Ultrasonic inspection probe for inspecting a component and related method

Abstract

This document discloses an ultrasonic inspection probe and related methods for inspecting components. The ultrasonic inspection probe includes a probe body comprising an ultrasonic array and a plate attachment surface. The ultrasonic array includes a plurality of ultrasonic elements, each selectively operable to generate an ultrasonic beam and all fixed relative to the plate attachment surface. The ultrasonic inspection probe also includes an interface plate comprising a body attachment surface removably attached to the plate attachment surface of the probe body and a component inspection surface shaped to complement the shape of one of the components.

Description

Technical Field

[0001] This disclosure generally relates to nondestructive testing of components, and more specifically to an ultrasonic testing probe for nondestructive testing of components. Background Technology

[0002] Non-destructive testing of components using ultrasonic testing technology involves penetrating the component with an ultrasonic beam and detecting the behavior of the ultrasonic beam on the existing component. In some cases, to ensure proper penetration of the ultrasonic beam, the tool used to generate the ultrasonic beam travels along the surface of the component under test. Therefore, the tool needs to be calibrated and recalibrated based on the shape of the component under test. Accurately calibrating conventional tools to conform to the different shapes of the components under test is difficult and time-consuming. Summary of the Invention

[0003] The subject matter of this application provides examples of ultrasonic inspection systems, ultrasonic inspection probes, and methods for inspecting components that overcome the shortcomings of the prior art discussed above. The subject matter of this application has been developed in response to the shortcomings of the prior art, particularly conventional ultrasonic testing systems and methods.

[0004] This document discloses an ultrasonic inspection probe for inspecting components. The ultrasonic inspection probe includes a probe body comprising an ultrasonic array and a plate attachment surface. The ultrasonic array includes a plurality of ultrasonic elements, each selectively operable to generate an ultrasonic beam and all fixed relative to the plate attachment surface. The ultrasonic inspection probe also includes an interface plate comprising a body attachment surface removably attached to the plate attachment surface of the probe body and a component inspection surface shaped to complement the shape of one of the components. The foregoing subject matter of this paragraph characterizes Example 1 of this disclosure.

[0005] When the main attachment surface of the interface plate is removably attached to the plate attachment surface of the probe body, each ultrasonic beam generated by the plurality of ultrasonic elements is substantially perpendicular to the component inspection surface at each intersection of the ultrasonic beam and the component inspection surface. The foregoing subject matter of this paragraph characterizes Example 2 of this disclosure, wherein Example 2 also includes the subject matter according to Example 1 above.

[0006] The plurality of ultrasonic elements of the ultrasonic array are arranged in a first arc having a first radius. The foregoing subject matter of this paragraph characterizes Example 3 of this disclosure, wherein Example 3 also includes subject matter according to any one of Examples 1-2 above.

[0007] The component inspection surface defines a second arc having a second radius. The second radius is smaller than the first radius. When the body attachment surface of the interface board is removably attached to the board attachment surface of the probe body, the first arc and the second arc are substantially concentric. The foregoing subject matter of this paragraph characterizes Example 4 of this disclosure, wherein Example 4 also includes the subject matter according to Example 3 above.

[0008] The interface board is removably attached to the probe body by at least one fastener. The foregoing subject matter of this paragraph characterizes Example 5 of this disclosure, wherein Example 5 also includes subject matter according to any one of Examples 1-4 above.

[0009] The probe body further includes a first fluid supply line. The interface plate further includes a second fluid supply line. The second fluid supply line is fluidly connected to the first fluid supply line when the body attachment surface of the interface plate is removably attached to the plate attachment surface of the probe body. The interface plate also includes a fluid storage container formed in the body attachment surface. The second fluid supply line is fluidly connected to the fluid storage container. The foregoing subject matter of this paragraph characterizes Example 6 of this disclosure, wherein Example 6 also includes subject matter according to any one of Examples 1-5 above.

[0010] The interface board also includes a plurality of second fluid supply lines. Each of the plurality of second fluid supply lines is fluidly connected to the first fluid supply line when the main body attachment surface of the interface board is removably attached to the plate attachment surface of the probe body. Each of the plurality of second fluid supply lines is fluidly connected to the fluid storage container. The foregoing subject matter of this paragraph characterizes Example 7 of this disclosure, wherein Example 7 also includes the subject matter according to Example 6 above.

[0011] The interface board includes at least two component inspection surfaces spaced apart from each other, with the ultrasonic array positioned between the at least two component inspection surfaces. The foregoing subject matter of this paragraph characterizes Example 8 of this disclosure, wherein Example 8 also includes the subject matter according to Example 1 above.

[0012] The plurality of ultrasonic elements of the ultrasonic array are arranged in an arc. One of the components has a shape including an inner radius. The at least two component inspection surfaces are configured such that when the at least two component inspection surfaces engage the one of the components, the inner radius is substantially concentric with the arc of the plurality of ultrasonic elements. The foregoing subject matter of this paragraph characterizes Example 9 of this disclosure, wherein Example 9 also includes the subject matter according to Example 8 above.

[0013] The probe body also includes at least two plate attachment surfaces spaced apart from each other. The interface plate also includes at least two body attachment surfaces spaced apart from each other. Each of the at least two body attachment surfaces of the interface plate is removably attachable to a corresponding one of the at least two plate attachment surfaces of the probe body. The foregoing subject matter of this paragraph characterizes Example 10 of this disclosure, wherein Example 10 also includes subject matter according to any one of Examples 8 or 9 above.

[0014] The interface board is removably attached to the probe body by only one fastener. The foregoing subject matter of this paragraph characterizes Example 11 of this disclosure, wherein Example 11 also includes the subject matter according to Example 10 above.

[0015] The component inspection surface of the interface board is non-adjustable. The foregoing subject matter of this paragraph characterizes Example 12 of this disclosure, wherein Example 12 also includes subject matter according to any one of Examples 1-11 above.

[0016] The ultrasound probe also includes a plurality of interface plates. Each of the components is shaped differently from any other component. The plurality of interface plates are interchangeably and removably attached to the probe body. The component inspection surface of each of the plurality of interface plates is shaped differently from the component inspection surface of any other interface plate, to complement the shape of a corresponding one of the components. The foregoing subject matter of this paragraph characterizes Example 13 of this disclosure, wherein Example 13 also includes subject matter according to any one of Examples 1-12 above.

[0017] The plurality of ultrasonic elements of the ultrasonic array are arranged in a first arc having a first radius. The component inspection surface of each of the plurality of interface plates defines a second arc. The second radius of the second arc of the component inspection surface of each of the plurality of interface plates is smaller than the first radius and different from the second radius of the second arc of the component inspection surface of any other interface plate. When the body attachment surface of any one of the plurality of interface plates is removably attached to the plate attachment surface of the probe body, the first arc and the second arc of the corresponding component inspection surface of the plurality of interface plates are substantially concentric. The foregoing subject matter of this paragraph characterizes Example 14 of this disclosure, wherein Example 14 also includes the subject matter according to Example 13 above.

[0018] When the body attachment surface of any one of the plurality of interface plates is removably attached to the plate attachment surface of the probe body, each ultrasonic beam generated by the plurality of ultrasonic elements is substantially perpendicular to the component inspection surface of the corresponding one of the plurality of interface plates at each intersection of the ultrasonic beam and the component inspection surface. The foregoing subject matter of this paragraph characterizes Example 15 of this disclosure, wherein Example 15 also includes the subject matter according to Example 14 above.

[0019] Each of the plurality of interface plates includes at least two component inspection surfaces spaced apart from each other. The plurality of ultrasonic elements of the ultrasonic array are arranged in an arc. Each of the components includes an inner radius portion and is shaped differently from any other component. When the at least two component inspection surfaces of any of the plurality of interface plates removably attached to the probe body engage a corresponding one of the components, the inner radius portion of the corresponding one of the components is substantially concentric with the arc of the plurality of ultrasonic elements. The at least two component inspection surfaces of any one of the plurality of interface plates are configured differently from the at least two component inspection surfaces of any other interface plate in the plurality of interface plates. The foregoing subject matter of this paragraph characterizes Example 16 of this disclosure, wherein Example 16 also includes the subject matter according to Example 13 above.

[0020] This document also discloses an ultrasonic inspection system for inspecting components. The ultrasonic inspection system includes a robot and an end effector coupled to and movable via the robot. The end effector includes: a compliance interface assembly directly coupled to the robot; and an ultrasonic inspection probe coupled to the compliance interface assembly such that the compliance interface assembly connects the ultrasonic inspection probe to the robot. The ultrasonic inspection probe includes a probe body comprising an ultrasonic array and a plate attachment surface. The ultrasonic array includes a plurality of ultrasonic elements, each selectively operable to generate an ultrasonic beam and fixed relative to the plate attachment surface. The ultrasonic array also includes an interface plate comprising a body attachment surface removably attached to the plate attachment surface of the probe body and a component inspection surface shaped to complement the shape of one of the components. The foregoing subject matter of this paragraph characterizes Example 17 of this disclosure.

[0021] This document also discloses a method for inspecting components. The method includes: removably attaching a first interface plate to a probe body. The method further includes: traveling a first component inspection surface of the first interface plate along a first component. The method further includes: guiding an ultrasonic beam generated from an ultrasonic array of the probe body and fixed relative to the probe body toward the first component while traveling the first component of the first interface plate along the first component. The foregoing subject matter of this paragraph characterizes Example 18 of this disclosure.

[0022] The method further includes: removing the first interface plate from the probe body. The method further includes: removably attaching a second interface plate to the probe body in place of the first interface plate. The method further includes: traveling a second component inspection surface of the second interface plate along a second component of the components. The second component of the components is differently shaped from the first component of the components. The method further includes: guiding an ultrasonic beam generated from the ultrasonic array of the probe body toward the second component as the second component of the second interface plate travels along the second component. The foregoing subject matter of this paragraph characterizes Example 19 of this disclosure, wherein Example 19 also includes the subject matter according to Example 18 above.

[0023] The step of removably attaching the first interface plate to the probe body includes tightening at least one fastener. The step of removing the first interface plate from the probe body includes loosening the at least one fastener. The step of removably attaching the second interface plate to the probe body instead of the first interface plate includes tightening the at least one fastener. The foregoing subject matter of this paragraph characterizes Example 20 of this disclosure, wherein Example 20 also includes the subject matter according to Example 19 above.

[0024] The features, structures, advantages, and / or characteristics described in this disclosure can be combined in any suitable manner in one or more examples, including embodiments and / or implementations. Numerous specific details are provided in the following description to provide a thorough understanding of the examples of the subject matter of this disclosure. Those skilled in the art will recognize that the subject matter of this disclosure can be practiced without one or more of specific features, details, components, materials, and / or methods in particular examples, embodiments, or implementations. In other instances, additional features and advantages may become apparent in particular examples, embodiments, and / or implementations, and may not be present in all examples, embodiments, or implementations. Furthermore, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of this disclosure. The features and advantages of the subject matter of this disclosure will become more apparent from the following description and the appended claims, or may be learned by practice of the subject matter set forth below. Attached Figure Description

[0025] To facilitate a clearer understanding of the advantages of the subject matter, a more specific description of the subject matter briefly described above will be provided with reference to specific examples shown in the accompanying drawings. It is understood that these drawings depict only representative examples of the subject matter and therefore should not be considered as limiting the scope of the invention. The subject matter will be described and explained using additional features and details illustrated in the drawings, in which:

[0026] Figure 1 This is a schematic side view of an ultrasonic inspection system for inspecting components according to one or more examples of this disclosure;

[0027] Figure 2 It is based on one or more examples of this disclosure, such as those that can be used with Figure 1 The first perspective view of an ultrasound probe used in an ultrasound examination system;

[0028] Figure 3 It is based on one or more examples of this disclosure. Figure 2 The first perspective view of the disassembled ultrasound examination probe.

[0029] Figure 4 It is based on one or more examples of this disclosure. Figure 2 The second perspective view of the ultrasound probe;

[0030] Figure 5 It is based on one or more examples of this disclosure. Figure 2 A disassembled second perspective view of the ultrasound examination probe;

[0031] Figure 6 It is based on one or more examples of this disclosure. Figure 2Bottom view of the ultrasound probe;

[0032] Figure 7 It is based on one or more examples of this disclosure. Figure 2 Front view of the ultrasound probe;

[0033] Figure 8 It is based on one or more examples of this disclosure along Figure 6 The line cut from 8-8 Figure 2 A front view of the cross-section of an ultrasound probe;

[0034] Figure 9 It is based on one or more examples of this disclosure along Figure 6 The line 8-8 cut Figure 2 Another front view of the ultrasound probe;

[0035] Figure 10 This is a front view of a plurality of interchangeable interface plates of an ultrasound examination probe according to one or more examples of the present disclosure, the plurality of interchangeable interface plates being schematically shown as being interchangeably and removably attached to the probe body of the ultrasound examination probe.

[0036] Figure 11 It is based on one or more examples of this disclosure along Figure 6 The line 11-11 cut Figure 2 A front view of the cross-section of an ultrasound probe;

[0037] Figure 12 It is based on one or more examples of this disclosure along Figure 7 The line 12-12 cut Figure 2 A cross-sectional side view of an ultrasound probe;

[0038] Figure 13 It is based on one or more examples of this disclosure, such as those that can be used with Figure 1 The first perspective view of an ultrasound probe used in an ultrasound examination system;

[0039] Figure 14 It is based on one or more examples of this disclosure. Figure 13 The first perspective view of the disassembled ultrasound examination probe.

[0040] Figure 15 It is based on one or more examples of this disclosure. Figure 13 The second perspective view of the ultrasound probe;

[0041] Figure 16 It is based on one or more examples of this disclosure. Figure 13 A perspective view of the interface board of the ultrasound probe;

[0042] Figure 17 It is based on one or more examples of this disclosure. Figure 13 The third perspective view of the ultrasound probe;

[0043] Figure 18 It is based on one or more examples of this disclosure. Figure 13 Bottom view of the ultrasound probe;

[0044] Figure 19 It is based on one or more examples of this disclosure. Figure 13 A side view of the ultrasound probe being examined is shown.

[0045] Figure 20 This is a side view of a plurality of interchangeable interface plates of an ultrasound probe according to one or more examples of the present disclosure, the plurality of interchangeable interface plates being schematically shown as being interchangeably and removably attached to the probe body of the ultrasound probe.

[0046] Figure 21 This is a schematic flowchart of a method for inspecting components according to one or more examples of this disclosure. Detailed Implementation

[0047] Throughout this specification, references to “an example,” “example,” or similar language mean that a particular feature, structure, or characteristic described in connection with that example is included in at least one example of this disclosure. Throughout this specification, the phrases “in an example,” “in the example,” and similar language may, but are not necessarily, refer to the same example. Similarly, the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more examples of this disclosure; however, unless explicitly associated, an implementation may be related to one or more examples.

[0048] This document discloses an ultrasonic inspection system and corresponding method for inspecting components. The ultrasonic inspection system includes an ultrasonic inspection tool that facilitates the inspection of multiple components of different shapes using the same tool. More specifically, multiple components of different shapes can be inspected without replacing the entire ultrasonic inspection tool by using a common probe body and multiple interface plates of different shapes that are interchangeably and removably attached to the common probe body. Because the common probe body houses the ultrasonic array required for ultrasonic inspection, the interface plates can be made and manufactured more cost-effectively. Furthermore, the interface plates can be replaced more easily and quickly compared to replacing the entire ultrasonic inspection tool with another. Therefore, the ultrasonic inspection system and method for inspecting components disclosed herein provide a cheaper, more efficient, and simpler alternative to conventional ultrasonic testing instruments and methods.

[0049] Reference Figure 1Based on some examples, an ultrasonic inspection system 100 for inspecting a component 104 using an ultrasonic beam is disclosed herein. The ultrasonic inspection system 100 includes a robot 102 and an end effector 110. The robot 102 is an industrial robot that is automated, programmable, and capable of movement on three or more axes. The end effector 110 is coupled to and movable via the robot 102. In a particular example, the end effector 110 is removably (e.g., releasably) coupled to the robot 102. The end effector 110 includes an ultrasonic inspection probe 120 operable to generate an ultrasonic beam. The end effector 110 also includes a compliance interface assembly 112. The ultrasonic inspection probe 120 is coupled to the robot 102 via the compliance interface assembly 112. The robot 102 is operable to move the end effector 110 relative to the component 104 being inspected such that the ultrasonic inspection probe 120 travels along the outer surface of the component 104 being inspected when the ultrasonic inspection probe 120 generates an ultrasonic beam. As the ultrasonic probe 120 travels along the outer surface of the component 104, the compliance interface assembly 112 is configured to provide compliance (e.g., flexure or cushioning) for the ultrasonic probe 120 and its movement relative to the robot 102 in appropriate directions. For example, the compliance interface assembly 112 may include one or more springs and a universal joint mechanism, the springs allowing the ultrasonic probe 120 to adapt to variations in the surface of the component 104 being inspected, and the universal joint mechanism allowing the ultrasonic probe 120 to rotate as it moves along undulations in the surface of the component 104 being inspected.

[0050] Depending on a specific example, such as Figures 2-8 As shown, the ultrasonic probe 120 includes a probe body 122 and an interface plate 124. Generally, the ultrasonic probe 120 is configured to inspect components with rounded outer surfaces, such as circular reinforcements with an outer diameter 109. The interface plate 124 is removably attached to the probe body 122. Figure 2 , Figure 4 and Figures 6-8In this configuration, the interface plate 124 is removably attached to the probe body 122. The probe body 122 is directly attached to the compliance interface assembly 112. In some examples, the probe body 122 is directly attached to the compliance interface assembly 112 in a substantially permanent, non-removable manner. In other words, attaching and removing the probe body 122 from the compliance interface assembly 112 is more laborious and complex than attaching and removing the interface plate 124 from the probe body 122. For this reason, to test different components with different shapes, the ultrasound examination system 100 replaces only the interface plate 124, rather than the entire ultrasound examination probe 120 or the entire end effector 110.

[0051] The probe body 122 includes a plate attachment surface 140, and the interface plate 124 includes a body attachment surface 141. The body attachment surface 141 is removably attached to the plate attachment surface 140 to form an attachment interface 126 therebetween. In other words, the plate attachment surface 140 of the probe body 122 and the body attachment surface 141 of the interface plate 124 are configured to mate with each other to form the attachment interface 126. Therefore, the shape of the plate attachment surface 140 is complementary to the shape of the body attachment surface 141. In one example, the body attachment surface 141 of the interface plate 124 is configured to nestably engage the plate attachment surface 140 of the probe body 122. In a particular example, when the interface plate 124 is removably attached to the probe body 122, the body attachment surface 141 is flush with the plate attachment surface 140. The plate attachment surface 140 and the body attachment surface 141 can have any of a variety of shapes. In the example shown, the plate attachment surface 140 is a recessed surface with an arcuate shape, and the body attachment surface 141 is a convex surface with an arcuate shape. The recess of the plate attachment surface 140 of the probe body 122 facilitates the placement of the arcuate ultrasonic array 150 within the probe body 122. However, in alternative examples, the plate attachment surface 140 and the body attachment surface 141 may be non-arcuate, non-flat, or flat.

[0052] In some examples, one or more fasteners 142 help to removably attach the body attachment surface 141 to the plate attachment surface 140. For example... Figure 3 and Figure 5As shown, in one example, the ultrasound probe 120 includes a plurality of fasteners 142 (e.g., four fasteners 142). The fasteners 142 are configured to extend through aligned holes in the probe body 122 and the interface plate 124. More specifically, in the illustrated example, the probe body 122 includes a hole 136 leading to a plate attachment surface 140, and the interface plate 124 includes a hole 138 extending entirely through the interface plate 124 and leading to a body attachment surface 141. Holes 136 or 138 include internal threads for engaging with the external threads of the fasteners 142. When the plate attachment surface 140 mates with the body attachment surface 141, each of the holes 136 in the probe body 122 aligns with a corresponding hole 138 in the interface plate 124. When aligned, the corresponding fastener 142 can extend into the aligned hole to engage the threads of the threaded hole. In the illustrated example, the hole 136 of the probe body 122 includes threads to engage the threads of the fastener 142 after the fastener passes through the hole 138 of the interface plate 124. The threadable engagement between the fastener 142 and the threads of the hole 136 allows the fastener 142 to be tightened to attach the interface plate 124 to the probe body 122 or allows the fastener 142 to be loosened to remove the interface plate 124 from the probe body 122. Although a fastener is used in the illustrated example, in other examples, other coupling devices that facilitate the removable attachment of the interface plate 124 to the probe body 122, such as quick-release clips, resilient clips / tabs, interference fit assemblies, etc., may be used.

[0053] The probe body 122 includes and houses the ultrasound array 150 (e.g., see...). Figure 5 , Figure 6 , Figure 8 and Figure 9 An ultrasonic array 150 is immovably fixed to a probe body 122 and includes a plurality of ultrasonic elements 152. In one example, each ultrasonic element 152 is operable to generate an ultrasonic beam 162. The collection of ultrasonic beams 162 generated by the ultrasonic elements 152 of the ultrasonic array 150 defines an ultrasonic field 160. In some examples, the ultrasonic elements 152 are arranged side-by-side such that one ultrasonic element 152 is directly adjacent to at least one other ultrasonic element 152.

[0054] The ultrasonic elements 152 are arranged relative to each other in a specially shaped configuration to define the shape of the ultrasonic array 150. The shape of the ultrasonic array 150 depends on the desired directionality of the ultrasonic beams 162 generated by the ultrasonic elements 152 of the ultrasonic array 150 (e.g., see...). Figure 9Furthermore, the directionality of a given ultrasonic beam 162 depends on the orientation of the ultrasonic element 152 that generates the ultrasonic beam 162. In the example shown, the ultrasonic element 152 is arranged in an arc having a first radius r1. In other words, the ultrasonic array 150 has an arc shape. The ultrasonic element 152 arranged in the arc generates an ultrasonic beam 162 that passes through the center 164 of the arc. In other words, each ultrasonic beam 162 generated by the ultrasonic array 150 passes through the center of the arc defined by the ultrasonic array 150.

[0055] Reference Figure 5 , Figure 6 , Figure 8 and Figure 9 The probe body 122 includes an internal cavity 148. An ultrasonic array 150 is fixedly positioned within the internal cavity 148. Therefore, the internal cavity 148 is shaped to accommodate the ultrasonic array 150 within it. The internal cavity 148 is open at a plate attachment surface 140.

[0056] The probe body 122 also includes an opening 132 leading to the internal cavity 148 of the body. For example... Figure 2 As shown, aperture 132 allows power communication line 114 to be connected to ultrasound array 150. Power communication line 114 extends from a location outside probe body 122 (e.g., at the controller of ultrasound examination system 100) through aperture 132 and enters the power and / or communication section that engages with ultrasound array 150.

[0057] Further reference Figure 2 The probe body 122 also includes a first fluid supply line 134 formed within the probe body 122. For example... Figure 11 As shown, a first fluid supply line 134 extends through the probe body 122. The first fluid supply line 134 is configured to receive fluid from a fluid source line 116, which can be fluidly coupled to a fluid source external to the probe body 122. The fluid source supplies coupling fluid to the first fluid supply line 134 via the fluid source line 116. The coupling fluid is configured to provide a fluid medium between the ultrasonic array 150 and the surface of the component 104 being inspected, facilitating the propagation of the ultrasonic beam 162 from the ultrasonic array 150 to the surface of the component 104.

[0058] like Figures 3-9As shown, the interface plate 124 also includes a component inspection surface 128 on the side of the interface plate 124 opposite to the body attachment surface 141. The component inspection surface 128 is fixed or non-adjustable. Therefore, in a particular example, the shape of the component inspection surface 128 is not flexible and cannot be changed. The component inspection surface 128 is shaped to be complementary to the shape of the component 104 being inspected. In other words, at least a portion of the component inspection surface 128 has a shape substantially the same as the surface of the component 104 being inspected. In this way, the component inspection surface 128 can travel along the surface of the component 104 being inspected with almost no offset between the component inspection surface 128 and the surface of the component 104. Figure 8 In one example shown, component 104 includes a convex arcuate outer surface with a second radius r2, along which component inspection surface 128 travels when inspecting component 104. Therefore, component inspection surface 128 has a component traveling portion 166 with a concave arcuate shape having a second radius r2. In some examples, such as... Figure 8 and Figure 9 As shown, the component inspection surface 128 may include a gap portion 168 located on the side of the component travel portion 166. The gap portion 168 does not have the same shape as the component 104. Instead, the gap portion 168 is shaped such that interference between the ultrasonic inspection probe 120 and the component 104 is avoided when the ultrasonic inspection probe 120 moves to the travel position on the component 104.

[0059] Figure 8 The component 104 shown is a cap-shaped longitudinal beam. However, component 104 can be any of various components with similar convex arcuate outer surfaces, along which the component inspection surface 128 travels when component 104 is inspected by the ultrasonic inspection probe 120.

[0060] Reference Figures 3-6 and Figure 8 The interface plate 124 also includes a fluid storage container 130 formed in and leading to the body attachment surface 141 and the component inspection surface 128. In other words, the fluid storage container 130 extends from the body attachment surface 141 to the component inspection surface 128. When the interface plate 124 and the probe body 122 are removably attached, the fluid storage container 130 opens to the internal cavity 148 of the body. Figure 11 and Figure 12As shown, the interface plate 124 also includes at least one second fluid supply line (e.g., second fluid supply lines 172A-C) leading to the fluid storage container 130. In the example shown, the interface plate 124 includes three second fluid supply lines 172A-C. When the probe body 122 and the interface plate 124 are removably attached, each of the three second fluid supply lines 172A-C leads to a fluid supply line 134 of the probe body 122. Therefore, fluid supplied to the fluid supply line 134 flows into the second fluid supply lines 172A-C and then into the fluid storage container 130 and the internal cavity 148 of the body. The second fluid supply lines 172A-C are separated from each other and spaced apart, such that fluid flowing into the fluid storage container 130 from them enters the fluid storage container 130 at spaced locations, thereby promoting uniform filling of the fluid in the fluid storage container 130. To allow fluid to flow into and out of the fluid storage container 130 during the inspection procedure, the interface plate 124 also includes one or more outlets 144 extending from the fluid storage container 130 to the outside of the interface plate 124 (e.g., see...). Figure 7 and Figure 12 ).

[0061] Now refer to Figure 9 In some examples, the second radius r2 of the component travel portion 166 of the component inspection surface 128 is smaller than the first radius r1 of the ultrasonic array 150. Furthermore, the top center of the component inspection surface 128 of the interface plate 124 is a distance D1 from the top center of the body attachment surface 141 of the interface plate 124. Distance D1 is chosen such that when the interface plate 124 is removably attached to the probe body 122, the ultrasonic array 150 is concentric or substantially concentric with the component travel portion 166 of the component inspection surface 128 of the interface plate 124. In other words, the arc defined by the ultrasonic array 150 and the arc of the component inspection surface 128 share or substantially share the same center 164, from which the radii of the ultrasonic array 150 and the component inspection surface 128 are defined. As used herein, the two arcs are substantially concentric when the normal drawn from the first arc is substantially perpendicular to the second arc.

[0062] Because the ultrasonic array 150 is concentric or substantially concentric with the component travel portion 166 of the component inspection surface 128 of the interface plate 124, and the ultrasonic beam 162 generated by the ultrasonic array 150 passes through a common center 164, the ultrasonic beam 162 is perpendicular or substantially perpendicular to the surface of the component 104 when the component travel portion 166 travels on the arcuate portion of the component 104. When the interface plate 124 is removably attached to the probe body 122, the concentricity of the component inspection surface 128 and the ultrasonic array 150 allows each ultrasonic beam 162 generated by the plurality of ultrasonic elements 152 to be perpendicular or substantially perpendicular to the component inspection surface 128 at each intersection of the ultrasonic beam 162 and the component inspection surface 128. Therefore, when the inspection surface 128 travels on the arcuate surface of the component 104 and the radius of the surface of the component 104 is substantially equal to the second radius r2 of the component inspection surface 128, each ultrasonic beam 162 is perpendicular to the surface of the component 104 at each intersection of the ultrasonic beam 162 and the surface of the component 104. The ultrasonic beam 162, which contacts and penetrates component 104 at an angle perpendicular to the surface of the component, improves accuracy, reliability, and increases the detectability of anomalies within component 104. As used herein, substantially perpendicular means within 1.5 degrees of the normal.

[0063] Now refer to Figure 10 According to some examples, an ultrasound examination probe 120 includes a probe body 122 and a plurality of interface plates. The plurality of interface plates are interchangeably and removably attached to the probe body 122 to examine parts 104 of different shapes. Each of the plurality of interface plates includes the same general features as the interface plate 124 described above, and the same reference numerals refer to the same features. However, each of the plurality of interface plates has a different shape of part examination surface 128 compared to any other interface plate in the plurality of interface plates, to complement the shape of a corresponding one of the different shaped parts 104. For example, in the illustrated embodiment, the ultrasound examination probe 120 includes a first interface plate 124A, a second interface plate 124B, and a third interface plate 124C. The arcuate part travel portion 166 of the part examination surface 128 of each of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C is shaped to have a second radius r2, a third radius r3, and a fourth radius r4, respectively. The third radius r3 is greater than the second radius r2, and the fourth radius r4 is smaller than the second radius r2. The second radius r2 is substantially equal to the radius of the arcuate surface of the first component in component 104, the third radius r3 is substantially equal to the radius of the arcuate surface of the second component in component 104, and the fourth radius r4 is substantially equal to the radius of the arcuate surface of the third component in component 104. As used herein, a surface having a different shape relative to another surface can refer to surfaces of different dimensions having the same general shape (e.g., a circle).

[0064] Although the component inspection surfaces 128 of the first interface board 124A, the second interface board 124B, and the third interface board 124C have different shapes, their main body attachment surfaces 141 have the same shape. Therefore, as described below with reference to method 300, each of the first interface board 124A, the second interface board 124B, and the third interface board 124C can be removably attached to and removed from the plate attachment surface 140 of the probe body 122 in the same manner. In this way, the first interface board 124A, the second interface board 124B, and the third interface board 124C can be interchangeably and removably attached to the probe body 122.

[0065] When any one of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C is removably attached to the probe body 122, each ultrasonic beam 162 generated by the plurality of ultrasonic elements 152 is perpendicular to the component inspection surface 128 of the corresponding one of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C at the intersection of each ultrasonic beam 162 and the component inspection surface. Because the first radius r1 of the ultrasonic array 150 and the main body attachment surfaces 141 of the first interface plate 124A, second interface plate 124B, and third interface plate 124C are fixed, and the second radius r2, third radius r3, and fourth radius r4 are different, in order to maintain the concentricity between the ultrasonic array 150 and the component inspection surfaces 128 of the first interface plate 124A, second interface plate 124B, and third interface plate 124C when attached to the probe body 122, the distances between the component inspection surfaces 128 of the first interface plate 124A, second interface plate 124B, and third interface plate 124C and the main body attachment surfaces 141 are different. For example, the distance D1 between the top center position of the main body attachment surface 141 and the component inspection surface 128 of the first interface plate 124A is greater than the distance D2 between the top center position of the main body attachment surface 141 and the component inspection surface 128 of the second interface plate 124B. Similarly, the distance D3 between the top center of the main body attachment surface 141 and the component inspection surface 128 of the third interface plate 124C is greater than the distance D1 between the top center of the main body attachment surface 141 and the component inspection surface 128 of the first interface plate 124A.

[0066] Although the ultrasound probe 120 shown in the example includes three interchangeable interface plates, in other examples, the ultrasound probe 120 includes two or at least four interchangeable interface plates. The probe body 122 and the interface plates 124 can be made of any of a variety of materials. For example, in a particular embodiment, any one or both of the probe body 122 and the interface plates 124 are made of a polymeric material. In a particular example, the interface plate 124 has a one-piece, integral structure.

[0067] Now refer to Figures 13-19 According to an alternative example, an ultrasound examination probe 220 is shown. The ultrasound examination probe 220 is configured to provide at least similar features and functions to the ultrasound examination probe 120 previously shown and described. Therefore, unless otherwise shown, the same markings between ultrasound examination probe 120 and ultrasound examination probe 220 indicate the same features. Unless otherwise indicated, the description of the same features in ultrasound examination probe 120 provided above applies to the same features in ultrasound examination probe 220. Similar to ultrasound examination probe 120, ultrasound examination probe 220 may be formed... Figure 1 It is part of the end effector 110 of the ultrasound examination system 100. For example, the ultrasound examination probe 220 can be coupled to the robot 102 via the compliance interface assembly 112.

[0068] Generally, instead of being configured like ultrasonic probe 120 to inspect external rounded surfaces, ultrasonic probe 220 is configured to inspect component 204 having internal rounded surfaces such as flange assemblies. (See reference...) Figure 19 In one example, component 204 includes an inner radius or inner radius portion 209 having a sixth radius r6, and can be inspected using the ultrasonic inspection probe 220 shown.

[0069] Reference Figure 13 and Figure 14 According to the example shown, the ultrasound probe 220 includes a probe body 222 and an interface plate 224. The interface plate 224 is removably attached to the probe body 222. Figure 13 , Figure 15 as well as Figures 17-19 In this configuration, the interface plate 224 is removably attached to the probe body 222, which, as described above, can be directly attached to the compliance interface assembly 112. Similarly, at the ultrasound probe 120, to test different components with different shapes, the ultrasound system 100 can replace only the interface plate 224, rather than the entire ultrasound probe 220 or the entire end effector 110.

[0070] The probe body 222 includes a first plate attachment surface 240A, a second plate attachment surface 240B, and a third plate attachment surface 240C. The first plate attachment surface 240A and the second plate attachment surface 240B are spaced apart from each other, and the third plate attachment surface 240C is located between the first plate attachment surface 240A and the second plate attachment surface 240B. Correspondingly, the interface plate 224 includes a first body attachment surface 241A, a second body attachment surface 241B, and a third body attachment surface 241C (e.g., see...). Figures 14-16 The first main body attachment surface 241A is removably attached to the first plate attachment surface 240A, the second main body attachment surface 241B is removably attached to the second plate attachment surface 240B, and the third main body attachment surface 241C is removably attached to the third plate attachment surface 240C. In other words, the first main body attachment surface 241A and the first plate attachment surface 240A are configured to mate with each other, the second main body attachment surface 241B and the second plate attachment surface 240B are configured to mate with each other, and the third main body attachment surface 241C and the third plate attachment surface 240C are configured to mate with each other. Therefore, the shape of the first plate attachment surface 240A is complementary to the shape of the first main body attachment surface 241A, the shape of the second plate attachment surface 240B is complementary to the shape of the second main body attachment surface 241B, and the shape of the third plate attachment surface 240C is complementary to the shape of the third main body attachment surface 241C.

[0071] In one example, the first body attachment surface 241A and the second body attachment surface 241B of the interface plate 224 are flat surfaces configured to be flush with the flat surfaces of the first plate attachment surface 240A and the second plate attachment surface 240B, respectively. The first body attachment surface 241A and the second body attachment surface 241B are angled relative to each other. Correspondingly, the first plate attachment surface 240A and the second plate attachment surface 240B are angled relative to each other. The angled surfaces facilitate securing and supporting the interface plate 224 in place relative to the probe body 222. In some examples, the third body attachment surface 241C and the third plate attachment surface 240C are curved (e.g., non-flat) to facilitate nestable engagement between the third body attachment surface 241C and the third plate attachment surface 240C. In alternative examples, the attachment surfaces of the ultrasound probe 220 may have shapes other than those described above.

[0072] In some examples, at least one fastener 242 facilitates the removable attachment of the first plate attachment surface 240A, the second plate attachment surface 240B, and the third plate attachment surface 240C to the first body attachment surface 241A, the second body attachment surface 241B, and the third body attachment surface 241C. For example... Figure 13 and Figure 14As shown, in one example, the ultrasound probe 220 includes a single fastener 242 (i.e., only one fastener). The fastener 242 is configured to extend through aligned holes in the probe body 222 and the interface plate 224. More specifically, in the illustrated example, the probe body 222 includes a hole 236, and the interface plate 224 includes a hole 238 extending entirely through the interface plate 224. Hole 236 or hole 238 includes internal threads for engaging with the external threads of the fastener 242.

[0073] When the plate attachment surface of probe body 222 mates with the corresponding body attachment surface of interface plate 224, the hole 236 in probe body 222 aligns with the hole 238 in interface plate 224. When aligned, fastener 242 can extend into the aligned hole to engage the threads of the threaded hole. In the illustrated example, the hole 236 of probe body 222 includes threads to engage the threads of fastener 242 after the fastener passes through the hole 238 of interface plate 224. The threadable engagement between fastener 242 and the threads of hole 236 allows fastener 242 to be tightened to attach interface plate 224 to probe body 222 or loosened to remove interface plate 224 from probe body 222. Although fasteners are used in the illustrated example, in other examples, other coupling devices that facilitate the removable attachment of interface plate 224 to probe body 122, such as quick-release clips, resilient clips / tabs, interference fit assemblies, etc., may be used.

[0074] The probe body 222 includes and houses the ultrasound array 250 (e.g., see...). Figures 15-19 The ultrasonic array 250 is immovably fixed to the probe body 222 and includes a plurality of ultrasonic elements 252. The ultrasonic array 250 is constructed and operable in the same manner as the ultrasonic array 150. Similar to the ultrasonic array 150, the ultrasonic elements 252 of the ultrasonic array 250 are arranged in an arc having a fifth radius r5, such that the ultrasonic beams 262 generated by the ultrasonic array 250 pass through the center 264 of the arc defined by the ultrasonic array 250. In other words, each ultrasonic beam 262 generated by the ultrasonic array 250 passes through the center 264 of the arc defined by the ultrasonic array 250. The collection of ultrasonic beams 262 generated by the ultrasonic elements 252 of the ultrasonic array 250 defines an ultrasonic field 260.

[0075] In the example, the probe body 222 includes an internal cavity formed in the array receiving surface 290 of the probe body 222. An ultrasonic array 250 is fixed within the internal cavity, which can be shaped to assemble the ultrasonic array 250 within it. The internal cavity may be open at the array receiving surface 290.

[0076] The probe body 222 also includes an opening leading to an internal cavity. This opening allows a power communication line 214 to be connected to the ultrasound array 250. The power communication line 214 extends from a location outside the probe body 222 (e.g., at the controller of the ultrasound examination system 100) through the opening and into the power and / or communication section that engages with the ultrasound array 250.

[0077] like Figures 15-19 As shown, the interface board 224 also includes a first component inspection surface 292 and a second component inspection surface 294. The first component inspection surface 292 and the second component inspection surface 294 are configured to engage corresponding surfaces of the component 204 (e.g., travel on corresponding surfaces of the component 204). Therefore, the shapes of the first component inspection surface 292 and the second component inspection surface 294 correspond to the shapes of the surfaces of the component 204. In the example shown, at least a portion of both the first component inspection surface 292 and the second component inspection surface 294 is flat to engage corresponding flat surfaces of the component 204.

[0078] The first component inspection surface 292 and the second component inspection surface 294 are spaced apart from each other, which allows the ultrasonic array 250 to be positioned between the first component inspection surface 292 and the second component inspection surface 294. Figure 19 As shown, the first component inspection surface 292 and the second component inspection surface 294 are angled relative to each other, such that a first angle θ1 is defined between the first component inspection surface 292 and the second component inspection surface 294. The first angle θ1 corresponds to the angle (e.g., the same as the angle described above) defined between the two surfaces of the component 204 that converge to define the inner radius 209. In the example shown, the first angle θ1 is approximately 90 degrees. The first component inspection surface 292 and the second component inspection surface 294 engage a corresponding one of the surfaces of the component 204 that converge to define the inner radius 209.

[0079] The first component inspection surface 292 and the second component inspection surface 294 are further configured to align the center 264 of the ultrasonic array 250 with the center of the inner radius 209 when the first component inspection surface 292 and the second component inspection surface 294 engage the corresponding surfaces of the component 204. In other words, when the first component inspection surface 292 and the second component inspection surface 294 engage the corresponding surfaces of the component 204, the inner radius 209 of the component 204 is concentric with the arc defined by the plurality of ultrasonic elements 252 of the ultrasonic array 250. Therefore, the size, shape, and / or relative angle θ1 of the first component inspection surface 292 and the second component inspection surface 294 depend on the size, shape, and / or relative angle of the corresponding surfaces of the component 204 and the radius of the inner radius 209 of the component. Figure 19As shown, when the first component inspection surface 292 and the second component inspection surface 294 properly engage the component 204, the inner radius 209 has a sixth radius r6, the center of which coincides with the center 264 of the arc of the ultrasonic array 250. Because the first component inspection surface 292 and the second component inspection surface 294 ensure that the ultrasonic array 250 and the inner radius 209 are concentric with each other, they also ensure that the ultrasonic beam 262 generated by the ultrasonic array 250 passes through the common center 264 and is therefore perpendicular to the surface of the inner radius 209 of the component 204.

[0080] Now refer to Figure 20 According to some examples, the ultrasound probe 220 includes a probe body 222 and a plurality of interface plates. The plurality of interface plates are interchangeably and removably attached to the probe body 222 to examine components 104 of different shapes (e.g., different inner radii). Each of the plurality of interface plates includes the same general features as interface plate 224 described above, and the same reference numerals refer to the same features. However, each of the plurality of interface plates has a first component inspection surface 292 and a second component inspection surface 294 with different configurations compared to any other interface plate in the plurality of interface plates, to complement the shape of a corresponding one of the different shaped components 204. For example, in the illustrated embodiment, the ultrasound probe 220 includes a first interface plate 224A, a second interface plate 224B, and a third interface plate 224C. The first component inspection surface 292 and the second component inspection surface 294 of each of the first interface plate 224A, the second interface plate 224B, and the third interface plate 224C are configured to define a first angle θ1, a second angle θ2, and a third angle θ3 between the surfaces, respectively. The second angle θ2 is greater than the first angle θ1, and the third angle θ3 is less than the first angle θ1, but the radius r5 of the ultrasonic array 150 is the same. According to some examples, the sixth radius r6 of the inner radius portion 209 of the component 204 to which the first interface plate 224A is configured for inspection can be smaller than the sixth radius r6 of the inner radius portion 209 of the component 204 to which the second interface plate 224B is configured for inspection. Similarly, in the same example, the sixth radius r6 of the inner radius portion 209 of the component 204 to which the first interface plate 224A is configured for inspection can be greater than the sixth radius r6 of the inner radius portion 209 of the component 204 to which the third interface plate 224C is configured for inspection.

[0081] Although the first component inspection surface 292 and the second component inspection surface 294 of the first interface board 224A, the second interface board 224B, and the third interface board 224C have different shapes, the first body attachment surface 241A, the second body attachment surface 241B, and the third body attachment surface 241C of the first interface board 224A, the second interface board 224B, and the third interface board 224C have the same shape. Therefore, as described below with reference to method 300, each of the first interface board 224A, the second interface board 224B, and the third interface board 224C can be removably attached to and removed from the probe body 222 in the same manner. In this way, the first interface board 224A, the second interface board 224B, and the third interface board 224C can be interchangeably and removably attached to the probe body 222.

[0082] Although the ultrasound probe 220 shown in the example includes three interchangeable interface plates, in other examples, the ultrasound probe 220 includes two or at least four interchangeable interface plates. The probe body 222 and the interface plates 224 can be made of any of a variety of materials. For example, in a particular embodiment, either or both of the probe body 222 and the interface plates 224 are made of a polymeric material. In a particular example, the interface plate 224 has a one-piece, integral structure.

[0083] like Figure 21 As shown, according to a specific example, inspection method 300 for inspecting components (such as components having different shaped surfaces to be inspected) includes (box 302) removably attaching a first interface plate 124A to a probe body 122. Method 300 also includes (box 304) traveling a first component inspection surface 128 of the first interface plate 124A along a first component in the components 104. Method 300 further includes (box 306) guiding an ultrasonic beam 162 generated from an ultrasonic array 150 of the probe body 122 and fixed relative to the probe body 122 toward the first component as the first component inspection surface 128 of the first interface plate 124A travels along the first component in the components 104.

[0084] In some examples of method 300, method 300 further includes (box 308) removing the first interface plate 124A from the probe body 122, and (box 310) removably attaching a second interface plate 124B to the probe body 122 in place of the first interface plate 124A. Method 300 further includes (box 312) causing a second component inspection surface 128 of the second interface plate 124B to travel along a second component in component 104. Method 300 further includes (box 314) guiding an ultrasonic beam 162 generated from the ultrasonic array 150 of the probe body 122 toward the second component in component 104 as the second component inspection surface 128 of the second interface plate 124B travels along the second component in component 104.

[0085] According to some examples, method 300 is performed using an ultrasonic inspection system 100 including a robot 102 and an end effector 110. For example, the robot 102 can selectively and operably move the probe body relative to a component so that the component inspection surface of an interface plate removably attached to the probe body travels along the surface of the component to inspect the component. Furthermore, not shown, the ultrasonic inspection system 100 also includes a plate exchange system that stores multiple interface plates and facilitates the removal of one interface plate from the probe body to the plate exchange system and the removable attachment of another interface plate from the plate exchange system to the probe body. Some or part of the component inspection method 300 is fully automated. For example, the robot 102 can operably and autonomously remove interface plates from and attach them to the probe body using the plate exchange system. In one example, the interface plate is attached to and removed from the probe body by tightening and loosening one or more fasteners, which can be performed autonomously using the robot 102 and the plate exchange system.

[0086] In the above description, specific terms such as “upper,” “lower,” “upper part,” “lower part,” “horizontal,” “vertical,” “left,” “right,” “above,” “below,” etc., may be used. These terms are used appropriately to provide some clarity when dealing with relative relationships. However, these terms are not intended to imply absolute relationships, positions, and / or locations. For example, with respect to an object, the “upper” surface can become the “lower” surface simply by flipping the object. Nevertheless, it is still the same object. Furthermore, unless otherwise explicitly stated, the terms “including,” “contains,” “has,” and their variations mean “including but not limited to.” Unless otherwise explicitly stated, a list of enumerated items does not imply that any or all items are mutually exclusive and / or mutually inclusive. Unless otherwise explicitly stated, the singular form of the term also refers to “one or more.” Furthermore, the term “multiple” can be defined as “at least two.”

[0087] Furthermore, instances of one element being "connected" to another element in this specification can include direct and indirect connections. A direct connection can be defined as one element being connected to another element and forming some contact with said other element. An indirect connection can be defined as a connection between two elements that are not in direct contact with each other, but rather have one or more additional elements between the connected elements. Additionally, as used herein, securing one element to another element can include both direct and indirect securing. Furthermore, as used herein, "adjacent" does not necessarily mean contact. For example, an element can be adjacent to another element without contacting that element.

[0088] As used in this article, the phrase “at least one of…” when used with a list of items means that different combinations of one or more of the listed items can be used, and that only one of the items in the list may be required. An item can be a specific object, thing, or kind. In other words, “at least one of…” means that any combination or number of items can be used from the list, but not all of the items in the list. For example, “at least one of items A, B, and C” can mean item A; item A and item B; item B; item A, item B, and item C; item C; item A and item C; or item B and item C. In some cases, “at least one of items A, item B, and item C” can mean, for example, but not limited to, two of items A, one of items B, and ten of items C; four of items B and seven of items C; or some other suitable combination.

[0089] Unless otherwise stated, the terms “first,” “second,” etc., are used herein only as reference numerals and are not intended to impose any order, position, or hierarchy on the items referred to by these terms. Furthermore, reference to an item such as “second” does not require or exclude the existence of items such as “first” or lower numbered items and / or items such as “third” or higher numbered items.

[0090] As used herein, a system, device, structure, article, element, component, or hardware "constructed to" perform a specified function is actually capable of performing the specified function without any changes, and has the potential to perform more than just the specified function with further modifications. In other words, a system, device, structure, article, element, component, or hardware "constructed to" perform a specified function is specifically selected, created, implemented, used, programmed, and / or designed for the purpose of performing the specified function. As used herein, "constructed to" means an existing feature of the system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform the specified function without further modifications. For the purposes of this disclosure, a system, device, structure, article, element, component, or hardware described as "constructed to" perform a particular function may additionally or alternatively be described as "suitable" and / or "operably" to perform that function.

[0091] The illustrative flowcharts included herein are generally presented as logical flowcharts. Therefore, the sequence and labeled steps depicted indicate an example of the proposed method. Other steps and methods that are functionally, logically, or effectively equivalent to one or more steps or portions thereof of the illustrated method can be envisioned. Furthermore, the format and symbols used are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow and line types may be used in the flowcharts, they are understood not to limit the scope of the corresponding methods. In practice, some arrows or other connectors may be used only to indicate the logical flow of the method. For example, an arrow may indicate a waiting or monitoring period of unspecified duration between the enumerated steps of the depicted method. Furthermore, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.

[0092] Furthermore, this disclosure includes implementations according to the following provisions:

[0093] Clause 1. An ultrasonic inspection probe for inspecting components, the ultrasonic inspection probe comprising:

[0094] The probe body includes an ultrasonic array and a plate attachment surface, wherein the ultrasonic array includes multiple ultrasonic elements, each of which can be selectively operated to generate an ultrasonic beam and is fixed relative to the plate attachment surface; and

[0095] The interface board includes a body attachment surface that is removably attached to the probe body and a component inspection surface that is shaped to complement the shape of one of the components.

[0096] Clause 2. The ultrasonic inspection probe according to Clause 1, wherein when the body attachment surface of the interface plate is removably attached to the plate attachment surface of the probe body, each ultrasonic beam generated by the plurality of ultrasonic elements is substantially perpendicular to the component inspection surface at each intersection of the ultrasonic beam and the component inspection surface.

[0097] Clause 3. An ultrasound examination probe according to any one of Clauses 1-2, wherein the plurality of ultrasound elements of the ultrasound array are arranged in a first arc having a first radius.

[0098] Clause 4. The ultrasound examination probe as described in Clause 3, wherein:

[0099] The component inspection surface is defined by a second circular arc having a second radius;

[0100] The second radius is smaller than the first radius; and

[0101] When the main body attachment surface of the interface board is removably attached to the board attachment surface of the probe body, the first arc and the second arc are substantially concentric.

[0102] Clause 5. An ultrasound probe according to any one of Clauses 1-4, wherein the interface plate is removably attached to the probe body by at least one fastener.

[0103] Clause 6. An ultrasound probe according to any one of Clauses 1-5, wherein:

[0104] The probe body also includes a first fluid supply line;

[0105] The interface board also includes a second fluid supply line;

[0106] When the main body attachment surface of the interface board is removably attached to the board attachment surface of the probe body, the second fluid supply line can be fluidly connected to the first fluid supply line.

[0107] The interface board also includes a fluid storage container formed in the body attachment surface; and

[0108] The second fluid supply line can be fluidly connected to the fluid storage container.

[0109] Clause 7. The ultrasound examination probe as described in Clause 6, wherein:

[0110] The interface board also includes multiple secondary fluid supply lines;

[0111] When the main body attachment surface of the interface board is removably attached to the board attachment surface of the probe body, each of the plurality of second fluid supply lines can be fluidly connected to the first fluid supply line; and

[0112] Each of the plurality of second fluid supply lines is fluidly connected to a fluid storage container.

[0113] Clause 8. The ultrasound examination probe as described in Clause 1, wherein:

[0114] The interface board includes at least two component inspection surfaces spaced apart from each other;

[0115] An ultrasonic array is positioned between the inspection surfaces of the at least two components.

[0116] Clause 9. The ultrasound examination probe as described in Clause 8, wherein:

[0117] The plurality of ultrasonic elements of the ultrasonic array are arranged in an arc;

[0118] The shape of one component in the assembly includes an inner radius portion; and

[0119] The at least two component inspection surfaces are configured such that when the at least two component inspection surfaces engage one of the components, the inner radius is substantially concentric with the arc of the plurality of ultrasonic elements.

[0120] Clause 10. An ultrasound examination probe according to any one of Clauses 1 and 8-9, wherein:

[0121] The probe body also includes at least two plate attachment surfaces spaced apart from each other;

[0122] The interface board also includes at least two body attachment surfaces spaced apart from each other; and

[0123] Each of the at least two body attachment surfaces of the interface board is removably attached to a corresponding one of the at least two plate attachment surfaces of the probe body.

[0124] Clause 11. The ultrasound examination probe as described in Clause 10, wherein the interface plate is removably attached to the probe body by only one fastener.

[0125] Clause 12. An ultrasound examination probe according to any one of Clauses 1-11, wherein the component inspection surface of the interface plate is non-adjustable.

[0126] Clause 13. The ultrasound probe according to any one of Clauses 1-12 further includes a plurality of interface boards, wherein:

[0127] Each component in the assembly is shaped differently from any other component in the assembly;

[0128] The plurality of interface boards are interchangeably and removably attached to the probe body; and

[0129] The component inspection surface of each of the plurality of interface boards is shaped differently from the component inspection surface of any other interface board in the plurality of interface boards, so as to complement the shape of the corresponding one of the components.

[0130] Clause 14. The ultrasound examination probe as described in Clause 13, wherein:

[0131] The plurality of ultrasonic elements of the ultrasonic array are arranged in a first arc having a first radius;

[0132] The component inspection surface of each of the plurality of interface boards defines a second arc;

[0133] The second radius of the second arc of the component inspection surface of each of the plurality of interface boards is smaller than the first radius and is different from the second radius of the second arc of the component inspection surface of any other interface board in the plurality of interface boards; and

[0134] When the body attachment surface of any one of the plurality of interface boards is removably attached to the board attachment surface of the probe body, the first arc and the second arc of the component inspection surface of the corresponding one of the plurality of interface boards are substantially concentric.

[0135] Clause 15. The ultrasonic inspection probe according to Clause 14, wherein when the body attachment surface of any one of the plurality of interface plates is removably attached to the plate attachment surface of the probe body, each ultrasonic beam generated by the plurality of ultrasonic elements is substantially perpendicular to the component inspection surface of the respective one of the plurality of interface plates at each intersection of the ultrasonic beam and the component inspection surface.

[0136] Clause 16. The ultrasound examination probe as described in Clause 13, wherein:

[0137] Each of the plurality of interface boards includes at least two component inspection surfaces spaced apart from each other;

[0138] The plurality of ultrasonic elements of the ultrasonic array are arranged in an arc;

[0139] Each component in the assembly includes an inner radius portion and is shaped differently from any other component in the assembly;

[0140] When at least two components of the plurality of interface boards, which are removably attached to any one of the interface boards of the probe body, inspect a corresponding component of the surface bonding component, the inner radius of the corresponding component is substantially concentric with the arc of the plurality of ultrasonic elements.

[0141] The at least two component inspection surfaces of any one of the plurality of interface boards are configured to be different from the at least two component inspection surfaces of any other interface board among the plurality of interface boards.

[0142] Clause 17. An ultrasonic inspection system for inspecting components, the ultrasonic inspection system comprising:

[0143] robot;

[0144] An end effector, coupled to and movable via the robot, includes: a compliance interface component directly coupled to the robot; and an ultrasound probe coupled to the compliance interface component, such that the compliance interface component connects the ultrasound probe to the robot, wherein the ultrasound probe includes:

[0145] The probe body includes an ultrasonic array and a plate attachment surface, wherein the ultrasonic array includes multiple ultrasonic elements, each of which can be selectively operated to generate an ultrasonic beam and is fixed relative to the plate attachment surface; and

[0146] The interface board includes a body attachment surface that is removably attached to the probe body and a component inspection surface that is shaped to complement the shape of one of the components.

[0147] Clause 18. A method for inspecting a component, the method comprising:

[0148] The first interface board is removably attached to the probe body;

[0149] The first component inspection surface of the first interface board travels along the first component in the component;

[0150] As the first component inspection surface of the first interface plate travels along the first component in the component, an ultrasonic beam generated from the ultrasonic array of the probe body and fixed relative to the probe body is guided toward the first component in the component.

[0151] Clause 19. The method described pursuant to Clause 18 further includes:

[0152] Remove the first interface board from the probe body;

[0153] The second interface board is removably attached to the probe body in place of the first interface board;

[0154] The second component inspection surface of the second interface board travels along the second component in the component, wherein the second component in the component is differently shaped from the first component in the component; and

[0155] As the second component inspection surface of the second interface board travels along the second component in the component, the ultrasonic beam generated from the ultrasonic array of the probe body is guided toward the second component in the component.

[0156] Clause 20. The method described pursuant to Clause 19, wherein:

[0157] The step of removably attaching the first interface board to the probe body includes tightening at least one fastener;

[0158] The step of removing the first interface board from the probe body includes loosening the at least one fastener;

[0159] The step of removably attaching the second interface board to the probe body instead of the first interface board includes tightening the at least one fastener.

[0160] This subject matter may be practiced in other specific forms without departing from the spirit or essential characteristics thereof. The examples described are to be considered in all respects only as illustrative and not restrictive. All modifications falling within the equivalent meaning and scope of the claims are included within the scope of the claims.

Claims

1. An ultrasonic inspection probe (120) for inspecting a component (104), the ultrasonic inspection probe (120) comprising: The probe body (122) includes an ultrasonic array (150) and a plate attachment surface (140), wherein the ultrasonic array (150) includes a plurality of ultrasonic elements (152) arranged in a first arc having a first radius (r1), each ultrasonic element being selectively operable to generate an ultrasonic beam (162) and fixed relative to the plate attachment surface (140); and An interface plate (124) includes a main attachment surface (141) and a component inspection surface (128), the main attachment surface being removably attached to the plate attachment surface (140) of the probe body (122), the component inspection surface being shaped to complement the shape of one of the components (104), and wherein, when the main attachment surface (141) of the interface plate (124) is removably attached to the plate attachment surface (140) of the probe body (122), each ultrasonic beam (162) generated by the plurality of ultrasonic elements (152) is substantially perpendicular to the component inspection surface (128) at the intersection of each ultrasonic beam (162) and the component inspection surface (128). The component inspection surface (128) defines a second arc having a second radius (r2); the second radius (r2) is smaller than the first radius (r1); and the first arc and the second arc are substantially concentric when the body attachment surface (141) of the interface board (124) is removably attached to the plate attachment surface (140) of the probe body (122).

2. The ultrasound examination probe (120) according to claim 1, wherein: The interface board (124) includes at least two component inspection surfaces (292, 294) spaced apart from each other; and The ultrasonic array (150) is located between the at least two component inspection surfaces (292, 294).

3. The ultrasound examination probe (120) according to claim 2, wherein: One of the components (104) has an inner radius portion (209) in its shape; and The at least two component inspection surfaces (292, 294) are configured such that when the at least two component inspection surfaces (292, 294) engage one of the components (104), the inner radius (209) is substantially concentric with the arc of the plurality of ultrasonic elements (152).

4. The ultrasound examination probe (120) according to any one of claims 1 to 3, wherein: The probe body (122) also includes at least two plate attachment surfaces (140) spaced apart from each other. The interface board (124) also includes at least two body attachment surfaces (141) spaced apart from each other; and Each of the at least two body attachment surfaces (141) of the interface board (124) can be removably attached to a corresponding one of the at least two plate attachment surfaces (140) of the probe body (122).

5. The ultrasound examination probe (120) according to claim 1 or 2, wherein, The component inspection surface (128) of the interface board (124) is not adjustable.

6. The ultrasound probe (120) according to claim 1 or 2 further includes a plurality of interface boards (124), wherein: Each of the components (104) is formed differently from any other component (104); The plurality of interface boards (124) can be interchangeably and removably attached to the probe body (122); and The component inspection surface (128) of each of the plurality of interface boards (124) is shaped differently from the component inspection surface (128) of any other interface board in the plurality of interface boards (124) to complement the shape of a corresponding component in the components (104).

7. The ultrasound examination probe (120) according to claim 6, wherein: The component inspection surface (128) of each of the plurality of interface boards (124) defines a second arc; The second radius (r2, r3, r4) of the second arc of the component inspection surface (128) of each of the plurality of interface boards (124) is smaller than the first radius (r1) and different from the second radius of the second arc of the component inspection surface (128) of any other interface board in the plurality of interface boards (124); and When the body attachment surface (141) of any of the plurality of interface boards (124) is removably attached to the board attachment surface (140) of the probe body (122), the first arc and the second arc of the component inspection surface (128) of the corresponding one of the plurality of interface boards (124) are substantially concentric.

8. The ultrasound examination probe (120) according to claim 7, wherein, When the body attachment surface (141) of any one of the plurality of interface plates (124) is removably attached to the plate attachment surface (140) of the probe body (122), each ultrasonic beam (162) generated by the plurality of ultrasonic elements (152) is substantially perpendicular to the component inspection surface (128) of the corresponding one of the plurality of interface plates (124) at the intersection of each ultrasonic beam (162) and the component inspection surface (128).

9. The ultrasound examination probe (120) according to claim 6, wherein: Each of the plurality of interface boards (124) includes at least two component inspection surfaces (292, 294) spaced apart from each other. Each of the components (104) includes an inner radius portion (209) and is shaped differently from any other component in the components (104); When the inspection surfaces (292, 294) of at least two components of any of the interface plates (124) removably attached to the probe body (122) engage with a corresponding component of the component (104), the inner radius (209) of that corresponding component of the component (104) is substantially concentric with the arc of the plurality of ultrasonic elements (152); and The at least two component inspection surfaces (292, 294) of any one of the plurality of interface boards (124) are configured to be different from the at least two component inspection surfaces (292, 294) of any other interface board of the plurality of interface boards (124).

10. The ultrasound examination probe (120) according to claim 1, wherein, The ultrasonic probe (120) is located within an ultrasonic inspection system (100) for inspecting the component (104), the ultrasonic inspection system (100) comprising: Robot (102); and An end effector (110) is coupled to the robot (102) and can move through the robot, wherein the end effector (110) includes: a compliance interface component (112) directly coupled to the robot (102); and an ultrasound probe (120) coupled to the compliance interface component (112) such that the compliance interface component (112) connects the ultrasound probe (120) to the robot (102).

11. A method for examining a component (104) using an ultrasound examination probe (120) according to any one of claims 1 to 10, the method comprising: The interface board (124) can be removably attached to the probe body (122). The component inspection surface of the interface board (124) is made to travel along the first component of the components (104); and As the component inspection surface of the interface plate (124) travels along the first component in the component (104), the ultrasonic beam (162) generated from the ultrasonic array (150) of the probe body (122) is guided toward the first component in the component (104).

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