light source 235 to the desired position.
  • controls 260 include individual controls for taking a still picture, for zooming in or out on a selected target, for rotating the CCD camera 230 and the light source 235 about the longitudinal axis ofthe telescoping support 221, and for adjusting the elevation ofthe CCD camera 230 and light source 235.
  • the field of view ofthe camera 230 can be changed without changing the position ofthe distal end of the handle 240. and without requiring any additional space in which to perform such rotation.
  • the CCD camera 230 can be rotated from zero to 360 °.
  • Controls 260 may include a rotary dial 262 that can be manipulated by an operator ' s thumb to extend or retract the telescoping support 221.
  • a rocker switch or joystick 264 that can be used for rotating the CCD camera 230 and the light source 235 left or right about a longitudinal axis ofthe telescoping support 221 and for adjusting the elevation of the CCD camera 230 and the light source 235 upward or downward.
  • the controls 260 may also include one or a number of other buttons 266 that may be used for taking a still picture at a particular moment in time or for taking a series of pictures over a period of time (i.e.. a moving picture), for zooming in or out on a selected target, or for turning on and off the light source 235.
  • controls 260 may also include one or a number of other buttons 266 that may be used for taking a still picture at a particular moment in time or for taking a series of pictures over a period of time (i.e.. a moving picture), for zooming in or out on a selected target, or for turning on and off the light source 235.
  • this explanation of potential use of controls 260 is merely provided for illustration, as numerous additional or alternative controls can be provided, and mechanisms other than a rotary dial or joy stick can be employed for implementing the controls 260.
  • the visualization system 200 also includes a local display 270 mounted on the handle 240 that is used to provide the operator of the system with a continuous image of
  • one of the controls 260 may also be used to enter a menu-based control program that can be displayed on the local display 270. After entering the menu-based control program, others of the controls 260 can be used for navigating the menus shown on the local display 270. such as for adjusting picture quality (e.g., white balance, contrast, etc.) of the CCD camera 230. etc.
  • the visualization system 200 can include a monitor and/or storage device to view and store images observed by the CCD camera 230. For example images may be stored on any type of storage medium, including a hard drive, a CD.
  • the visualization system 200 can also include a keyboard or other input device by which the operator can provide detailed information relating to the object being viewed. For example, the operator can identify the type of aircraft engine being inspected, the make, model number and registration number ofthe aircraft, the name ofthe operator, the date the inspection was performed, as well as other information that would be useful during such an inspection.
  • the visualization system may also include another input device, such as a pointer or mouse, for highlighting a specific region of interest. For example, a particular region of the engine could be highlighted, or placed within a border to call attention to a particular detail. This feature may be used, for example, to place a watch on a particular region of the engine that may be prone to excessive wear.
  • photographs of a particular region of interest may be compared to photographs of the same region in failed engines or in known good engines by an expert system to detect signs of incipient failure.
  • photographs taken by the visualization system 200 may be easily sent to a remote location using conventional communication networks (e.g.. the Internet).
  • conventional communication networks e.g.. the Internet
  • photographs may be sent electronically to those most knowledgeable with the system of interest.
  • FIG. 2B illustrates an aircraft visualization system according to another embodiment of the present invention.
  • the aircraft visualization system 201 is similar to the aircraft visualization system 200 of Figure 2A in most respects, with the same reference designators identifying similar structures. However, in the embodiment of Figure 2B. the visualization system 201 does not include a local display 270 that is mounted adjacent the handle 240. This reduces the size and weight ofthe hand-held portion ofthe visualization system 201, and permits its use within even more confined regions of the aircraft.
  • the visualization system 201 includes a battery operated computer control module 271 that includes a CPU. a monitor, and a storage device for displaying pictures of objects viewed by the CCD camera 230 and for storing those pictures on the storage device.
  • the control module 271 is coupled to the hand held portion ofthe visualization system via cable 250.
  • the storage device may include a removable RAM module (e.g., a PCMCIA RAM card) to reduce the size and weight ofthe control module 271.
  • a removable RAM module e.g., a PCMCIA RAM card
  • solid state types of storage devices such as RAM modules are less prone to damage from environmental conditions, changes in orientation, and impacts with other objects (such as from dropping the storage device) than many other forms of storage media.
  • the storage device can be removed from the control module 271 and pictures stored thereon may be transferred to another computer system.
  • the computer control module 271 is configured to attach to the belt of an operator to permit hands-free operation.
  • FIG 3A illustrates an aircraft visualization system according to another embodiment of the present invention.
  • the aircraft visualization system 300 is similar to those described with respect to Figures 2A and 2B above. However, in contrast to the visualization systems 200 and 201 of Figures 2A and 2B.
  • telescoping support 320 is attached to the distal end of elongated support 310 by a hinge 325. Hinge 325 is used to allow the telescoping support 320 to extend significantly farther than the telescoping support 221 of Figures 2A and 2B.
  • Hinge 325 allows telescoping support 320 to move along arrow 345 from a closed position, wherein the telescoping support 320 is recessed in the elongated support 310 within groove 315. to the open position shown in Figure 3 A.
  • the telescoping support 320 can have a fixed portion 365, that, when moved to the open position, permits the CCD camera 330 and light source 335 to be placed in an already extended position. Where further extension is desired, telescoping portion 355 can then be extended. In this manner, the CCD camera 330 and light source 335 can be extended great distances from the elongated support 310.
  • visualization system 300 also includes a handle 340 that is attached to the proximal end of the elongated support 310.
  • the handle 340 includes a number of controls 360 for controlling the operation ofthe CCD camera 330, the light source 335, and the extension and retraction of the telescoping portion 355 ofthe telescoping support 320.
  • Controls can also be provided, for example, to move fixed po ⁇ ion 365 from its closed position recessed within groove 315 to the open position, to take a series of pictures over a period of time or a still picture at a particular moment in time, for zooming in or out on a selected target, for rotating the CCD camera 330 and the light source 335 about the longitudinal axis ofthe telescoping support 320, and for adjusting the elevation ofthe CCD camera 330 and light source 335.
  • images observed by the CCD camera 330 of visualization system 300 can be relayed to a monitor and/or a storage device (not shown) via cable 350.
  • FIG 3B illustrates an aircraft visualization system 301 according to another embodiment ofthe present invention.
  • the aircraft visualization system 301 is similar to that described in Figure 2B, in that the visualization system 301 dispenses with a local display on the hand held po ⁇ ion ofthe visualization system 301.
  • the visualization system 301 includes a computer control module 371 that is coupled via cable 350 to the hand-held portion ofthe system and can be used for storing and viewing pictures of an object.
  • the visualization system 301 is also similar to the embodiment described with respect to Figure 3 A, in that the telescoping support 320 is attached to the distal end of elongated support 310 by a hinge 325.
  • Hinge 325 again allows telescoping support 320 to move along arrow 345 from a closed position, wherein the telescoping support 320 is recessed in the elongated support 310 within groove 315, to the open position shown.
  • telescoping support 320 does not have a fixed po ⁇ ion 365. This permits the CCD camera 330 to
  • RECTIFIED SHEET (RULE 91) incrementally move from a position adjacent to the elongated support 310 to its maximum length.
  • the visualization system 301 may include a charge coupled device camera 330 and light source 335 that are attached to the telescoping support 320, and controls 360 to move the telescoping support 320 from its ciosed position recessed within groove 315 to the open position, to take a series of pictures over a period of time or a still picture at a particular moment in time, for zooming in or out on a selected target, for rotating the CCD camera 330 and the light source 335 about the longitudinal axis ofthe telescoping support 320, and for adjusting the elevation of the CCD camera 330 and light source 335.
  • Figure 4 is an enlarged fragmentary perspective view of a telescoping support and camera assembly that may be used with any of the embodiments of Figures 2A, 2B, 3 A. and 3B.
  • the camera assembly 400 includes a CCD camera 430 including a CCD imaging device 432 and a lens 431.
  • the CCD imaging device 432 and the lens 431 may be formed as a unitary structure such that no focusing ofthe lens 431 relative to the CCD imaging device 432 is necessary.
  • the lens 431 may include a constant focus lens assembly such as that described in co-pending U.S.
  • Patent Application Serial Number 09/126,368 (hereafter the '368 application), filed July 30, 1998, and entitled IMAGING DEVICE, in which the applicant is a named inventor.
  • the '368 application describes a lens assembly that includes a distal lens, a doublet lens, and a proximal lens that are bonded together and permit high resolution images to be taken of any object that is more than approximately one inch away from the lens assembly without requiring the use of focusing or lens positioning equipment. While the lens described in the * 368 patent is particularly advantageous in view of its constant focus properties, it should be appreciated that the present invention is not limited to using this lens assembly, as numerous other lenses can alternatively be employed.
  • the camera assembly 400 may also include one or a plurality of light sources 435 that are mounted adjacent to the CCD camera 430.
  • two light sources 435 are disposed at opposing sides of the CCD camera 430, although more or fewer light sources 435 may alternatively be used.
  • the light sources 435 include miniature incandescent bulbs that are capable of providing illumination that is far brighter and more diffuse than a conventional fiber optic light source. It should also be
  • the present invention is not limited to employing light sources adjacent the camera assembly 400. as a fiber optic light source can alternatively be employed.
  • the camera assembly 400 is disposed within a gimbled camera housing 450 that is mounted to a top ring 421 of the telescoping support 420 for rotation about a shaft 422.
  • the top ring 421 of the telescoping support 420 is capable of rotating anywhere between zero and 360° relative to the longitudinal axis of the telescoping support 420.
  • the gimbled camera housing 450 is capable of rotating in elevation about the shaft 422 from approximately 20° below horizontal to over 90° above horizontal. It should be appreciated that because the gimbled camera housing 450 is entirely recessed within the top ring 421 of the telescoping support 420. the field of view of the camera assembly 400 can be elevated, depressed and/or rotated without requiring any additional space other than that required to receive the top-most ring of the extendable support. This is in contrast to rigid and flexible borescopes in which movement of the head of the borescope from one position to another typically requires additional space.
  • FIGS 5-9 illustrate an aircraft visualization system according to yet another embodiment of the present invention.
  • the visualization system illustrated in Figures 5-9 is configured to extend and retract a camera assembly significant distances along a longitudinal axis of a telescoping support.
  • the camera assembly is capable of changing its position both rotationally and elevationally.
  • the visualization system 500 includes a multi-positional camera module 510 and a telescoping support 520.
  • the multi-positional camera module 510 can be easily connected and separated from the telescoping support 520.
  • a number of different telescoping supports 520 may be provided, each having a different length when fully extended. In one embodiment ofthe present invention, four different sizes of telescoping supports are provided, one with an extendable length of approximately 2 feet, another with an extended length of approximately 4 feet another with an extended length of approximately 6 feet, and another with an extended length of approximately 8 feet
  • the multi-positional camera module 510 may be easily removed from one telescoping support 520 and attached to another, a single multi- positional camera module 510 can be used to perform a variety of tasks. Furthermore, should either a telescoping support 520 or the multi-positional camera module 510 be dropped or otherwise damaged during use, a new multi-positional camera module 510 or support 520 may be provided. It should be appreciated that in a conventional borescope, should any portion ofthe borescope be damaged during use, it is typically required that the entire instrument be replaced as a whole.
  • the multi-positional camera module 510 includes a camera assembly 600 having a CCD camera 630.
  • the CCD camera includes a CCD imaging device 632 and a lens 631.
  • the CCD imaging device 632 and the lens 631 optionally may be formed as a unitary structure in a manner similar to that described in the '368 application, such that no focusing ofthe lens 631 relative to the CCD imaging device 632 is necessary.
  • the camera assembly 600 also includes a plurality of light sources 635 that are mounted adjacent to the CCD camera 630.
  • two light sources 635 are disposed at opposing sides ofthe CCD camera 630, although more or fewer light sources 635 may alternatively be used.
  • the light sources 635 may include miniature incandescent bulbs, although other sources of light can alternatively be employed.
  • Camera assembly 600 is disposed within a gimbled camera housing 650 that is mounted in a nose 640 of an upper po ⁇ ion 680 of the multi-positional camera module 510. It should be appreciated that the illustrated placement ofthe camera assembly 600 within the nose 640 protects the camera assembly 600 from contact with other objects and from potential damage during inse ⁇ ion of the multi -positional camera module 510 or extension thereof.
  • the gimbled camera housing 650 is mounted for rotation about a shaft 622 and is capable of rotating in elevation about the shaft 622 from approximately 60° below horizontal to over 90 ° above horizontal.
  • the upper po ⁇ ion 680 of the multi-positional camera module 510 is capable of rotating anywhere between zero and 360° relative to a lower portion 690 of the multi-positional camera module 510. It should be appreciated that because the gimbled camera housing 650 is entirely recessed within the nose 640 of upper portion 680, the field of view ofthe camera assembly 600 can be elevated, depressed and/or rotated without requiring any additional space. It should be appreciated that the ranges of motion discussed above are provided mereiy for illustrative purposes, as numerous other arrangements arc possible. Image signals transmitted from the camera assembly 600 are conveyed to other portions of the visualization system 500 via a flexible cable or flex circuit 695. The flex circuit 695 also provides power to the light sources 635.
  • the lower portion 690 ofthe multi-positional camera module 510 includes a ring 685 that is threaded on the inside and knurled on the outside and is used for securely mounting the multi-positional camera module onto the telescoping support 520.
  • the telescoping support 520 includes a threaded portion (not shown) that is adapted to mate with the ring 685 and securely attach the multi-positional camera module thereto.
  • Signals to alter the position ofthe upper portion 680 ofthe module with respect to the lower portion 690 ofthe module, to alter the elevation ofthe camera assembly 600, to control the light sources 635, and to electronically transmit image data from the camera assembly 600 to a monitor and/or storage device (not shown) are provided via a card edge connector 698.
  • Tne card edge connector 698 mates with a receptacle (not shown) in the telescoping support 520 to provide these signals to a control unit or to a monitor and/or storage system.
  • Figures 7A and 7B illustrate different cross-sectional views of some of the internal aspects ofthe multi-positional camera module 510. As shown in Figure 7 A, a rotation motor 710 is mechanically coupled to a bearing surface 712 on the upper portion 680 of the multi- positional camera module 510 for rotation ofthe upper po ⁇ ion 680 relative to the lower portion 690.
  • An elevation motor 720 is disposed above the bearing surface 712 and engages an elevation shaft 715 that is coupled to the gimbled camera housing 650 for altering the elevation ofthe gimbled camera housing 650. and thus the camera assembly 600 about the shaft 622.
  • a printed circuit board 730 provides electronic circuitry for amplifying and
  • the printed circuit board 730 is electrically coupled to the flexible circuit 695 and the card edge connector 698. Tne printed circuit board 730 also transmits power and control signals to the motors 710, 720, and to the light sources 635. Details of a multi-positional camera module that may be used in the visualization system are described further below with respect to Figures 10-21. Although the particular implementation ofthe camera module of Figures 10-21 provides a number of advantages, it should be appreciated that the present invention is not limited to this implementation, as numerous others are possible.
  • Figure 8 is an exposed cross-sectional view ofthe aircraft visualization system 500 of Figure 5.
  • the aircraft visualization system includes a multi-positional camera module 510 and a telescoping support 520.
  • two bearings 815 and 820 are disposed on opposite sides of a flat tape 817 that is attached to a base 835 of each of a plurality of rings 836.
  • a motor 810 engages bearing 815 causing bearings 815 and 820 to rotate in one of two opposing directions.
  • bearing 815 rotates counterclockwise (and bearing 820 rotates clockwise)
  • flat tape 817 is pushed upwardly in
  • Figure 9 illustrates aircraft visualization system of Figure 5 in a fully extended position.
  • Controls 960 for extending and retracting the telescoping support, for rotating the camera relative to the longitudinal axis ofthe telescoping support and for changing the elevation ofthe camera assembly 600 are provided at the base 930 ofthe system. Images transmitted by the CCD camera are provided to a monitor and display (not shown) via a cable 950
  • Figure 10 is a functional block diagram of an optical imaging system that is suitable for use with the embodiments ofthe present invention discussed above.
  • the optical imaging system 1000 includes a camera head 1070 that is coupled to a camera
  • Camera head 1070 includes a lens assembly 1010 and an imaging device 1020. Light from a target enters lens assembly 1010 and is focused on the imaging device 1020.
  • the imaging device is a charge coupled device (CCD).
  • CCD charge coupled device
  • the imaging device 1020 can alternatively be of another type, such as a microbolometer array (e.g.. an infra-red detection array) that is capable of perceiving objects at very low levels of light, as the present invention is not limited to the use of a CCD as the imaging device.
  • Imaging device 1020 includes a plurality of pixel elements (e.g.. photo diodes) that convert light energy focused by the lens assembly 1010 into a plurality of electrical signals.
  • the plurality of electrical signals from the imaging device 1020 are provided to an amplifier 1030 that is coupled to the imaging device 1020 by a connection 1090.
  • Amplifier 1030 amplifies each ofthe plurality of electrical signals from the imaging device 1020 and provides the amplified electrical signals to a camera control unit (CCU) 1040 that forms an image based on the plurality of amplified electrical signals.
  • CCU camera control unit
  • CCU 1040 can be a microprocessor-based system that may include some memory (not shown) for temporarily storing an image prior to providing the image to a display 1050 and/or a storage (recording) device 1060. Alternatively, the CCU 1040 can provide the image directly to the display 1050 or storage device 1060. As shown in Figure 10. the display 1050 can be coupled to the storage device 1060 so that a previously recorded image (or images) can be displayed on the display 1050.
  • the imaging device 1020 is coupled to the amplifier 1030 by a flexible connection 1090, such as a flexible cable or a flexible circuit.
  • a flexible connection 1090 such as a flexible cable or a flexible circuit.
  • flexible connection 1090 also permits the lens assembly 1010 and the imaging device 1020 to be located within the camera head 1070 of the imaging system 1000. with the amplifier 1030 and the CCU 1040 being disposed in a physically separate camera body 1080.
  • the display 1050 and storage device 1060 can be disposed in the camera body 1080 of the imaging system 1000 along with amplifier 1030 and CCU 1040. or they may alternatively be disposed in a location separate therefrom.
  • the physical separation of the lens assembly 1010 and the imaging device 1020 from other portions of the imaging system 1000 provides a number of advantages over conventional imaging systems in which all of these devices (i.e.. the lens assembly 1010. the imaging device 1020. and the amplifier 1030) are located within the same housing.
  • separation ofthe amplifier 1030 from the camera head permits camera head 1070 to be significantly smaller and lighter in weight than that of conventional imaging systems.
  • this separation permits the optical elements (e.g.. the lens and CCD) within the camera head to be larger, thereby increasing image resolution.
  • flexible connection 1090 and the small scale of the camera head 1070 permit the camera head to be pivoted and/or rotated in a confined space for viewing in a number of different directions.
  • the optical imaging system described in Figure 10 has been employed in a design for a surgical/diagnostic imaging device for use in interabdominal. interthoracic. and other surgical and diagnostic procedures.
  • a surgical/diagnostic imaging device examples of such a surgical/diagnostic imaging device are described in U.S. Patent No. 5.762,603 (hereinafter, the '603 patent) which is entitled “Endoscope Having Elevation and Azimuth Control of Camera Assembly' " and shares a common inventor with the present application.
  • the technology employed in implementing the surgical/diagnostic imaging devices of the '603 patent, which are described below with reference to Figures 1 1 -21. can also be used in the embodiments of the present invention described above.
  • Figures 1 1-13 show an imaging device 1.
  • the device 1 comprises an upper housing 3, a camera housing 5. and left and right camera housing supports 7, 9.
  • the device 1 is inserted into a sterile sheath 1 1.
  • the “camera” are then inserted through an incision into the patient ' s body (not shown).
  • the camera is inserted so as to place the camera housing 5 in a position from which it can be pointed at the surgical site or the area to be diagnosed.
  • the incision is sealed around the camera with a purse string stitch, thereby preventing leakage of the C0 2 gas which is used to distend the patient's abdomen or chest during surgery or diagnosis.
  • the sheath 1 1 may be constructed of medical-grade plastic provided in a sterilized condition, and may be intended to be disposed of after use. Alternately, the sheath 1 1 can be constructed of heat-resistant materials to allow it to be sterilized using an autoclave, then reused. It will be appreciated that the sterile sheath 1 1 eliminates the need to sterilize the camera. For non-medical applications, it may be possible to eliminate the use of the sheath. However, for numerous non-medical applications, it may still be desired to employ the sheath as it protects the other components of the system.
  • the camera housing 5 contains a CCD (not shown) and a zoom lens assembly (not shown).
  • a plurality of high intensity lights 13 are mounted within a light housing 15 which extends about the outer circumference of the camera housing 5.
  • the lights 13 are aligned with the focal axis 17 of the CCD. and they illuminate the area at which the camera housing 5. and hence, the CCD are pointed.
  • the left and right camera housing supports 7. 9 engage complimentary locking keys 19. 21 within a sheath cap 23.
  • the camera housing 5 is locked into a position in which the CCD's focal axis 17 is aligned perpendicular to an optically-clear window 25.
  • the locking keys 19, 21 cause the sheath cap 13 to rotate about the longitudinal axis 27 ofthe camera when the camera housing supports 7, 9 are rotated about that axis.
  • the image system of the device 1 can be implemented using the techniques described above in connection with the imaging system 1000 of Figure 10.
  • the camera housing 5 can include only the CCD and the lens assembly, with the amplifier 1030.
  • CCU 1040 and other components of the imaging system being disposed outside the body of the device 1.
  • a camera cable 29 extends between the camera housing 5 and the upper housing 3.
  • the camera cable 29 contains conductors which carry the CCD ' s signals to the upper housing 3 and which supply electrical power to the CCD and lights 13.
  • An imaging device cable 31 is provided to carry control signals and supply electrical power to the device 1. and to carry the CCD ' s signals to the externally-located processing, display and storage devices (not shown) ofthe imaging system.
  • an elevation motor 51 drives an elevation shaft 53 by means of gears 55. 57.
  • the elevation shaft 53 extends downwardly through the hollow left camera support 7.
  • a ring and pinion gear arrangement 59 at the lower end of the elevation shaft 53 transfers the rotary motion of the elevation shaft 53 to the camera housing 15, thereby causing the camera housing 15 to elevate or depress, depending on the direction of rotation of the elevation motor 51.
  • the camera housing 15 can be elevated 70 ° above and depressed 90 ° below a plane perpendicular to the longitudinal axis 27 of the camera and passing through intersection of the longitudinal axis 27 and the focal axis 17 ofthe camera.
  • the elevation motor 51 is mounted on a plate 63.
  • the plate 63 is rotatably mounted within the upper housing 3 on a bearing 65.
  • An azimuth motor 67 is also mounted on the plate 63.
  • the azimuth motor 67 drives an azimuth gear 69.
  • the azimuth gear 69 engages a housing gear 71 which is attached to the inner surface ofthe upper housing 3.
  • the plate 63 rotates within the upper housing 3.
  • the plate 63 rotates plus or minus 180 ° to minimize the amount the camera cable 21 is twisted.
  • Full 360 degree rotation can easily be achieved by using conventional slip rings.
  • a zoom/focus motor 72 drives gears 73, 75, which rotate a zoom/focus shaft 77.
  • the zoom/focus shaft extends downwardly through the right camera support 9.
  • a ring and pinion arrangement 79 transfers the rotary motion of the focus shaft 77 to a zoom lens mechanism (not shown) within the camera housing 5.
  • the imaging device 1 is connected to a control console 101 by means of the imaging device cable 31. Signals from the CCD of the imaging device 1 are amplified by circuits in the control console 101 and directed to a display device 103.
  • the display device 103 is a conventional television set.
  • a foot pedal control assembly 105 allows the operator (not shown) to control the imaging device 1.
  • the foot pedal control assembly 105 includes four controls (not shown): (1 ) camera housing left and right; (2) camera housing up and down; (3) zoom in and out; and (4) light intensity up and down. Signals from the foot pedal control assembly 105 are routed to the control console 101. Circuits (not shown) in the control console 103 convert the control assembly signals into signals which are suitable to control the imaging device 1. then route the converted signals to the imaging device 1. It should be appreciated that the control assembly 105 is not limited to implementation as a foot pedal control assembly, as numerous other control assemblies (examples of which are described above) can be employed.
  • a computer 107 is interposed between the control console 101 and the display device 103.
  • a plurality of computer programs contained in the computer 107 allow personnel to manipulate and/or store the signals from the imaging device 1.
  • Figures 19-21 illustrate a second imaging device which employs technology that can be employed to implement the embodiments of the present invention described above. Referring first to Figure 19. the imaging device comprises two major assemblies: a camera assembly 150 and a disposable sheath assembly 152.
  • a rotary stepper motor 154 is rigidly mounted in an upper housing 156.
  • planetary gear assembly 162 are press fitted in a linear stepper motor housing 164.
  • the proximal end of the planetary gear assembly 162 is attached to the upper housing 156 by screws 168.
  • Three planetary gears 170 are rotatably mounted on pins 172 within the planetary gear assembly 162.
  • the rotary stepper motor 154 drives the planetary gears 170 through a sun gear 174.
  • a camera housing 180 is pivotally mounted between pair of arms 182 (only one of which is shown in Figure 10) that are integral with and extend from the distal end of the camera support tube 178.
  • the linear stepper motor 158 acts through a pushrod 186 and a fork 188 to control the elevation of the camera housing 180.
  • the sheath assembly 152 comprises a sheath 190, a sheath housing 192. and a ring gear 194.
  • the distal portion of the sheath 190 is optically clear.
  • the proximal end of the sheath 190 is adhesively attached within the distal end of the sheath housing 192.
  • the ring gear 194 is adhesively attached within the proximal end of the sheath housing 192.
  • the camera assembly 150 Prior to use. the camera assembly 150 is inserted into the sheath assembly 152, and the planet gears 170 engage the ring gear. As a result, when the rotary stepper motor 154 is actuated, the camera assembly 150 rotates in relation to the longitudinal axis 202 of the sheath assembly. As is best shown in Figures 20 and 21.
  • a CCD assembly 204 and a lens 206 are mounted within a camera bore 208 in the camera housing 180.
  • a pair of high intensity lights 210 are mounted in bores that are coaxial with the camera bore 208.
  • a multi-conductor flexcable 212 provides the necessary connections for the CCD assembly 204. for the camera housing lights 210, and for three high intensity lights 214, that are disposed in bores in the pushrod 186.
  • the flexcable 212 extends from the camera housing 180 to the upper housing 156. In the upper housing 156. the flexcable 212 is combined with power and control wires (not shown) for the rotary stepper motor 154 and the linear stepper motor 158 to form the camera assembly cable 218.
  • the camera assembly cable 218 passes through an orifice 220 in the upper housing 156. As with the surgical/diagnostic device of Figures 1 1-18, the camera assembly cable 218 connects the camera assembly 150 to external display and control devices (not shown). It should be appreciated that each of the embodiments ofthe present invention described herein is not limited to use solely in the aviation field, but may be used to image any inaccessible target. Moreover, the present invention is not solely limited to examining the engines of aircraft, as the present invention may be used to examine other portions of an aircraft, such as the hydraulic systems controlling flaps on the wings, the rudder control mechanisms, etc.
  • each ofthe above-described embodiments ofthe present invention permits digital images of a region or regions of an aircraft to be generated and saved on conventional digital storage media.
  • images generated by embodiments ofthe invention may be viewed in a location that is remote from the location where the inspection was performed, and may be transmitted electronically over a conventional communication network (e.g., the Internet).
  • a conventional communication network e.g., the Internet
  • embodiments ofthe present invention are not limited to the use of an all digital system.
  • a coupling device may be provided for use with conventional borescopes and other types of imaging equipment.

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Abstract

An aircraft visualization system (200) that is capable of visualizing relatively inaccessible portions of an aircraft includes a support (221) having a proximal end and a distal end, and a camera (230) that is mounted to the distal end of the support (221). The camera (230) is movably mounted to the distal end of the support (221) for movement, relative to the distal end of the support (221). In one embodiment the support (221) is extendable and is disposed at a distal end of an elongated support (211). The extendable support (221) can be extended in a direction other than a longitudinal axis of the elongated support (211), such that the system (200) can be inserted into a confined space and the camera (230) then extended in a direction other than the direction of insertion. The camera (230) is movable mounted to the distal end of the extendable support (221), and can be rotated and pivoted . The visualization system is capable of generating and storing digital images, and portions of the visualization system may be used with conventional optical imaging equipment to realize the many benifits of digital imagery.

Description

INSPECTION DEVICE FOR AIRCRAFT
Field of the Invention The present invention is directed to an imaging system, and more particularly, to an imaging system for visualizing relatively inaccessible regions of an aircraft or other inaccessible areas.
Description of the Related Art Aircraft arc routinely visually inspected to ensure their safe operation. However. many regions of an aircraft are relatively inaccessible and direct visual inspection is difficult if not impossible. These regions include, but are not limited to. the aircraft's engines, the aircraft" s structural airframe. the aircraft's rudder, stabilizers, ilaps. and other steering controls, the aircraft's fuel cells, the aircraft's instrumentation panels, cockpit wiring harnesses, etc. For example, because most aircraft engines are confined within an engine housing with only the inlet and exhaust portions of the engine being externally visible, specialized visual inspection equipment is necessary to view the interior regions of the aircraft's engines. For this purpose, portions of the aircraft engine housing and portions of the aircraft engine typically include a number of small openings by which specialized viewing instruments can be inserted to inspect the interior of the aircraft's engine. To date, most of the specialized visual inspection equipment that is used to inspect aircraft has been taken directly from the medical industry with little or no modification. In particular, where laparoscopes. colonoscopes. arthroscopes. and other forms of endoscopes were originally designed for use in performing minimally invasive surgical and diagnostic procedures, these instruments are now being used in a number of other applications. including the visual inspection of aircraft. When used in non-medical applications, these visual inspection instruments are commonly called borescopes.
Borescopes used in the visual inspection of aircraft generally fit into two categories: rigid borescopes and flexible borescopes. Rigid borescopes generally include a rigid, typically cylindrical, hollow tube or borescope body with an objective lens disposed at a distal poπion of the body and an eyepiece disposed at a proximal end o the body. The objective lens may be disposed in line with a longitudinal axis of the body for viewing objects that are straight ahead, or disposed at an angle to the longitudinal axis of the body for viewing objects that are disposed at a fixed angle obliquely ahead.
Flexible borescopes generally include a flexible, typically cylindrical, hollow tube or borescope body having a distal end and a proximal end. with an objective lens disposed at the distal end and a camera or eyepiece disposed at the proximal end. Enclosed within the body is one or a number of optical fibers that extend from the distal end to the proximal end of the body and transmit images from the objective lens to the camera or eyepiece. Other optical fibers may be enclosed within the body to illuminate the object being viewed. Some flexible borescopes permit an analog image of an object that is transmitted to the camera or the eyepiece to be displayed on an external monitor.
Current generation flexible borescopes are either straight, two-way articulating, or four-way articulating. Straight flexible borescopes are simply inserted into an opening and pushed distally toward the intended object, with the contours of the opening in which the borescope body is inserted forcing the body of the borescope to bend in the appropriate manner. Two-way and four way flexible borescopes typically include a mechanism
(frequently a wire cable, a number of wire cables, or other mechanical control) that permits the distal end (termed the "head") of the body to be moved in two or four, typically orthogonal, directions relative to the adjacent portion of the body. Movement is controlled remotely from the distal end of the body via knobs, or pulleys. Flexible borescopes make it possible to see around corners inside of the original insertion point and can snake through a set of pipes or travel down one's digestive tract (a frequent medical application).
A problem with both rigid and flexible borescopes is that their design, which was originally intended for medical purposes, is ill-suited for use in many non-medical applications, such as the visual inspection of aircraft. In particular, rigid borescopes generally require that the operator be positioned so that his/her eye is aligned with the eyepiece at the end of the borescope. In the area of aircraft inspection, this positioning of the operator can be quite difficult to achieve. Furthermore, even with an angled borescope that is capable of viewing objects that are not aligned along the longitudinal axis of the body of the borescope. when a different direction of view is desired, the repositioning of the distal end of the scope results in a repositioning of the proximal end of the scope. It should be appreciated that within the tight confines of an aircraft engine, an instrument panel, etc.. there may not be - sufficient room to reposition the distal end of the scope. In addition, most rigid borescopes require the use an external light source to illuminate the object being viewed.
As noted above, some flexible borescopes permit an image of an object to be displayed on an external monitor, and thus do not require that an operator be physically adjacent the distal end of the scope. Further, because some flexible borescopes permit their distal end to be remotely moved relative to an adjacent portion ofthe scope, certain movements of the distal end may be made without repositioning the proximal end. Nonetheless, for movement in a direction other than those predefined directions, the proximal end of the scope must be moved to reposition the distal end. Moreover, even where the direction of movement is such that it may be remotely performed without repositioning the proximal end of the scope, such movement may not be possible due to the shape and/or dimensions of what may be a confined space in which the distal end is placed. Furthermore, it should be appreciated that the very flexibility of flexible borescopes limits their usefulness in aircraft inspection as the body of the scope must frequently traverse large distances to reach the intended target. Flexible medical laparoscopes are typically incapable of spanning large distances without sagging, absent some additional support structure. Hence when such flexible borescopes are used for aircraft inspection, they are frequently inserted into a pipe for support.
Because the use of technology developed for the medical industry is ill-suited for the inspection of aircraft, its use. when possible, often results in the false detection of problems, when no problem actually exists. To ensure the safety of passengers and the public, whenever even a suspected problem is detected, the aircraft is typically removed from service and then dismantled to determine whether a problem actually exists. In the event that there is no actual problem with the aircraft, then a great deal of time and money has been wasted. For example, with respect to the visual inspection of aircraft engines, it is estimated that five out of every eight aircraft engines are pulled out of service unnecessarily. It should further be appreciated that each time an aircraft is removed from service and a portion of the aircraft is dismantled to determine if an actual problem exits, there is a possibility for the re-assembly to be performed improperly, thereby creating a problem where none existed before. Alternatively, where the use of a conventional medical technology results in not detecting a problem that actually does exist, the effects of such an error can be catastrophic. Summary of the Invention According to an aspect of the present invention, an aircraft visualization system is provided that is capable of visualizing relatively inaccessible regions of an aircraft, such as the aircraft's engine, the aircraft's rudder, stabilizers, flaps, and other steering controls, the aircraft's fuel cells, the aircraft's cockpit, etc. It should be appreciated that although embodiments of the present invention are described with reference to an airplane, the present invention is not so limited, as embodiments ofthe present invention may be used to inspect helicopters, gliders, and other fixed-wing and non-fixed wing aircraft. Moreover, use ofthe present invention is not limited to the aviation or transportation fields, as embodiments ofthe present invention may be used to inspect any object that can be difficult to access and view directly. Thus, exemplary uses for embodiments of the present invention include inspecting underground storage tanks, inspecting turbines used in electrical generators, military tanks or transports or other land, water, or airborne vehicles, etc.
According to one embodiment of the present invention, aircraft inspection apparatus is provided. The aircraft inspection apparatus includes a support having a proximal end and a distal end and a camera that is mounted to the distal end of the support. The camera is movably mounted to the distal end ofthe support for movement relative to the distal end of the support.
According to another embodiment of the present invention, a method of inspecting an aircraft is provided for a camera that is mounted at a first position to a distal end of an elongated support. The method includes acts of inserting the camera into a portion of the aircraft and moving the camera to a second position that is spaced apart from the first position without changing a position of a proximal end of the elongated support.
According to further embodiment ofthe present invention, another method of inspecting an aircraft is provided. The method includes acts of inserting a camera that is mounted to a distal end of an elongated support into a first portion of the aircraft, the camera being mounted to the distal end ofthe elongated support at a first position, and telescoping the camera to a second position that is spaced apart from the first position.
According to another embodiment of the present invention, a method of inspecting an aircraft is provided that includes acts of inserting a camera that is mounted to a distal end of a support into a portion of the aircraft, the distal end of the support being in a first position inside the poπion of he aircraft, and remotely telescoping the support to a second position inside the poπion of the aircraft.
According to yet another embodiment ofthe present invention, a method of inspecting an aircraft is provided that includes acts of inseπing a camera that is mounted to a distal end of a suppoπ into a poπion of the aircraft and illuminating the portion of the aircraft with a light source that is disposed adjacent to the camera.
According to another embodiment ofthe present invention a further method of inspecting an aircraft is provided. The method includes acts of inserting a camera that is mounted to a distal end of a suppoπ into a poπion ofthe aircraft, generating a digital image of the poπion ofthe aircraft, transmitting the digital image ofthe portion ofthe aircraft to a storage device, and storing the digital image on the storage device.
According to another embodiment of he present invention, a method of inspecting an aircraft is provided that includes acts of inserting a camera that is mounted to a distal end of a suppoπ into a portion ofthe aircraft and telescoping the camera in a direction other than along a longitudinal axis of the suppoπ.
According to a further embodiment ofthe present invention, a method of inspecting an aircraft with a conventional borescope is provided. The method includes acts of inseπing the borescope into a poπion of the aircraft, the borescope having an eyepiece, coupling a digital camera to the eyepiece ofthe borescope. and generating a digital image of the poπion cf the aircraft.
Brief Description of the Drawings Illustrative, non-limiting embodiments ofthe present invention are described by way of example with reference to the accompanying drawings, in which: Figure 1A is a frontal view of a conventional aircraf jet engine;
Figure IB is a schematic cross-sectional view of a conventional aircraft jet engine; Figure IC is a fragmentary enlarged perspective view of a porrion of the jet engine of Figure IB;
Figure 2A is a perspective view of an aircraft visualization system according to one embodiment ofthe present invention;
Figure 2B is a perspective view of an aircraft visualization system according to another embodiment ofthe present invention;
T RULE 91 Figure 3 A is a perspective view of an aircraft visualization svstεm according to another embodiment ofthe present invention:
Figure 3B is a perspective view of an aircraft visuaiizauon system according to another embodiment of the present invention; Figure 4 is an enlarged fragmentary perspective view of a telescoping suppoπ and camera assembly that may be used with any ofthe embodiments of Figures 2A. 2B. 3 A. and 3B,
Figure 5 is a front elevauonai view of an aircraft visuaiizauon system according to another embodiment ofthe present invention;
Figure 6A is a perspecuve view of outwardh visible aspects of a multi-positional camera module that may be used with the visuaiizauon system of Figure 5;
Figure 6B is an alternative perspective view of the muiti-Dosmonal camera moαule of Figure 6A;
Figure 7A is a cross-secuonal view of some of the internal aspects of a muin-positional camera module of Figures 6 A and 6B; Figure 7B is an alternative cross-secuonal view ofthe internal aspect of he multi- positional camera module of Figure 7A;
Figure 8 is a cross-sectional view of internal aspects ofthe aircraft visuaiizauon system of Figure 5;
Figure 9 is a perspective view ofthe aircraft visuaiizauon system of Figure 5 in a fully extended position;
Figure 10 is a funcuonal block diagram of an opucai imaging system accordmg to one aspect ofthe present invention;
Figure 11 is an exploded front view of an imaging device in accordance with one embodiment ofthe present invention; Figure 12 is a partially cutaway side elevational view of the imaging device of Figure 1 1;
Figure 13 is a cutaway top view taken through plane 1 -13 in Figure 1 1 , of a sheath cap in the imaging device of Figure 11;
Figure 14 is an enlarged cutaway side view of the upper housing and the lower poπion of the imaging device of Figure 11; Figure 15 is a cutaway top view of he upper housing of he imaging device of Figure 11 taken through plane 15-15 in Figure 14;
TIFIED SHEET RULE 91) Figure 16 is a cutaway top view of the lower poπion of the imaging device of Figure 1 1 taken through piane 16-16 in Figure 14;
Figure 17 is a funcuonal block diagram of a system for controlling the imaging device of Figure 1 1 and for displaying the images transmitted by the imaging device;
Figure 18 is a functional block diagram of an alternate control and display system for the imaging device of Figure 1 1;
Figure 19 is an exploded cutaway side view of an alternate embodiment of a surgical/diagnostic imaging device in accordance with the present invention;
Figure 20 is a front view of the camera housing ofthe image device of Figure 19; and Figure 21 is a cutaway side view of the camera housing taken through plane 21-21 in Figure 20.
Detailed Description Embodiments of the present invention will be understood more completely through the following detailed description which should be read in conjunction with the attached drawings in which similar reference numbers indicate similar structures.
While the embodiments of the present invention are described below in connection with use in aircraft inspection, it should be appreciated that the described systems can be used in numerous other applications for viewing in confined or otherwise inaccessible areas. Thus, the embodiments ofthe present invention described are not limited to use in an aircraft visualization environment.
Figure 1A is a frontal view of a conventional aircraft jet engine 100 looking toward the turbine blades 140 of the jet engine 100. As shown in Figure 1A, the engine 100 is disposed within an engine housing 110. The engine 100 can be accessed via a small opening 120 in the engine housing 1 10. Interior regions ofthe engine 100 can be examined via a small opening 130 in the engine 100 that is aligned with the opening 120 in the engine housing 110.
Figure IB is a cross-sectional view ofthe aircraft jet engine 100 shown in Figure 1A. As shown in Figure IB. the engine 100 includes a plurality of small openings or viewing holes 130 through which various interior regions and paπs ofthe engine 100 may be inspected. In Figure IB, these opemngs 130 are labeled with reference indicators A-H. Some of these openings (e.g., openings A and F) can only be accessed using a flexible borescope while others can be accessed using a rigid borescope (e.g., openings B - E, G, and H). Furthermore, many of the interior portions of the engine 100 can only be viewed from a
TIFIED SHEET RULE 91) direction that is perpendicular to the direction in which the borescope is iπseπed in the engine 100. It should be appreciated that depending on the size of the aircraft engine 100 (e.g., an engine of a Boeing 757 or an engine of a Lear jet), the distance between the opening 130 in the engine through which the borescope is inseπed and the intended object to be view can be quite large, on the order of several feet.
Figure IC is a fragmentary enlarged perspective view of various internal components of the aircraft jet engine of Figure IB showing some of the internal components that are conventionally subject to periodic visual inspection.
Figure 2A illustrates an aircraft visualization system according to one embodiment ofthe present invention. The aircraft visualization system 200 includes an imaging component attached to a telescoping suppoπ 221.
In one embodiment, the imaging component is a charged coupled device (CCD), but it should be appreciated that the invention is not limited in this respect as other imaging devices can be employed. In the embodiment shown, the aircraft visualization system 200 also includes a light 235 attached to the telescoping suppoπ 221, to illuminate the area viewed by the imaging device. In one embodiment ofthe invention, the light is a light source (e.g., a light bulb) that generates light. However, it should be appreciated that the present invention is not limited in this respect and the light can alternatively be a fiber optic bundle that carries light, generated from an external light source, to the viewing area. However, the use of a light source mounted to the telescoping suppoπ 221 is advantageous, in that it can be cheaper than using a fiber optic system, and also enables the system to be used without a light source for a fiber optic bundle which can be rather large and inconvenient to transpoπ.
Telescoping suppoπ 221 is attached to a distal end of an elongated suppoπ 21 1, with the proximal end ofthe elongated support 211 being attached to a handle 240. In the embodiment shown in Figure 2A the telescoping support 221 is disposed at an angle that is perpendicular to the elongated support 211. This peimits the hand held poπion of the aircraft visualization system 200 to be inseπed into a small opening and then extended in a direction perpendicular to the direction of insertion. However, it should be appreciated that the present invention is not limited to a telescoping support 221 that is disposed perpendicular to a longitudinal axis ofthe elongated support 211 , as other orientations may be used.
The handle 240 includes a number of controls 260 that control the operation of the CCD camera 230, the light source 235, and the telescoping support 221. Images observed by
RECTIFIED SHEET (RULE 91) the CCD camera 230 are relayed to a monitor and/or a storage device (not shown) via cable 250. In one embodiment, the telescoping support 221 is capable of retracting into a position that is flush with the outer surface o the elongated support 21 1 to permit easy insertion through the openings 120. 130 in the engine housing 1 10 and the engine 100 (Figure 1). In another embodiment, the telescoping support 221 is capable of retracting into a position that extends beyond the outer surface ofthe elongated support 21 1. but is still capable of insertion through openings having a small diameter, for example four millimeters.
In operation, the distal end of the elongated support 21 1 is inserted through the opening 120 in the engine housing 1 10 and the opening 130 in the engine 100. Once inserted through these openings, controls 260 are used to extend the telescoping support 221, and thus, the CCD camera 230 and light source 235 to the desired position. In addition to providing the ability to extend and retract the telescoping support 221. controls 260 include individual controls for taking a still picture, for zooming in or out on a selected target, for rotating the CCD camera 230 and the light source 235 about the longitudinal axis ofthe telescoping support 221, and for adjusting the elevation ofthe CCD camera 230 and light source 235. Advantageously, the field of view ofthe camera 230 can be changed without changing the position ofthe distal end of the handle 240. and without requiring any additional space in which to perform such rotation. In one embodiment, the CCD camera 230 can be rotated from zero to 360 °. Controls 260 may include a rotary dial 262 that can be manipulated by an operator's thumb to extend or retract the telescoping support 221. a rocker switch or joystick 264 that can be used for rotating the CCD camera 230 and the light source 235 left or right about a longitudinal axis ofthe telescoping support 221 and for adjusting the elevation of the CCD camera 230 and the light source 235 upward or downward. The controls 260 may also include one or a number of other buttons 266 that may be used for taking a still picture at a particular moment in time or for taking a series of pictures over a period of time (i.e.. a moving picture), for zooming in or out on a selected target, or for turning on and off the light source 235. It should be appreciated that this explanation of potential use of controls 260 is merely provided for illustration, as numerous additional or alternative controls can be provided, and mechanisms other than a rotary dial or joy stick can be employed for implementing the controls 260. In the embodiment shown in Figure 2A. the visualization system 200 also includes a local display 270 mounted on the handle 240 that is used to provide the operator of the system with a continuous image of what is being viewed by the CCD camera. In this manner, an operator can remotely maneuver the CCD camera into a desired position and then take a still picture of the area of interest when desired. In one embodiment, one of the controls 260 may also be used to enter a menu-based control program that can be displayed on the local display 270. After entering the menu-based control program, others of the controls 260 can be used for navigating the menus shown on the local display 270. such as for adjusting picture quality (e.g., white balance, contrast, etc.) of the CCD camera 230. etc. As noted above, the visualization system 200 can include a monitor and/or storage device to view and store images observed by the CCD camera 230. For example images may be stored on any type of storage medium, including a hard drive, a CD. a floppy disc, a RAM card, etc. The visualization system 200 can also include a keyboard or other input device by which the operator can provide detailed information relating to the object being viewed. For example, the operator can identify the type of aircraft engine being inspected, the make, model number and registration number ofthe aircraft, the name ofthe operator, the date the inspection was performed, as well as other information that would be useful during such an inspection. The visualization system may also include another input device, such as a pointer or mouse, for highlighting a specific region of interest. For example, a particular region of the engine could be highlighted, or placed within a border to call attention to a particular detail. This feature may be used, for example, to place a watch on a particular region of the engine that may be prone to excessive wear. By comparing photographs of this particular region over time, it can be possible to detect problems before they result in actual failure. Moreover, it should be appreciated that photographs of a particular region of interest may be compared to photographs of the same region in failed engines or in known good engines by an expert system to detect signs of incipient failure. In addition, because the embodiment of Fig. 2A utilizes digital technology, photographs taken by the visualization system 200 may be easily sent to a remote location using conventional communication networks (e.g.. the Internet). Thus, rather than being dependent upon local experts to review inspection data, or having other experts transported to the inspection site, photographs may be sent electronically to those most knowledgeable with the system of interest. Although the use of digital technology provides a number of advantages, it should be appreciated that the invention is not limited to the use of digital technology.
Figure 2B illustrates an aircraft visualization system according to another embodiment of the present invention. The aircraft visualization system 201 is similar to the aircraft visualization system 200 of Figure 2A in most respects, with the same reference designators identifying similar structures. However, in the embodiment of Figure 2B. the visualization system 201 does not include a local display 270 that is mounted adjacent the handle 240. This reduces the size and weight ofthe hand-held portion ofthe visualization system 201, and permits its use within even more confined regions of the aircraft. To permit the operator to position the CCD camera 230, the visualization system 201 includes a battery operated computer control module 271 that includes a CPU. a monitor, and a storage device for displaying pictures of objects viewed by the CCD camera 230 and for storing those pictures on the storage device. The control module 271 is coupled to the hand held portion ofthe visualization system via cable 250. Advantageously, the storage device may include a removable RAM module (e.g., a PCMCIA RAM card) to reduce the size and weight ofthe control module 271. It should be appreciated that solid state types of storage devices such as RAM modules are less prone to damage from environmental conditions, changes in orientation, and impacts with other objects (such as from dropping the storage device) than many other forms of storage media. After use ofthe visualization system 201. the storage device can be removed from the control module 271 and pictures stored thereon may be transferred to another computer system. In one embodiment, the computer control module 271 is configured to attach to the belt of an operator to permit hands-free operation. It should be appreciated that the control module 271 need not be attached to the belt of an operator, as the control module 271 may be positioned wherever it is most convenient. Figure 3A illustrates an aircraft visualization system according to another embodiment of the present invention. The aircraft visualization system 300 is similar to those described with respect to Figures 2A and 2B above. However, in contrast to the visualization systems 200 and 201 of Figures 2A and 2B. telescoping support 320 is attached to the distal end of elongated support 310 by a hinge 325. Hinge 325 is used to allow the telescoping support 320 to extend significantly farther than the telescoping support 221 of Figures 2A and 2B. Hinge 325 allows telescoping support 320 to move along arrow 345 from a closed position, wherein the telescoping support 320 is recessed in the elongated support 310 within groove 315. to the open position shown in Figure 3 A. By using hinge 325, the telescoping support 320 can have a fixed portion 365, that, when moved to the open position, permits the CCD camera 330 and light source 335 to be placed in an already extended position. Where further extension is desired, telescoping portion 355 can then be extended. In this manner, the CCD camera 330 and light source 335 can be extended great distances from the elongated support 310.
As shown in Figure 3 A, visualization system 300 also includes a handle 340 that is attached to the proximal end of the elongated support 310. The handle 340 includes a number of controls 360 for controlling the operation ofthe CCD camera 330, the light source 335, and the extension and retraction of the telescoping portion 355 ofthe telescoping support 320. Controls can also be provided, for example, to move fixed poπion 365 from its closed position recessed within groove 315 to the open position, to take a series of pictures over a period of time or a still picture at a particular moment in time, for zooming in or out on a selected target, for rotating the CCD camera 330 and the light source 335 about the longitudinal axis ofthe telescoping support 320, and for adjusting the elevation ofthe CCD camera 330 and light source 335. As in the embodiment described with respect to Figure 2A, images observed by the CCD camera 330 of visualization system 300 can be relayed to a monitor and/or a storage device (not shown) via cable 350.
Figure 3B illustrates an aircraft visualization system 301 according to another embodiment ofthe present invention. The aircraft visualization system 301 is similar to that described in Figure 2B, in that the visualization system 301 dispenses with a local display on the hand held poπion ofthe visualization system 301. As in the embodiment described with respect to Figure 2B, the visualization system 301 includes a computer control module 371 that is coupled via cable 350 to the hand-held portion ofthe system and can be used for storing and viewing pictures of an object. The visualization system 301 is also similar to the embodiment described with respect to Figure 3 A, in that the telescoping support 320 is attached to the distal end of elongated support 310 by a hinge 325. Hinge 325 again allows telescoping support 320 to move along arrow 345 from a closed position, wherein the telescoping support 320 is recessed in the elongated support 310 within groove 315, to the open position shown. However, in contrast to the embodiment of Figure 3 A, telescoping support 320 does not have a fixed poπion 365. This permits the CCD camera 330 to
RECTIFIED SHEET (RULE 91) incrementally move from a position adjacent to the elongated support 310 to its maximum length.
In a manner similar to that of Figures 2A, 2B, and 3A, the visualization system 301 may include a charge coupled device camera 330 and light source 335 that are attached to the telescoping support 320, and controls 360 to move the telescoping support 320 from its ciosed position recessed within groove 315 to the open position, to take a series of pictures over a period of time or a still picture at a particular moment in time, for zooming in or out on a selected target, for rotating the CCD camera 330 and the light source 335 about the longitudinal axis ofthe telescoping support 320, and for adjusting the elevation of the CCD camera 330 and light source 335.
Figure 4 is an enlarged fragmentary perspective view of a telescoping support and camera assembly that may be used with any of the embodiments of Figures 2A, 2B, 3 A. and 3B. As shown in Figure 4, the camera assembly 400 includes a CCD camera 430 including a CCD imaging device 432 and a lens 431. Advantageously the CCD imaging device 432 and the lens 431 may be formed as a unitary structure such that no focusing ofthe lens 431 relative to the CCD imaging device 432 is necessary. In one embodiment, the lens 431 may include a constant focus lens assembly such as that described in co-pending U.S. Patent Application Serial Number 09/126,368 (hereafter the '368 application), filed July 30, 1998, and entitled IMAGING DEVICE, in which the applicant is a named inventor. The '368 application describes a lens assembly that includes a distal lens, a doublet lens, and a proximal lens that are bonded together and permit high resolution images to be taken of any object that is more than approximately one inch away from the lens assembly without requiring the use of focusing or lens positioning equipment. While the lens described in the *368 patent is particularly advantageous in view of its constant focus properties, it should be appreciated that the present invention is not limited to using this lens assembly, as numerous other lenses can alternatively be employed.
The camera assembly 400 may also include one or a plurality of light sources 435 that are mounted adjacent to the CCD camera 430. In the embodiment shown in Figure 4, two light sources 435 are disposed at opposing sides of the CCD camera 430, although more or fewer light sources 435 may alternatively be used. In one embodiment, the light sources 435 include miniature incandescent bulbs that are capable of providing illumination that is far brighter and more diffuse than a conventional fiber optic light source. It should also be
RECTIFIED SHEET (RULE 91) appreciated that should one or more of the incandescent bulbs be damaged or burn out. they may be replaced at a much lower cost than a conventional fiber optic light source. Of course, as discussed above, the present invention is not limited to employing light sources adjacent the camera assembly 400. as a fiber optic light source can alternatively be employed. The camera assembly 400 is disposed within a gimbled camera housing 450 that is mounted to a top ring 421 of the telescoping support 420 for rotation about a shaft 422. The top ring 421 of the telescoping support 420 is capable of rotating anywhere between zero and 360° relative to the longitudinal axis of the telescoping support 420. The gimbled camera housing 450 is capable of rotating in elevation about the shaft 422 from approximately 20° below horizontal to over 90° above horizontal. It should be appreciated that because the gimbled camera housing 450 is entirely recessed within the top ring 421 of the telescoping support 420. the field of view of the camera assembly 400 can be elevated, depressed and/or rotated without requiring any additional space other than that required to receive the top-most ring of the extendable support. This is in contrast to rigid and flexible borescopes in which movement of the head of the borescope from one position to another typically requires additional space. Although the particular gimble mount shown in Figure 4 is advantageous, it should be appreciated that the present invention is not limited in this respect, as the camera assembly 400 could be mounted to the telescoping support 420 in numerous other ways. Figures 5-9 illustrate an aircraft visualization system according to yet another embodiment of the present invention. In contrast to embodiments depicted in Figures 2-4. the visualization system illustrated in Figures 5-9 is configured to extend and retract a camera assembly significant distances along a longitudinal axis of a telescoping support. As in the embodiments described with respect to Figures 2-4, the camera assembly is capable of changing its position both rotationally and elevationally. The visualization system 500 includes a multi-positional camera module 510 and a telescoping support 520. Advantageously, the multi-positional camera module 510 can be easily connected and separated from the telescoping support 520. This permits the multi- positional camera module 510 to be used with different telescoping supports 520 of varying lengths, depending upon the requirements of the task at hand. For example, to inspect a horizontal or vertical stabilizer in the tail of an aircraft, an extended length of up to eight feet may be required. For other tasks, such as inspecting the wiring harness of the instrument console in the cockpit of the aircraft, a length of only two feet may be required. Accordingly, a number of different telescoping supports 520 may be provided, each having a different length when fully extended. In one embodiment ofthe present invention, four different sizes of telescoping supports are provided, one with an extendable length of approximately 2 feet, another with an extended length of approximately 4 feet another with an extended length of approximately 6 feet, and another with an extended length of approximately 8 feet
It should be appreciated that because the multi-positional camera module 510 may be easily removed from one telescoping support 520 and attached to another, a single multi- positional camera module 510 can be used to perform a variety of tasks. Furthermore, should either a telescoping support 520 or the multi-positional camera module 510 be dropped or otherwise damaged during use, a new multi-positional camera module 510 or support 520 may be provided. It should be appreciated that in a conventional borescope, should any portion ofthe borescope be damaged during use, it is typically required that the entire instrument be replaced as a whole.
Figures 6A and 6B show different perspective views ofthe outwardly visible aspects of the multi-positional camera module 510, whereas Figures 7 A and 7B show different cross- sectional views of some ofthe internal aspects ofthe multi-positional camera module 510. In a manner similar to that of embodiments of Figures 2-4, the multi-positional camera module 510 includes a camera assembly 600 having a CCD camera 630. The CCD camera, in turn, includes a CCD imaging device 632 and a lens 631. Again, in one embodiment the CCD imaging device 632 and the lens 631 optionally may be formed as a unitary structure in a manner similar to that described in the '368 application, such that no focusing ofthe lens 631 relative to the CCD imaging device 632 is necessary.
The camera assembly 600 also includes a plurality of light sources 635 that are mounted adjacent to the CCD camera 630. In the embodiment shown, two light sources 635 are disposed at opposing sides ofthe CCD camera 630, although more or fewer light sources 635 may alternatively be used. As in the embodiments of Figures 2-4, the light sources 635 may include miniature incandescent bulbs, although other sources of light can alternatively be employed.
Camera assembly 600 is disposed within a gimbled camera housing 650 that is mounted in a nose 640 of an upper poπion 680 of the multi-positional camera module 510. It should be appreciated that the illustrated placement ofthe camera assembly 600 within the nose 640 protects the camera assembly 600 from contact with other objects and from potential damage during inseπion of the multi -positional camera module 510 or extension thereof. The gimbled camera housing 650 is mounted for rotation about a shaft 622 and is capable of rotating in elevation about the shaft 622 from approximately 60° below horizontal to over 90 ° above horizontal. The upper poπion 680 of the multi-positional camera module 510 is capable of rotating anywhere between zero and 360° relative to a lower portion 690 of the multi-positional camera module 510. It should be appreciated that because the gimbled camera housing 650 is entirely recessed within the nose 640 of upper portion 680, the field of view ofthe camera assembly 600 can be elevated, depressed and/or rotated without requiring any additional space. It should be appreciated that the ranges of motion discussed above are provided mereiy for illustrative purposes, as numerous other arrangements arc possible. Image signals transmitted from the camera assembly 600 are conveyed to other portions of the visualization system 500 via a flexible cable or flex circuit 695. The flex circuit 695 also provides power to the light sources 635.
The lower portion 690 ofthe multi-positional camera module 510 includes a ring 685 that is threaded on the inside and knurled on the outside and is used for securely mounting the multi-positional camera module onto the telescoping support 520. The telescoping support 520, in turn, includes a threaded portion (not shown) that is adapted to mate with the ring 685 and securely attach the multi-positional camera module thereto. Signals to alter the position ofthe upper portion 680 ofthe module with respect to the lower portion 690 ofthe module, to alter the elevation ofthe camera assembly 600, to control the light sources 635, and to electronically transmit image data from the camera assembly 600 to a monitor and/or storage device (not shown) are provided via a card edge connector 698. Tne card edge connector 698 mates with a receptacle (not shown) in the telescoping support 520 to provide these signals to a control unit or to a monitor and/or storage system. Figures 7A and 7B illustrate different cross-sectional views of some of the internal aspects ofthe multi-positional camera module 510. As shown in Figure 7 A, a rotation motor 710 is mechanically coupled to a bearing surface 712 on the upper portion 680 of the multi- positional camera module 510 for rotation ofthe upper poπion 680 relative to the lower portion 690. An elevation motor 720 is disposed above the bearing surface 712 and engages an elevation shaft 715 that is coupled to the gimbled camera housing 650 for altering the elevation ofthe gimbled camera housing 650. and thus the camera assembly 600 about the shaft 622. A printed circuit board 730 provides electronic circuitry for amplifying and
RECTIFIED SHEET (RULE 91) processing image signals from the CCD camera 630. The printed circuit board 730 is electrically coupled to the flexible circuit 695 and the card edge connector 698. Tne printed circuit board 730 also transmits power and control signals to the motors 710, 720, and to the light sources 635. Details of a multi-positional camera module that may be used in the visualization system are described further below with respect to Figures 10-21. Although the particular implementation ofthe camera module of Figures 10-21 provides a number of advantages, it should be appreciated that the present invention is not limited to this implementation, as numerous others are possible.
Figure 8 is an exposed cross-sectional view ofthe aircraft visualization system 500 of Figure 5. As described above, the aircraft visualization system includes a multi-positional camera module 510 and a telescoping support 520. Referring now to the telescoping support 520, two bearings 815 and 820 are disposed on opposite sides of a flat tape 817 that is attached to a base 835 of each of a plurality of rings 836. A motor 810 engages bearing 815 causing bearings 815 and 820 to rotate in one of two opposing directions. When bearing 815 rotates counterclockwise (and bearing 820 rotates clockwise), flat tape 817 is pushed upwardly in
Figure 8 to extend the rings 836, and thus, multi-positional camera module 510. Alternatively, when bearing 815 rotates clockwise (and bearing 820 rotates counterclockwise), flat tape 817 is pulled downwardly in Figure 8 to retract the rings 836 and thus, multi-positional camera module 510. In a fully retracted position, excess portions ofthe flat tape 817 are coiled about a spindle 840 in a base 830 ofthe telescoping support It should be appreciated that other forms of achieving the extension ofthe telescoping support may alternatively be provided as the present invention is not limited to any particular implementation.
Figure 9 illustrates aircraft visualization system of Figure 5 in a fully extended position. Controls 960 for extending and retracting the telescoping support, for rotating the camera relative to the longitudinal axis ofthe telescoping support and for changing the elevation ofthe camera assembly 600 are provided at the base 930 ofthe system. Images transmitted by the CCD camera are provided to a monitor and display (not shown) via a cable 950
Figure 10 is a functional block diagram of an optical imaging system that is suitable for use with the embodiments ofthe present invention discussed above. As shown in Figure 10, the optical imaging system 1000 includes a camera head 1070 that is coupled to a camera
RECTIFIED SHEET (RULE 91) body 1080. Camera head 1070 includes a lens assembly 1010 and an imaging device 1020. Light from a target enters lens assembly 1010 and is focused on the imaging device 1020. In one embodiment, the imaging device is a charge coupled device (CCD). However, it should be appreciated that the imaging device 1020 can alternatively be of another type, such as a microbolometer array (e.g.. an infra-red detection array) that is capable of perceiving objects at very low levels of light, as the present invention is not limited to the use of a CCD as the imaging device.
Imaging device 1020 includes a plurality of pixel elements (e.g.. photo diodes) that convert light energy focused by the lens assembly 1010 into a plurality of electrical signals. The plurality of electrical signals from the imaging device 1020 are provided to an amplifier 1030 that is coupled to the imaging device 1020 by a connection 1090. Amplifier 1030 amplifies each ofthe plurality of electrical signals from the imaging device 1020 and provides the amplified electrical signals to a camera control unit (CCU) 1040 that forms an image based on the plurality of amplified electrical signals. CCU 1040 can be a microprocessor-based system that may include some memory (not shown) for temporarily storing an image prior to providing the image to a display 1050 and/or a storage (recording) device 1060. Alternatively, the CCU 1040 can provide the image directly to the display 1050 or storage device 1060. As shown in Figure 10. the display 1050 can be coupled to the storage device 1060 so that a previously recorded image (or images) can be displayed on the display 1050.
According to one aspect of the present invention, the imaging device 1020 is coupled to the amplifier 1030 by a flexible connection 1090, such as a flexible cable or a flexible circuit. Accordingly, the optical elements in the camera head 1070 that focus and receive light from the target (e.g., the lens assembly 1010 and the imaging device 1020) need not be in-line with the amplifier 1030 or other elements of the imaging system (e.g., those elements in the camera body 1080). and can be positionable independently therefrom. This in contrast to a conventional camera in which the lens, the viewing aperture and the recording medium (e.g., film) are optically aligned within the body of the camera. Furthermore, flexible connection 1090 also permits the lens assembly 1010 and the imaging device 1020 to be located within the camera head 1070 of the imaging system 1000. with the amplifier 1030 and the CCU 1040 being disposed in a physically separate camera body 1080. The display 1050 and storage device 1060 can be disposed in the camera body 1080 of the imaging system 1000 along with amplifier 1030 and CCU 1040. or they may alternatively be disposed in a location separate therefrom.
The physical separation of the lens assembly 1010 and the imaging device 1020 from other portions of the imaging system 1000 provides a number of advantages over conventional imaging systems in which all of these devices (i.e.. the lens assembly 1010. the imaging device 1020. and the amplifier 1030) are located within the same housing. For example, separation ofthe amplifier 1030 from the camera head permits camera head 1070 to be significantly smaller and lighter in weight than that of conventional imaging systems. Alternatively, for a camera head of a fixed size, this separation permits the optical elements (e.g.. the lens and CCD) within the camera head to be larger, thereby increasing image resolution. Furthermore, flexible connection 1090 and the small scale of the camera head 1070 permit the camera head to be pivoted and/or rotated in a confined space for viewing in a number of different directions.
The optical imaging system described in Figure 10 has been employed in a design for a surgical/diagnostic imaging device for use in interabdominal. interthoracic. and other surgical and diagnostic procedures. Examples of such a surgical/diagnostic imaging device are described in U.S. Patent No. 5.762,603 (hereinafter, the '603 patent) which is entitled "Endoscope Having Elevation and Azimuth Control of Camera Assembly'" and shares a common inventor with the present application. The technology employed in implementing the surgical/diagnostic imaging devices of the '603 patent, which are described below with reference to Figures 1 1 -21. can also be used in the embodiments of the present invention described above.
Figures 1 1-13 show an imaging device 1. The device 1 comprises an upper housing 3, a camera housing 5. and left and right camera housing supports 7, 9. For medical applications, the device 1 is inserted into a sterile sheath 1 1. The device 1 and sheath 11
(collectively, the "camera") are then inserted through an incision into the patient's body (not shown). The camera is inserted so as to place the camera housing 5 in a position from which it can be pointed at the surgical site or the area to be diagnosed. The incision is sealed around the camera with a purse string stitch, thereby preventing leakage of the C02 gas which is used to distend the patient's abdomen or chest during surgery or diagnosis.
The sheath 1 1 may be constructed of medical-grade plastic provided in a sterilized condition, and may be intended to be disposed of after use. Alternately, the sheath 1 1 can be constructed of heat-resistant materials to allow it to be sterilized using an autoclave, then reused. It will be appreciated that the sterile sheath 1 1 eliminates the need to sterilize the camera. For non-medical applications, it may be possible to eliminate the use of the sheath. However, for numerous non-medical applications, it may still be desired to employ the sheath as it protects the other components of the system.
The camera housing 5 contains a CCD (not shown) and a zoom lens assembly (not shown). A plurality of high intensity lights 13 are mounted within a light housing 15 which extends about the outer circumference of the camera housing 5. The lights 13 are aligned with the focal axis 17 of the CCD. and they illuminate the area at which the camera housing 5. and hence, the CCD are pointed.
When the device 1 is inserted in the sheath 1 1. the left and right camera housing supports 7. 9 engage complimentary locking keys 19. 21 within a sheath cap 23. As a result, the camera housing 5 is locked into a position in which the CCD's focal axis 17 is aligned perpendicular to an optically-clear window 25. In addition, as will be described below in connection with Figures 13-15, the locking keys 19, 21 cause the sheath cap 13 to rotate about the longitudinal axis 27 ofthe camera when the camera housing supports 7, 9 are rotated about that axis.
The image system of the device 1 can be implemented using the techniques described above in connection with the imaging system 1000 of Figure 10. The camera housing 5 can include only the CCD and the lens assembly, with the amplifier 1030. CCU 1040 and other components of the imaging system being disposed outside the body of the device 1. A camera cable 29 extends between the camera housing 5 and the upper housing 3. The camera cable 29 contains conductors which carry the CCD's signals to the upper housing 3 and which supply electrical power to the CCD and lights 13. An imaging device cable 31 is provided to carry control signals and supply electrical power to the device 1. and to carry the CCD's signals to the externally-located processing, display and storage devices (not shown) ofthe imaging system.
The length ofthe camera housing supports 7. 9 and the length of the sheath 1 1 can be selected to match the needs of a particular application. Referring now to Figures 14-16. an elevation motor 51 drives an elevation shaft 53 by means of gears 55. 57. The elevation shaft 53 extends downwardly through the hollow left camera support 7. A ring and pinion gear arrangement 59 at the lower end of the elevation shaft 53 transfers the rotary motion of the elevation shaft 53 to the camera housing 15, thereby causing the camera housing 15 to elevate or depress, depending on the direction of rotation of the elevation motor 51. In this embodiment ofthe invention, the camera housing 15 can be elevated 70 ° above and depressed 90 ° below a plane perpendicular to the longitudinal axis 27 of the camera and passing through intersection of the longitudinal axis 27 and the focal axis 17 ofthe camera.
The elevation motor 51 is mounted on a plate 63. The plate 63 is rotatably mounted within the upper housing 3 on a bearing 65. An azimuth motor 67 is also mounted on the plate 63. The azimuth motor 67 drives an azimuth gear 69. The azimuth gear 69 engages a housing gear 71 which is attached to the inner surface ofthe upper housing 3. When the azimuth motor 67 rotates, the plate 63 rotates within the upper housing 3. In this embodiment, the plate 63 rotates plus or minus 180 ° to minimize the amount the camera cable 21 is twisted. Full 360 degree rotation can easily be achieved by using conventional slip rings. A zoom/focus motor 72 drives gears 73, 75, which rotate a zoom/focus shaft 77. The zoom/focus shaft extends downwardly through the right camera support 9. At the bottom of the focus shaft 77, a ring and pinion arrangement 79 transfers the rotary motion of the focus shaft 77 to a zoom lens mechanism (not shown) within the camera housing 5.
Referring now to Figure 17, the imaging device 1 is connected to a control console 101 by means of the imaging device cable 31. Signals from the CCD of the imaging device 1 are amplified by circuits in the control console 101 and directed to a display device 103. In one embodiment, the display device 103 is a conventional television set.
A foot pedal control assembly 105 allows the operator (not shown) to control the imaging device 1. The foot pedal control assembly 105 includes four controls (not shown): (1 ) camera housing left and right; (2) camera housing up and down; (3) zoom in and out; and (4) light intensity up and down. Signals from the foot pedal control assembly 105 are routed to the control console 101. Circuits (not shown) in the control console 103 convert the control assembly signals into signals which are suitable to control the imaging device 1. then route the converted signals to the imaging device 1. It should be appreciated that the control assembly 105 is not limited to implementation as a foot pedal control assembly, as numerous other control assemblies (examples of which are described above) can be employed. In the embodiment shown in Figure 18, a computer 107 is interposed between the control console 101 and the display device 103. A plurality of computer programs contained in the computer 107 allow personnel to manipulate and/or store the signals from the imaging device 1. Figures 19-21 illustrate a second imaging device which employs technology that can be employed to implement the embodiments of the present invention described above. Referring first to Figure 19. the imaging device comprises two major assemblies: a camera assembly 150 and a disposable sheath assembly 152.
In the camera assembly 150. a rotary stepper motor 154 is rigidly mounted in an upper housing 156. A linear stepper motor 158 and the distal end of a planetary gear assembly
162 are press fitted in a linear stepper motor housing 164. The proximal end of the planetary gear assembly 162 is attached to the upper housing 156 by screws 168.
Three planetary gears 170 (only two of which are shown in Figure 19) are rotatably mounted on pins 172 within the planetary gear assembly 162. The rotary stepper motor 154 drives the planetary gears 170 through a sun gear 174.
The proximal end of a camera support tube 178 is press fitted in the linear stepper housing 164. A camera housing 180 is pivotally mounted between pair of arms 182 (only one of which is shown in Figure 10) that are integral with and extend from the distal end of the camera support tube 178. The linear stepper motor 158 acts through a pushrod 186 and a fork 188 to control the elevation of the camera housing 180.
The sheath assembly 152 comprises a sheath 190, a sheath housing 192. and a ring gear 194. The distal portion of the sheath 190 is optically clear. The proximal end of the sheath 190 is adhesively attached within the distal end of the sheath housing 192. The ring gear 194 is adhesively attached within the proximal end of the sheath housing 192. Prior to use. the camera assembly 150 is inserted into the sheath assembly 152, and the planet gears 170 engage the ring gear. As a result, when the rotary stepper motor 154 is actuated, the camera assembly 150 rotates in relation to the longitudinal axis 202 of the sheath assembly. As is best shown in Figures 20 and 21. a CCD assembly 204 and a lens 206 are mounted within a camera bore 208 in the camera housing 180. A pair of high intensity lights 210 are mounted in bores that are coaxial with the camera bore 208. A multi-conductor flexcable 212 provides the necessary connections for the CCD assembly 204. for the camera housing lights 210, and for three high intensity lights 214, that are disposed in bores in the pushrod 186. The flexcable 212 extends from the camera housing 180 to the upper housing 156. In the upper housing 156. the flexcable 212 is combined with power and control wires (not shown) for the rotary stepper motor 154 and the linear stepper motor 158 to form the camera assembly cable 218. The camera assembly cable 218 passes through an orifice 220 in the upper housing 156. As with the surgical/diagnostic device of Figures 1 1-18, the camera assembly cable 218 connects the camera assembly 150 to external display and control devices (not shown). It should be appreciated that each of the embodiments ofthe present invention described herein is not limited to use solely in the aviation field, but may be used to image any inaccessible target. Moreover, the present invention is not solely limited to examining the engines of aircraft, as the present invention may be used to examine other portions of an aircraft, such as the hydraulic systems controlling flaps on the wings, the rudder control mechanisms, etc.
Having described several embodiments ofthe invention in detail, various modifications and improvements will readily occur to those skilled in the art. Such modifications and improvements are intended to be within the spirit and scope ofthe invention. Accordingly, the foregoing description is by way of example only, and is not intended as limiting. The invention is limited only as defined by the following claims and the equivalents thereto.
It should be appreciated that each ofthe above-described embodiments ofthe present invention permits digital images of a region or regions of an aircraft to be generated and saved on conventional digital storage media. As a result, images generated by embodiments ofthe invention may be viewed in a location that is remote from the location where the inspection was performed, and may be transmitted electronically over a conventional communication network (e.g., the Internet). However, it should be appreciated that embodiments ofthe present invention are not limited to the use of an all digital system. In this regard, a coupling device may be provided for use with conventional borescopes and other types of imaging equipment. In particular, the techniques described in Applicant's co- pending U.S. Patent Application No. 09/064.542. filed on April 22. 1998. entitled COUPLING DEVICE FOR USE IN AN IMAGING SYSTEM, by the same Applicant, and incoφorated herein by reference, may be used to generate a digital image from conventional analog equipment or even a traditional optical borescope. What is claimed is:

Claims

1. Aircraft inspection apparatus, comprising: a support having a proximal end and a distal end: and a camera that is mounted to the distal end of the support; wherein the camera is movably mounted to the distal end of the support for movement, relative to the distal end of the support.
2. The aircraft inspection apparatus of claim 1. further comprising a shaft that mounts the camera to the distal end of the support, wherein the camera is movably mounted for rotation about the shaft.
3. The aircraft inspection apparatus of claim 1. wherein the camera is movably mounted to the distal end of the support for movement, relative to the proximal end ofthe support, without altering a position of the proximal end of the support.
4. The aircraft inspection apparatus of claim 1. wherein the camera is pivotably mounted to the distal end of the support.
5. The aircraft inspection apparatus of claim 1 , wherein the distal end of the support can be adjustably extended away from the proximal end of the support.
6. The aircraft inspection apparatus of claim 5. wherein the support is a first support, the aircraft inspection apparatus further comprising: a second support that is mounted to the proximal end of the first support at an angle relative to the first support, the distal end of the first support being movable toward and away from the second support in a direction other than along a longitudinal axis of the second support.
7. The aircraft inspection apparatus of claim 1. further comprising: a light source that is disposed adjacent the camera and mounted for movement together with the camera.
8. The aircraft inspection apparatus of claim 1. wherein the camera is removably mounted to the distal end ofthe support so that the camera can be replaced separately from the support.
9. A method of inspecting an aircraft, comprising acts of: inserting a camera that is mounted to a distal end of an elongated support into a portion ofthe aircraft, the camera being mounted to the distal end ofthe elongated support at a first position; and moving the camera to a second position that is spaced apart from the first position without changing a position of a proximal end ofthe elongated support.
10. The method of claim 9. wherein the act of moving the camera includes moving the camera in a direction other than along a longitudinal axis of the elongated support.
11. The method of claim 10, wherein the act of moving the camera includes rotating the camera in a direction other than about the longitudinal axis of the elongated support.
12. The method of claim 9. wherein the act of moving the camera includes rotating the camera in a direction other than about a longitudinal axis ofthe elongated support.
13. The method of claim 9, wherein the camera is mounted to the distal end ofthe elongated support by an extendable support, and wherein the act of moving the camera includes extending the extendable support.
14. The method of claim 13. wherein the act of extending includes extending the extendable support in a direction other than along a longitudinal axis of the elongated support.
15. A method of inspecting an aircraft, comprising acts of: inserting a camera that is mounted to a distal end of an elongated support into a first portion of the aircraft, the camera being mounted to the distal end of the elongated support at a first position; and telescoping the camera to a second position that is spaced apart from the first position.
16. A method of inspecting an aircraft, comprising acts of: inserting a camera that is mounted to a distal end of a support into a portion of the aircraft, the distal end ofthe support being in a first position inside the portion ofthe aircraft; and remotely telescoping the support to a second position inside the portion of the aircraft.
17. The method of claim 16. further comprising an act of: viewing images transmitted by the camera while remotely telescoping the support.
18. A method of inspecting an aircraft, comprising acts of: inserting a camera that is mounted to a distal end of a support into a portion of the aircraft; and illuminating the portion of the aircraft with a light source that is disposed adjacent to the camera.
19. A method of inspecting an aircraft, comprising acts of: inserting a camera that is mounted to a distal end of a support into a portion of the aircraft; generating a digital image of the portion of the aircraft; transmitting the digital image of the portion of the aircraft to a storage device; and storing the digital image on the storage device.
20. The method of claim 19. further comprising an act of: transmitting the digital image to a location that is remote from a location of the aircraft.
21. A method of inspecting an aircraft, comprising acts of: inserting a camera that is mounted to a distal end of a support into a portion ofthe aircraft; and telescoping the camera in a direction other than along a longitudinal axis ofthe support.
22. A method of inspecting an aircraft, comprising acts of: inserting a borescope into a portion ofthe aircraft, the borescope having an eyepiece; coupling a digital camera to the eyepiece ofthe borescope; and generating a digital image ofthe portion ofthe aircraft.
EP00911992A 1999-02-24 2000-02-24 Inspection device for aircraft Withdrawn EP1154928A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US12138299P 1999-02-24 1999-02-24
US121382P 1999-02-24
PCT/US2000/004911 WO2000050304A1 (en) 1999-02-24 2000-02-24 Inspection device for aircraft

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EP1154928A1 true EP1154928A1 (en) 2001-11-21

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WO (1) WO2000050304A1 (en)

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US6717664B2 (en) 2002-06-14 2004-04-06 The Boeing Company System and method for inspecting a beam using micro fiber-optic technology
EP2967287A4 (en) * 2013-03-15 2016-11-30 Mohammad Jalilian Borescope apparatus and a method of using same
CN106644392B (en) 2015-07-20 2019-06-11 西门子能源公司 Uniaxial ray examination observation device with spherical camera and the method for the internal check for generating project
FR3063488B1 (en) * 2017-03-06 2019-08-23 Nexeya France DEVICE FOR LIGHTING THE INTERIOR OF AN AIRCRAFT
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WO2000050304A1 (en) 2000-08-31
CA2362712A1 (en) 2000-08-31
AU3379700A (en) 2000-09-14

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