Device and method for non-destructive inspection of a variable angle machining part

Abstract

This application is titled "Apparatus and Method for Non-Destructive Inspection of Variable Angle Machined Components". Disclosed herein is a non-destructive inspection apparatus that utilizes a biased probe housing to maintain ultrasonic coupling with a part. The apparatus includes an attachment body attached to a robotic arm having a tool center point (TCP). The apparatus further includes: a probe assembly coupled to the attachment body such that movement of the TCP causes corresponding movement of the probe assembly; and a probe housing disposed around the probe assembly and movably coupled to the attachment body. The apparatus also includes a biasing member disposed between the attachment body and the probe housing that pushes the probe housing away from the attachment body. Also disclosed is a method that includes: positioning the probe housing and the probe assembly near a part; ultrasonically scanning for defects in the part; and biasing the probe housing relative to the attachment body to maintain engagement with the part.

Description

Technical Field

[0001] The present disclosure generally relates to non-destructive inspection, and more particularly to non-destructive inspection of components of vehicles and machinery. Background Art

[0002] Various machined components, such as vehicle parts, can be used in the manufacturing process. Such machined components can be composite structures formed of composite materials. The formation of these composite structures may inadvertently include defects. Therefore, the machined components are scanned to evaluate the quality of the components in order to identify defects. One scanning technique that can be used to identify defects uses ultrasonic energy to generate a representation or image inside the component. The generated representation is used to identify defects, such as cracks and voids. Typically, a robotic arm moves a scanning probe along the surface of the component. If the surface of the component has a variable curvature, the robotic arm moves to accommodate the changing curvature while the motor and sensors adjust the sensor array. However, it is often difficult or time-consuming to accommodate the changing curvature. In addition, it is generally difficult for a robot to maintain water coupling of the scanning probe to the component surface. Summary of the Invention

[0003] The subject matter of the present application provides exemplary non-destructive inspection devices that overcome the above disadvantages of the prior art. In response to the current state of the art, and in particular in response to the disadvantages of current non-destructive inspection devices, the subject matter of the present application has been developed.

[0004] Disclosed herein is a non-destructive inspection (NDI) device that includes an attachment body configured to be attached to a robotic arm, where the robotic arm defines a tool center point (TCP). The device further includes an ultrasonic probe assembly fixedly coupled to the attachment body such that movement of the TCP made by the robotic arm results in corresponding movement of the ultrasonic probe assembly. The device further includes a probe housing disposed around the ultrasonic probe assembly and movably coupled to the attachment body, and a biasing member disposed between the attachment body and the probe housing, where the biasing member pushes the probe housing away from the attachment body. The foregoing subject matter of this paragraph characterizes Example 1 of the present disclosure.

[0005] In some examples, the NDI device includes a first housing rod slidably coupled to an opening in the probe housing, where the biasing member is disposed between the opening in the probe housing and the attachment body. In some examples, the first housing rod includes a first end and a second end, the first end being coupled to the attachment body and the diameter of the second end being greater than the diameter of the opening in the probe housing. The foregoing subject matter of this paragraph characterizes Example 2 of the present disclosure, where Example 2 further includes the subject matter according to Example 1 above.

[0006] In some examples, the biasing member is a compression spring positioned around the first housing stem. The foregoing subject matter of this paragraph characterizes Example 3 of the present disclosure, where Example 3 further includes the subject matter described in Example 2 above.

[0007] In some examples, the NDI device includes a second housing stem slidably coupled to a second opening in the probe housing, where a second biasing member is disposed between the second opening of the probe housing and the attachment body. In some examples, the second housing stem includes a first end and a second end, the first end being coupled to the attachment body and the diameter of the second end being greater than the diameter of the second opening of the probe housing. The foregoing subject matter of this paragraph characterizes Example 4 of the present disclosure, where Example 4 further includes the subject matter described in Example 3 above.

[0008] In some examples, the second biasing member is a compression spring positioned around the second housing stem. The foregoing subject matter of this paragraph characterizes Example 5 of the present disclosure, where Example 5 further includes the subject matter described in Example 4 above.

[0009] In some examples, the attachment body includes an attachment plate and an overload protection device disposed between the attachment plate and the robotic arm. The foregoing subject matter of this paragraph characterizes Example 6 of the present disclosure, where Example 6 further includes the subject matter described in any one of Examples 1-5 above.

[0010] In some examples, the probe housing includes a part engagement surface and an end surface, the part engagement surface being configured to engage the surface of a part and facing away from the attachment body, and the end surface facing the attachment body. The probe housing further includes a sensor cavity formed in the body and configured to receive an ultrasonic probe assembly and allow the ultrasonic probe assembly to translate within the sensor cavity. In some examples, the sensor cavity extends completely through the body from the end surface to the part engagement surface. The foregoing subject matter of this paragraph characterizes Example 7 of the present disclosure, where Example 7 further includes the subject matter described in any one of Examples 1-6 above.

[0011] In some embodiments, the sensor cavity has an overall length between the part engagement surface and the end surface, the overall length being between about 1 inch and about 5 inches. The foregoing subject matter of this paragraph characterizes Example 8 of the present disclosure, where Example 8 further includes the subject matter described in Example 7 above.

[0012] In some examples, the NDI device further includes a water channel formed in the body and extending from a first opening in the end surface of the body to a second opening formed in the wall of the sensor cavity, the second opening being near an opening in the part engagement surface of the body. The foregoing subject matter of this paragraph characterizes Example 9 of the present disclosure, where Example 9 further includes the subject matter described in any one of Examples 7 and 8 above.

[0013] In some examples, the part is a spar having a varying radius and a varying web-to-flange angle. The size and shape of the probe housing are selected based on the maximum radius of the spar and the minimum web-to-flange angle of the spar. The foregoing subject matter of this paragraph characterizes Example 10 of the present disclosure, where Example 10 also includes the subject matter according to any one of Examples 7-9 above.

[0014] In some examples, the ultrasound probe assembly includes an ultrasound sensor array and at least one sensor rod having a first end rigidly coupled to an attachment body and a second end rigidly coupled to the ultrasound sensor array. The at least one sensor rod is configured to maintain a fixed position of the ultrasound sensor array relative to the attachment body. The foregoing subject matter of this paragraph characterizes Example 11 of the present disclosure, where Example 11 also includes the subject matter according to any one of Examples 1-10 above.

[0015] Also disclosed herein is a system for NDI. In some examples, the system includes: a robotic arm; a controller configured to control the movement of the tool center point (TCP) of the robotic arm; and an NDI device coupled to the TCP. In some examples, the NDI device includes: an attachment body configured to be attached to the robotic arm, where the robotic arm defines the TCP; and an ultrasound probe assembly fixedly coupled to the attachment body such that movement of the TCP performed by the robotic arm results in a corresponding movement of the ultrasound probe assembly. The NDI device further includes: a probe housing disposed around the ultrasound probe assembly and movably coupled to the attachment body; and a biasing member disposed between the attachment body and the probe housing, where the biasing member pushes the probe housing away from the attachment body. The foregoing subject matter of this paragraph characterizes Example 12 of the present disclosure.

[0016] In some examples, the system includes a first housing rod slidably coupled to an opening in the probe housing, where the biasing member is disposed between the opening in the probe housing and the attachment body. In some examples, the first housing rod includes a first end and a second end, the first end being coupled to the attachment body and the diameter of the second end being greater than the diameter of the opening in the probe housing. The foregoing subject matter of this paragraph characterizes Example 13 of the present disclosure, where Example 13 also includes the subject matter according to Example 12 above.

[0017] In some examples, the biasing member is a compression spring positioned around the first housing rod. The foregoing subject matter of this paragraph characterizes Example 14 of the present disclosure, where Example 14 also includes the subject matter according to Example 13 above.

[0018] In some examples, the ultrasonic probe assembly includes an ultrasonic sensor array and at least one sensor rod having a first end rigidly coupled to an attachment body and a second end rigidly coupled to the ultrasonic sensor array. The at least one sensor rod is configured to maintain a fixed position of the ultrasonic sensor array relative to the attachment body. The foregoing subject matter of this paragraph characterizes Example 15 of the present disclosure, where Example 15 further includes the subject matter according to any one of Examples 12-14 above.

[0019] In some examples, the probe housing includes a part engaging surface and an end surface, the part engaging surface being configured to engage the surface of a part and facing away from the attachment body, and the end surface facing the attachment body. The probe housing further includes a sensor cavity formed in the body and configured to receive the ultrasonic probe assembly and allow the ultrasonic probe assembly to translate within the sensor cavity. In some examples, the sensor cavity extends completely through the body from the end surface to the part engaging surface. The foregoing subject matter of this paragraph characterizes Example 16 of the present disclosure, where Example 16 further includes the subject matter according to any one of Examples 12-15 above.

[0020] In some examples, the system further includes a water channel formed in the body and extending from a first opening in the end surface of the body to a second opening formed in the wall of the sensor cavity, the second opening being near an opening in the part engaging surface of the body. The foregoing subject matter of this paragraph characterizes Example 17 of the present disclosure, where Example 17 further includes the subject matter according to Example 16 above.

[0021] In some examples, the controller includes a laser profiler configured to measure the distance between the TCP and the inspection radius, and wherein the controller is further configured to move the TCP in response to the measured distance. The foregoing subject matter of this paragraph characterizes Example 18 of the present disclosure, where Example 18 further includes the subject matter according to any one of Examples 12-17 above.

[0022] Additionally, a method of non-destructively inspecting a part is disclosed herein. In some examples, the method includes positioning the probe housing and the ultrasonic probe assembly such that the part engaging surface of the probe housing engages the part, wherein the ultrasonic probe assembly is fixedly coupled to an attachment body and the probe housing is movably coupled to the attachment body. The method further includes: ultrasonically scanning for defects in the part while traversing the part engaging surface across the surface of the part; adjusting the distance between the ultrasonic probe assembly and the surface of the part while traversing and scanning the part; and biasing the probe housing relative to the attachment body to maintain engagement of the part engaging surface with the surface of the part. The foregoing subject matter of this paragraph characterizes Example 19 of the present disclosure.

[0023] In some examples, the surface of the joining part includes pressing the part joining surface against the surface of the part. The foregoing subject matter of this paragraph characterizes Example 20 of the present disclosure, where Example 20 further includes the subject matter described in Example 19 above.

[0024] The described features, structures, advantages, and / or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more examples including embodiments and / or implementations. In the following description, numerous specific details are provided to afford a thorough understanding of examples of the subject matter of the present disclosure. Those skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and / or methods of a particular example, embodiment, or implementation. In other instances, additional features and advantages may be recognized in certain examples, embodiments, and / or implementations that may not be present in all examples, embodiments, or implementations. Additionally, 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 the present disclosure. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and the appended claims, or may be learned by practice of the subject matter described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] To more readily understand the advantages of the subject matter, a more specific description of the above briefly described subject matter will be provided by reference to specific examples illustrated in the drawings. It should be understood that these drawings only depict typical examples of the subject matter and should not be considered as limiting the scope of the present invention. By using the drawings, the subject matter will be described and explained with additional features and details, wherein:

[0026] Figure 1 is a schematic block diagram showing one embodiment of a system for non-destructive inspection (NDI) of a machined component according to an example of the present disclosure;

[0027] Figure 2 is a perspective view of an NDI device according to an example of the present disclosure;

[0028] Figure 3 is a perspective view of an ultrasonic probe assembly according to an example of the present disclosure;

[0029] Figure 4a and Figure 4b is a schematic diagram of the probe housing position relative to an attachment plate according to an example of the present disclosure;

[0030] Figure 5 is a perspective view of an NDI device according to an example of the present disclosure;

[0031] Figure 6is a perspective view showing a part mating surface of a probe housing according to an example of the present disclosure;

[0032] Figures 7a to 7c is an illustration of a body according to an example of the present disclosure;

[0033] Figure 8a and Figure 8b is a cross-sectional view of a body according to an example of the present disclosure;

[0034] Figure 9 is a schematic block diagram showing a controller according to an example of the present disclosure; and

[0035] Figure 10 is a flowchart showing a method for non-destructively inspecting a part according to an example of the present disclosure. Detailed Description

[0036] Throughout the specification, references to "an example", "example", or similar language mean that a particular feature, structure, or characteristic described in connection with the example is included in at least one example of the present disclosure. Throughout the specification, the appearances of the phrases "in an example", "in an example", and similar language may, but do not necessarily, all refer to the same example. Similarly, the use of the term "embodiment" means an embodiment having a particular feature, structure, or characteristic described in connection with one or more examples of the present disclosure, but may be associated with one or more examples without an explicit association being indicated.

[0037] Figure 1 is a schematic block diagram showing an embodiment of a system 100 for non-destructive inspection (NDI) of a component 112 (also referred to herein as a part) according to an example of the present disclosure. In certain embodiments, the system 100 is used to inspect various structures, including composite structures having various sizes and shapes, such as composite aircraft wings, spars, and fuselage barrels.

[0038] In some examples, system 100 includes robotic arm 102. Robotic arm 102 is an articulated arm robot configured to provide movement and positioning of a tool center point (TCP) 104. In some examples, TCP 104 is a mathematical point (located at the end of robotic arm 102) that robotic arm 102 moves in space relative to robotic base 106. In some examples, TCP 104 is located at the end of robotic arm 102 and is configured to be coupled to a tool such as non-destructive inspection device 108. For example, this end of robotic arm 102 is the plate to which the tool or end effector is attached. In some examples, TCP 104 is a point positioned a predetermined distance from the end of the robotic arm, and this point corresponds to the location where an ultrasonic sensor array is attached to the robotic arm. For example, TCP 104 can identify the location of the focus of a curved ultrasonic sensor array (see Figure 3 ), which focus is offset from the end of robotic arm 102. Controller 110 controls the movement and positioning of TCP 104.

[0039] In some examples, controller 110 is implemented using software, hardware, firmware, or a combination thereof. When using software, the operations performed by controller 110 are implemented using, for example, program code configured to run on a processor unit. When using firmware, these operations are implemented using, for example, program code and data stored in persistent memory to run on a processor unit. When using hardware, the hardware includes one or more circuits that perform operations to execute the operation of moving TCP 104. In some embodiments, the hardware takes the form of circuitry, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, and the like.

[0040] In some embodiments, controller 110 is configured to control the movement of robotic arm 102, which robotic arm 102 is capable of moving with up to six or more degrees of freedom. In some examples, robotic arm 102 is configured to be coupled to an end effector (e.g., NDI device 108). In one example, the end effector is integrated as part of robotic arm 102 or alternatively removably coupled to TCP 104. In some examples, inspection of machined part 112 uses ultrasonic probe assembly 114 having ultrasonic sensors (see Figure 3 ). The structure of machined part 112 is scanned by NDI device 108 to measure structural and mechanical properties to ensure that machined part 112 has no defects.

[0041] In some examples, machined part 112 has a portion with a bend having a changing radius and angle. To effectively perform the scan, probe housing 116 (see Figure 2) is positioned near the machining part 112. In some examples, the probe housing 116 remains in contact with the surface of the machining part 112. The ultrasonic probe assembly 114 is held at a specific distance and angle or orientation relative to a specific position of the machining part 112. However, certain configurations of the machining part 112 (such as a sharp transition from a flange to a web of a spar) may not provide the clearance necessary for a conventional inspection head attached to the robotic arm 102 to traverse the transition while maintaining an appropriate distance between the ultrasonic probe assembly and the machining part 112.

[0042] Advantageously, and as will be discussed in more detail below, the NDI device 108 is configured with a probe housing 116 that is movable relative to the attachment body 118 of the NDI device 108. The NDI device 108 provides the ability to inspect machining parts 112 with variable radii and variable angles. The system 100 (e.g., the NDI device 108) includes position sensors that monitor changes in the radius and angle of the machining part 112 and assist in adjusting the position of the TCP 104 relative to the machining part 112. The ultrasonic probe assembly 114 is fixedly coupled to the TCP 104 (see Figure 1 ) and moves with the TCP 104. Advantageously, the probe housing 116 is movably coupled to the TCP 104 and is biased away from the TCP 104 by a biasing member 120 (see Figure 2 ) so as to remain in contact with the machining part 112 even when the configuration of the machining part 112 causes the robotic arm 102 to increase the distance between the ultrasonic probe assembly 114 and the machining part (see FIG. 4). In some examples, regardless of the position of the ultrasonic probe assembly 114, the probe housing 116 always remains in contact with the machining part, thereby maintaining ultrasonic coupling (e.g., maintaining water coupling).

[0043] Figure 2 is a perspective view of the NDI device 108 according to an example of the present disclosure. In some examples, the NDI device 108 includes an attachment body 118 that is configured to connect the NDI device 108 to the robotic arm 102. The attachment body 118 includes an attachment plate 122 and an overload protection device 124. In some examples, the attachment plate 122 is a generally rectangular member having one or more openings for mounting the ultrasonic probe assembly 114, the probe housing 116, various position sensors, and the overload protection device 124. The overload protection device 124 is a sensor-enabled coupling that detects collisions between the probe housing 116 and any object not anticipated by the controller 110. In some examples, the overload protection device 124 is disposed between the attachment plate 122 and the TCP 104 or the end of the robotic arm 102.

[0044] In some examples, the ultrasonic probe assembly 114 is fixedly coupled to the attachment plate 122 and extends outwardly from the attachment plate 122. One or more sensor rods 126 position the ultrasonic sensor array (see Figure 3 ) at a fixed distance from the attachment plate 122. The sensor rods 126 maintain this distance as the robotic arm 102 moves the NDI device 108 over the surface of the workpiece 112. In the depicted example, the NDI device 108 is scanning the surface of a spar, specifically the transition between the flange 128 and the web 130 or sidewall of the spar. In some examples, the spar has a varying radius and a varying web-to-flange angle, and thus the size and shape of the probe housing 116 are selected based on the maximum radius of the spar and the minimum web-to-flange angle of the spar. However, the NDI device 108 is suitable for scanning any part of any vehicle or structure.

[0045] In some examples, the probe housing 116 is movably coupled to the attachment plate 122. One or more housing rods 132 are rigidly coupled to the attachment plate 122 and extend outwardly in a direction opposite to the overload protection device 124. In some examples, one or more housing rods 132 include a first housing rod and a second housing rod (see Figure 5 ). The probe housing 116 has an opening that slidably engages the housing rods 132 (see Figure 7b ). In some examples, a biasing member 120 is disposed around each housing rod 132 between the probe housing 116 and the attachment plate 122. The biasing member 120 is configured to push the probe housing 116 away from the attachment plate 122. Thus, the robotic arm 102 can adjust the position of the ultrasonic probe assembly 114 relative to the workpiece 112 while the probe housing 116 remains in contact with the surface of the workpiece 112. In other words, if the curvature of the workpiece 112 causes the robotic arm 102 to increase the distance between the ultrasonic probe assembly 114 and the workpiece 112, the biasing member 120 pushes the probe housing 116 away from the attachment plate 122 to maintain contact with the workpiece 112.

[0046] In some examples, the probe housing 116 is configured with one or more hose connectors 134 that are fluidly connected to a water channel in the probe housing 116. The hose connectors 134 receive a fluid such as water that can be used as an ultrasonic coupling medium to maintain ultrasonic coupling (i.e., "water coupling") between the sensors of the ultrasonic probe assembly 114 and the workpiece 112. For clarity, the various inlet tubes that supply water to the hose connectors 134 have been omitted from these figures.

[0047] Figure 3FIG. 0 is a perspective view of an ultrasonic probe assembly 114 according to an example of the present disclosure. In some examples, the ultrasonic probe assembly 114 includes an ultrasonic sensor array 136 or transducer. The ultrasonic sensor array 136 is configured to transmit energy to a machining part 112 being scanned and / or analyze energy received from the machining part 112 being scanned. In some examples, the ultrasonic sensor array 136 is configured to operate in a pulse-echo mode, which uses acoustic energy to detect and identify defects or flaws that may be present in the machining part 112. The ultrasonic probe assembly 114 communicates with a controller 110 to relay sensor values determined as the ultrasonic probe assembly 114 moves along a scan path 113 associated with the machining part 112 (see Figure 1 ).

[0048] In some examples, one or more sensor rods 126 are configured to position the ultrasonic sensor array 136 at a distance 137 from the attachment plate 122. Each elongated sensor rod 126 includes a first end 138 and a second end 140. In some examples, the first end 138 of the sensor rod is fixedly coupled to the attachment plate 122. In some examples, the second end 140 is fixedly coupled to the ultrasonic sensor array 136. In other examples, the second end 140 includes a flexible connection to the ultrasonic sensor array 136 to allow small movements of translation and rotation. For example, the flexible connection is configured to allow a + / - 3-degree rotation to accommodate movement of the probe housing 116 during traversal of the scan path 113.

[0049] Figure 4a and Figure 4b FIG. 11 is a schematic block diagram of the position of the probe housing 116 relative to the attachment plate 122 according to an example of the present disclosure. In some examples, the probe housing 116 includes one or more housing rod couplers 142. Each housing rod coupler 142 includes an opening configured to slidably engage a housing rod 132 (see Figures 7a - 8b ). In some examples, the housing rod 132 is an elongated rod having a first end 144 and a second end 146, the first end 144 being fixedly coupled to the attachment plate 122. As shown, the diameter of the second end 146 is greater than the diameter of the first end 144 or the diameter of the region of the housing rod 132 between the first end 144 and the second end 146. In this way, the second end 146 serves as a stop to prevent translational movement of the probe housing 116 along the housing rod 132 away from the attachment plate 122 and past the second end 146.

[0050] Figure 4a FIG. 17 depicts a first position of the probe housing 116 at a maximum distance 148 from the attachment plate 122. As described above, the biasing member 120 (for clarity, from Figure 4a and Figure 4b(Omitted in the middle) It is disposed between the middle probe housing 116 and the attachment plate around the housing rod 132. In some examples, the biasing member 120 is a compression spring, and its length is greater than the maximum distance between the housing rod coupler 142 and the attachment plate 122. Therefore, even at the maximum distance, the compression spring applies a biasing force to the probe housing in a direction away from the attachment plate.

[0051] In the depicted Figure 4a example, the ultrasonic sensor array 136 is disposed within the probe housing 116 and is configured to move within the cavity of the probe housing 116. When the configuration of the machining part 112 is such that the NDI device 108 does not have sufficient clearance, the controller 110 instructs the robotic arm 102 to increase the distance between the TCP 104 and the machining part 112. In some examples, the robotic arm 102 positions the TCP 104 at a certain distance from the machining part such that the robotic arm "pushes" the probe housing 116 against the surface of the machining part 112. This thrust overcomes the elastic force of the biasing member 120 and compresses the distance between the probe housing 116 and the attachment plate 122. Figure 4b is an illustration of the minimum distance 150 between the probe housing 116 and the attachment plate. When the robotic arm 102 moves the TCP 104 towards and away from the machining part 112 (to account for variations in the surface profile), the biasing member 120 pushes the probe housing 116 away from the attachment plate 122 and maintains contact between the probe housing 116 and the machining part 112. In some examples, although the probe housing 116 moves between the maximum distance 148 and the minimum distance 150, the relative distance 152 between the ultrasonic sensor array 136 and the attachment plate 122 remains constant.

[0052] Figure 5 is a perspective view of the NDI device 108 according to an example of the present disclosure. Figure 5 The probe housing 116 and the ultrasonic probe assembly 114 are omitted. As described above, the housing rod 132 is a rigid member having a first end 144 and a second end 146. In some examples, the second end 146 includes a head (or collar) having a diameter greater than the diameter of the housing rod 132.

[0053] The housing rod 132 is configured to slidably engage the probe housing 116 and allow the probe housing 116 to move between a fully extended position (see Figure 4a ) and a folded position (see Figure 4b ). In some examples, the biasing member 120 is a compression spring disposed around the housing rod 132. In some examples, a single component is used to act as both the housing rod 132 and the biasing member 120. For example, a gas spring, a gas strut, or a mechanical strut can apply a biasing force to the probe housing 116 in a direction away from the attachment plate 122.

[0054] Figure 6 is a perspective view showing the part engagement surface 154 of the probe housing 116 according to an example of the present disclosure. In some examples, the probe housing 116 is formed by a body 153 that includes a part engagement surface 154 configured to contact the surface of the machining component 112. In some examples, the part engagement surface 154 is generally V-shaped to allow the probe housing 116 to traverse various surface profiles, including but not limited to concave and convex surface profiles.

[0055] The part engagement surface 154 also includes an opening 156 through which the ultrasonic sensor array 136 transmits and receives ultrasonic energy. Water received by the hose coupler 134 and passing through the internal channel is discharged through the opening 164. In some examples, the part engagement surface 154 is substantially smooth and continuous to enable the probe housing 116 to traverse the surface of the machining component 112 without damaging the machining component 112.

[0056] Figures 7a to 7c is an illustration of the body 153 according to an example of the present invention. In particular, Figure 7a is a side view of the body 153 depicting the part engagement surface 154 and the opposing end surface 155. In some examples, the end surface 155 faces the attachment plate 122 of the attachment body 118, while the part engagement surface 154 faces away from the attachment plate 122. In some examples, the body 153 includes a pair of openings 156 formed in the body 153 for receiving the housing rod 132. In some examples, the openings 156 are formed in a housing rod coupler 142 that extends outward from the side surface 158 of the body 153. The diameter of the opening 156 is less than the second end 146 of the housing rod 132 such that the second end 146 of the housing rod 132 serves as a bump stop that prevents the body 153 from moving away from the attachment plate 122. In some examples, the distance 157 between the part engagement surface 154 and the end surface 155 is between about 1 inch and 5 inches.

[0057] In some examples, a sensor cavity 160 is formed in the body 153. An opening in the end surface 155 is configured to receive the ultrasonic probe assembly 114 and allow movement of the body 153 relative to the ultrasonic probe assembly 114. As the NDI device 108 traverses the surface of the machining component 112 and the probe housing 116 moves to different positions between the fully extended position and the folded position, the ultrasonic probe assembly 114 will translate within the sensor cavity 160. In some embodiments, the sensor cavity 160 extends from the opening in the end surface 155 to the opening 164 in the part engagement surface 154.

[0058] In some examples, the water channel extends from the end surface 155 through the body 153 to the component engagement surface 154. In some examples, the water opening 162 is threadedly engaged to connect to the hose coupler 134. The water opening 162 is fluidly coupled to the water channel extending through the body 153 to draw water out of the opening 164 in the component engagement surface 154.

[0059] Figure 8a and Figure 8b is a cross-sectional view of the body 153 according to an example of the present disclosure. As described above, the body 153 is formed with at least one water channel 166 that extends from the end surface 155 through the body 153 to the component engagement surface 154. In some examples, the water channel 166 extends to a second opening 168 in the sensor cavity 160 that is adjacent to the opening 164 in the component engagement surface 154. Advantageously, this allows water to flow into the region between the ultrasonic sensor array 136 and the machining component 112 and provides a coupling medium for ultrasonic energy.

[0060] Figure 9 is a schematic block diagram showing a controller 110 according to an example of the present disclosure. The controller 110 is an example of a computing device. In some examples, the controller 110 is used to implement one or more components of the examples of the present disclosure, and computer-usable program code or instructions for implementing the processes for the illustrative examples can be placed therein. In this illustrative example, the controller includes a communication structure 214 that provides communication between a processor unit 216, a memory 218, a laser profiler 125, a permanent storage device 220, a communication unit 235, and a display 237. In some examples, the laser profiler 125 is disposed on the attachment plate 122 and is configured to scan the surface of the machining component 112 to determine, for example, the inspection radius of the spar and also determine the minimum web-to-flange angle of the web 130 and the flange 128. The laser profiler 125 is also configured to measure the distance between the TCP 104 and the machining component 112 and transmit the distance to the controller 110. In turn, the controller 110 is configured to move the TCP 104 in response to the determined distance.

[0061] In some examples, the processor unit 216 is used to execute the instructions of software loaded into the memory 218. In one example, depending on the particular implementation, the processor unit 216 is a collection of one or more processors or can be a multi-processor core. Additionally, according to some examples, the processor unit 216 is implemented using one or more heterogeneous processor systems where a primary processor coexists with a secondary processor on a single chip. As another illustrative example, the processor unit 216 is a symmetric multi-processor system containing multiple processors of the same type.

[0062] Memory 218 and persistent storage 220 are examples of storage devices 228. A storage device is any piece of hardware capable of storing information such as, but not limited to, data on a temporary and / or permanent basis, program code in functional form, and / or other suitable information. In these examples, memory 218 is a random access memory or any other suitable volatile or non-volatile storage device. Depending on the particular implementation, persistent storage 220 takes various forms. In one example, persistent storage 220 contains one or more components or devices. In one example, persistent storage 220 is a hard disk drive, flash memory, rewritable optical disk, rewritable magnetic tape, or some combination of the above. In some examples, the medium used by persistent storage 220 is removable. For example, in various implementations, a removable hard disk drive is used for persistent storage 220.

[0063] In these examples, communication unit 235 provides communication with other data processing systems or devices. In these examples, communication unit 235 is a network interface card. Communication unit 235 provides communication by using one or both of a physical communication link and a wireless communication link. In some examples, communication unit 235 also provides a connection for user input via a keyboard, mouse, and / or some other suitable input device. Additionally, in various examples, the input / output unit sends output to a printer or receives input from any other peripheral device. Display 237 provides a mechanism for displaying information to a user.

[0064] In some examples, instructions for an operating system, applications, and / or programs are located in storage device 228, which communicates with processor unit 216 via communication structure 214. In these illustrative examples, these instructions exist in functional form on persistent storage 220. In some examples, these instructions are loaded into memory 218 for execution by processor unit 216. In certain examples, the processes of different examples are implemented by processor unit 216 using computer-implemented instructions that are located in a memory (such as memory 218).

[0065] These instructions are referred to as program code, computer-usable program code, or computer-readable program code, and they can be read and executed by a processor in processor unit 216. In different examples, the program code is embodied on different physical or computer-readable storage media, such as memory 218 or persistent storage 220.

[0066] Program code 230 exists in functional form on computer-readable medium 232, which is selectively removable and can be loaded onto or transferred to controller 110 for execution by processor unit 216. In some examples, the program code also includes the above referenceFigure 1 The scanning plan under discussion. The program code 230 and the computer-readable medium 236 form a computer program product 234. In one example, the computer-readable medium 232 is a computer-readable storage medium 236 or a computer-readable signal medium 238. In one example, the computer-readable storage medium 236 includes an optical disc or a magnetic disk inserted or placed in a drive or other device that is part of the permanent storage device 220 for transfer to a storage device (such as a hard disk drive) that is part of the permanent storage device 220. In other examples, the computer-readable storage medium 236 also takes the form of a permanent storage device, such as a hard disk drive, a thumb drive, or a flash memory connected to the controller 110. In some cases, the computer-readable storage medium 236 cannot be removed from the controller 110.

[0067] Alternatively, the program code 230 is transmitted to the controller 110 using the computer-readable signal medium 238. As an example, the computer-readable signal medium 238 is a propagated data signal containing the program code 230. For example, in one example, the computer-readable signal medium 238 is an electromagnetic signal, an optical signal, and / or any other suitable type of signal. These signals are transmitted through a communication link (such as a wireless communication link, a fiber optic cable, a coaxial cable, a wire, and / or any other suitable type of communication link). In other words, in the illustrative example, the communication link and / or connection is physical or wireless. In some examples, the computer-readable medium also takes the form of a non-tangible medium, such as a communication link or a wireless transmission containing the program code.

[0068] In some illustrative examples, the program code 230 is downloaded from another device or data processing system to the permanent storage device 220 via the computer-readable signal medium 238 for use within the controller 110. In one instance, the program code stored in a computer-readable storage medium in a server data processing system is downloaded from the server to the controller 110 via a network. According to various examples, the system providing the program code 230 is a server computer, a client computer, or some other device capable of storing and transmitting the program code 230.

[0069] Illustrating different components for the controller 110 does not imply a physical or architectural limitation on the ways in which different examples can be implemented. Different illustrative examples can be implemented in a controller that includes components additional to and / or in place of those shown for the controller 110. Figure 9The other components shown may be different from the illustrative examples shown. Any hardware device or system capable of executing program code may be used to implement the different examples. For example, the storage device in the controller 110 is any hardware device capable of storing data. The memory 218, the permanent storage device 220, and the computer-readable medium 232 are examples of storage devices in tangible form.

[0070] In another example, a bus system is used to implement the communication structure 214 and may include one or more buses, such as a system bus or an input / output bus. Of course, in some examples, any suitable type of architecture is used to implement the bus system, which provides data transfer between different components or devices attached to the bus system. In additional examples, the communication unit includes one or more devices for sending and receiving data, such as a modem or a network adapter. Further, for example, the memory is the memory 218 or a cache such as may be present in an interface and a memory controller hub in the communication structure 214.

[0071] Computer program code for carrying out operations for aspects of the present disclosure may be written in any combination of one or more programming languages, including object-oriented programming languages such as Java, Smalltalk, C++, and conventional procedural programming languages such as the "C" programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer, or entirely on the remote computer or server. In the latter case, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or may be connected to an external computer (e.g., through the Internet using an Internet service provider).

[0072] These computer program instructions may also be stored in a computer-readable medium that can direct a computer, other programmable data processing apparatus, or other devices to operate in a particular manner, such that the instructions stored in the computer-readable medium produce an article of manufacture including instructions for implementing the functions / acts specified in one or more blocks of the flowchart and / or block diagram. The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus, or other devices to produce a computer-implemented process, such that the instructions executed on the computer or other programmable apparatus provide a process for implementing the functions / acts specified in one or more blocks of the flowchart and / or block diagram.

[0073] Figure 10FIG. 0 is a flow chart showing a method 300 for non-destructively inspecting a part according to an example of the present disclosure. The method includes positioning a probe housing 116 and an ultrasonic probe assembly 114 at step 302 to engage a part engagement surface 154 with a part (e.g., a machined component 112). Engaging the surface of the part 112 may include pressing the part engagement surface 154 against the surface of the part 112. In some examples, method 300 includes ultrasonically scanning for defects in the part at step 304 while traversing the part engagement surface across the surface of the part. The method further includes adjusting the distance between the ultrasonic probe assembly and the surface of the part at step 306 while traversing and scanning the part. The method further includes biasing the probe housing 116 relative to an attachment body 118 at step 308 to maintain engagement of the part engagement surface 154 with the surface of the part.

[0074] In the above description, certain terms may be used, such as "upward", "downward", "upper", "lower", "horizontal", "vertical", "left", "right", "above", "below", etc. These terms are used to provide some clarity in dealing with relative relationships when applicable. However, these terms are not intended to imply absolute relationships, positions, and / or orientations. For example, for an object, just by flipping the object over, the "upper" surface can become the "lower" surface. Nevertheless, it is still the same object. In addition, unless otherwise explicitly stated, the terms "comprising", "including", "having" and their variants mean "including but not limited to". Unless otherwise explicitly stated, a list of items does not imply that any or all of the items are mutually exclusive and / or mutually inclusive. Unless otherwise explicitly stated, the terms "a", "an" and "the" also refer to "one or more". In addition, the term "plurality" may be defined as "at least two".

[0075] In addition, an example of one element "coupled / coupled to" another element in this specification may include direct coupling and indirect coupling. Direct coupling may be defined as one element being coupled to another element and having some contact therewith. Indirect coupling may be defined as a coupling between two elements that do not directly contact each other, but having one or more additional elements between the coupled elements. In addition, as used herein, fixing one element to another element may include direct fixing and indirect fixing. In addition, as used herein, "adjacent" does not necessarily mean in contact. For example, one element may be adjacent to another element without contacting the element.

[0076] As used herein, when used in connection with a list of items, the phrase "at least one" means that different combinations of one or more of the listed items may be used and that only one of the items in the list may be required. The item can be a particular object, thing, or category. In other words, "at least one" refers to any combination or any number of items that can be used from the list, but not necessarily all of the items in the list. For example, "at least one of item A, item B, and item C" can mean: item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, "at least one of item A, item B, and item C" can mean, for example but not limited to: two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

[0077] Unless otherwise indicated, the terms "first", "second", etc. are used herein only as labels and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Further, the mention of, for example, a "second" item does not require or preclude the presence of, for example, a "first" or lower-numbered item and / or, for example, a "third" or higher-numbered item.

[0078] As used herein, a system, apparatus, structure, article, element, component, or hardware "configured to" perform a specified function is indeed capable of performing the specified function without any change, rather than simply having the potential to perform the specified function after further modification. In other words, a system, apparatus, structure, article, element, component, or hardware "configured to" perform a specified function is selected, created, implemented, utilized, programmed, and / or designed specifically to perform the specified function. As used herein, "configured to" represents an existing characteristic of a system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of the present disclosure, a system, apparatus, structure, article, element, component, or hardware described as "configured to" perform a particular function may alternatively or additionally be described as "adapted to" and / or be described as "operable to" perform that function.

[0079] The schematic flowcharts included in this document are generally presented as logical flowcharts. Accordingly, the depicted order and labeled steps represent an example of the proposed method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps or portions thereof of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are to be understood as not limiting the scope of the method. Although various arrow types and line styles may be used in the flowcharts, they are to be understood as not limiting the scope of the corresponding method. In fact, some arrows or other connectors may be used to merely indicate the logical flow of the method. For example, an arrow may indicate a waiting or monitoring period of unspecified duration between the recited steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly follow the order of the corresponding steps shown.

[0080] In addition, the present disclosure includes embodiments according to the following clauses:

[0081] Clause 1. A non-destructive inspection (NDI) device (108) comprising:

[0082] An attachment body (118) configured to be attached to a robotic arm (102), wherein the robotic arm (102) defines a tool center point (TCP) (104);

[0083] An ultrasonic probe assembly (114) fixedly coupled to the attachment body (118) such that movement of the robotic arm (102) with respect to the TCP (104) causes corresponding movement of the ultrasonic probe assembly (114);

[0084] A probe housing (116) disposed around the ultrasonic probe assembly (114) and movably coupled to the attachment body (118); and

[0085] A biasing member (120) disposed between the attachment body (118) and the probe housing (116), wherein the biasing member (120) biases the probe housing (116) away from the attachment body (118).

[0086] Clause 2. The NDI device (108) according to Clause 1, further comprising a first housing rod (132) slidably coupled to an opening (156) in the probe housing (116), wherein the biasing member (120) is disposed between the opening (156) in the probe housing (116) and the attachment body (118), and the first housing rod (132) includes:

[0087] A first end (144) coupled to the attachment body (118); and

[0088] A second end (146) having a diameter greater than the diameter of the opening (156) of the probe housing (116).

[0089] Clause 3. The NDI device (108) according to Clause 2, wherein the biasing member (120) includes a compression spring (120) positioned around the first housing stem (132).

[0090] Clause 4. The NDI device (108) according to Clause 3, further comprising a second housing stem (132) slidably coupled to a second opening (156) in the probe housing (116), wherein a second biasing member (120) is disposed between the second opening (156) of the probe housing (116) and the attachment body (118), and the second housing stem (132) includes:

[0091] A first end (144) coupled to the attachment body; and

[0092] A second end (146) having a diameter greater than the diameter of the second opening (156) of the probe housing (116).

[0093] Clause 5. The NDI device (108) according to Clause 4, wherein the second biasing member (120) includes a second compression spring (120) positioned around the second housing stem (132).

[0094] Clause 6. The NDI device (108) according to any one of Clauses 1-5, wherein the attachment body (118) includes:

[0095] An attachment plate (122); and

[0096] An overload protection device (124) disposed between the attachment plate (122) and the robotic arm (102).

[0097] Clause 7. The NDI device (108) according to any one of Clauses 1-6, wherein the probe housing (116) includes:

[0098] A body (153) having:

[0099] A part engagement surface (154) configured to engage a surface of a part (112) and face away from the attachment body (118);

[0100] An end surface (155) facing the attachment body (118); and

[0101] A sensor cavity (160) is formed in the body (153) and configured to receive the ultrasonic probe assembly (114) and allow the ultrasonic probe assembly (114) to translate within the sensor cavity (160), wherein the sensor cavity (160) extends completely through the body (153) from the end surface (155) to the part engagement surface (154).

[0102] Clause 8. The NDI device (108) according to Clause 7, wherein an overall length of the sensor cavity (160) between the part engagement surface (154) and the end surface (155) is between about 1 inch and about 5 inches.

[0103] Clause 9. The NDI device (108) according to Clause 7 or Clause 8, further comprising a water channel (166) formed in the body (153) and extending from a first opening (162) in the end surface (155) of the body (153) to a second opening (168) formed in a wall of the sensor cavity (160), the second opening (168) being near an opening (164) in the part engagement surface (154) of the body (153).

[0104] Clause 10. The NDI device (108) according to any one of Clauses 7-9, wherein the part (112) includes a spar having a varying radius and a varying web (130) to flange (128) angle, and wherein the size and shape of the probe housing (116) are selected based on the maximum radius of the spar and the minimum web (130) to flange (128) angle of the spar.

[0105] Clause 11. The NDI device (108) according to any one of Clauses 1-10, wherein the ultrasonic probe assembly (114) includes:

[0106] An ultrasonic sensor array (136); and

[0107] One or more sensor rods (126) having a first end (138) rigidly coupled to the attachment body (118) and a second end (140) rigidly coupled to the ultrasonic sensor array (136), the one or more sensor rods (126) being configured to hold the ultrasonic sensor array (136) in a fixed position relative to the attachment body (118).

[0108] Clause 12. A system (100) for non-destructively inspecting a part (112), the system (100) comprising:

[0109] A robotic arm (102);

[0110] A controller (110) configured to control the movement of a tool center point (TCP) (104) of the robotic arm (102); and

[0111] A non-destructive inspection (NDI) device (108) coupled to the TCP (104), the NDI device (108) comprising:

[0112] An attachment body (118) configured to be attached to the robotic arm (102), wherein the robotic arm (102) defines the TCP (104);

[0113] An ultrasonic probe assembly (114) fixedly coupled to the attachment body (118) such that movement of the robotic arm (102) of the TCP (104) causes a corresponding movement of the ultrasonic probe assembly (114);

[0114] A probe housing (116) disposed around the ultrasonic probe assembly (114) and movably coupled to the attachment body (118); and

[0115] A biasing member (120) disposed between the attachment body (118) and the probe housing (116), wherein the biasing member (120) pushes the probe housing (116) away from the attachment body (118).

[0116] Clause 13. The system (100) according to clause 12, further comprising a first housing rod (132) slidably coupled to an opening (156) in the probe housing (116), wherein the biasing member (120) is disposed between the opening (156) of the probe housing (116) and the attachment body (118), and the first housing rod (132) comprises:

[0117] A first end (144) coupled to the attachment body (118); and

[0118] A second end (146) having a diameter greater than the diameter of the opening (156) of the probe housing (116).

[0119] Clause 14. The system (100) according to clause 13, wherein the biasing member (120) comprises a compression spring (120) positioned around the first housing rod (132).

[0120] Clause 15. The system (100) according to any one of clauses 12-14, wherein the ultrasonic probe assembly (114) comprises:

[0121] An ultrasonic sensor array (136); and

[0122] One or more sensor rods (126) having a first end (138) rigidly coupled to the attachment body (118) and a second end (140) rigidly coupled to the ultrasonic sensor array (136), the one or more sensor rods (126) being configured to hold the ultrasonic sensor array (136) in a fixed position relative to the attachment body (118).

[0123] Clause 16. The system (100) according to any one of clauses 12 - 15, wherein the probe housing (116) comprises:

[0124] A body (153) having:

[0125] A part engagement surface (154) configured to engage a surface of the part (112) and face away from the attachment body (118);

[0126] An end surface (155) facing the attachment body; and

[0127] A sensor cavity (160) formed in the body (153) and configured to receive the ultrasonic probe assembly (114) and allow translational movement of the ultrasonic probe assembly (114) within the sensor cavity (160), wherein the sensor cavity (160) extends completely through the body (153) from the end surface (155) to the part engagement surface (154).

[0128] Clause 17. The system (100) according to clause 16, further comprising a water channel (166) formed in the body (153) and extending from a first opening (162) in the end surface (155) of the body (153) to a second opening (168) formed in the wall of the sensor cavity (160), the second opening (168) being near an opening (164) in the part engagement surface (154) of the body (153).

[0129] Clause 18. The system (100) according to any one of clauses 12 - 17, wherein the controller (110) comprises a laser profiler (125) configured to measure the distance between the TCP (104) and the inspection radius, and wherein the controller (110) is further configured to move the TCP (104) in response to the measured distance.

[0130] Clause 19. A method of non - destructively inspecting a part (112), the method comprising:

[0131] Position the probe housing (116) and the ultrasonic probe assembly (114) such that the component engagement surface (154) of the probe housing (116) engages the component (112), wherein the ultrasonic probe assembly (114) is fixedly coupled to the attachment body (118), and the probe housing (116) is movably coupled to the attachment body (118);

[0132] While traversing the component engagement surface (154) across the surface of the component (112), ultrasonically scan for defects in the component (112);

[0133] While traversing and scanning the component (112), adjust the distance between the ultrasonic probe assembly (114) and the surface of the component (112); and

[0134] Bias the probe housing (116) relative to the attachment body to maintain the engagement of the component engagement surface (154) with the surface of the component (112).

[0135] Clause 20. The method according to Clause 19, wherein engaging the surface of the component (112) includes pressing the component engagement surface (154) against the surface of the component (112).

[0136] Without departing from the spirit or essential characteristics of the present invention, the present invention may be embodied in other specific forms. The described examples are to be considered illustrative rather than restrictive in all respects. All changes that fall within the equivalent meaning and scope of the claims are to be included within their scope.

Claims

1. A system (100) for non-destructive inspection of a part (112), comprising: A robotic arm (102) that defines a tool center point TCP (104); A controller (110) configured to control the movement of the tool center point TCP (104); and A non-destructive inspection NDI device (108) coupled to the tool center point TCP, the non-destructive inspection NDI device (108) including: An attachment body (118) configured to be attached to the robotic arm (102); An ultrasonic probe assembly (114) fixedly coupled to the attachment body (118) such that movement of the robotic arm (102) with respect to the TCP (104) causes a corresponding movement of the ultrasonic probe assembly (114); A probe housing (116) disposed around the ultrasonic probe assembly (114) and movably coupled to the attachment body (118); and A biasing member (120) disposed between the attachment body (118) and the probe housing (116), wherein the biasing member (120) pushes the probe housing (116) away from the attachment body (118), whereby the probe housing (116) includes a body (153) having a part engagement surface (154) configured to contact a surface of the part (112).

2. The system (100) according to claim 1, further comprising a first housing rod (132) slidably coupled to a first opening (156) in the probe housing (116), wherein the biasing member (120) is disposed between the first opening (156) of the probe housing (116) and the attachment body (118), and the first housing rod (132) comprises: A first end (144) coupled to the attachment body (118); and A second end (146) having a diameter greater than the diameter of the first opening (156) of the probe housing (116).

3. The system (100) according to claim 2, wherein the biasing member (120) comprises a compression spring (120) positioned around the first housing rod (132).

4. The system (100) according to claim 3, further comprising a second housing rod (132) slidably coupled to a second opening (156) in the probe housing (116), wherein a second biasing member (120) is disposed between the second opening (156) of the probe housing (116) and the attachment body (118), and the second housing rod (132) comprises: A first end (144) coupled to the attachment body; and A second end (146) having a diameter greater than the diameter of the second opening (156) of the probe housing (116).

5. The system (100) according to any one of claims 1-4, wherein the attachment body (118) comprises: An attachment plate (122); and An overload protection device (124) disposed between the attachment plate (122) and the robotic arm (102).

6. The system (100) according to any one of claims 1-4, wherein the probe housing (116) comprises: An end surface (155) facing the attachment body (118); and A sensor cavity (160) formed in the body (153) and configured to receive the ultrasonic probe assembly (114) and allow the ultrasonic probe assembly (114) to translate within the sensor cavity (160), wherein the sensor cavity (160) extends completely through the body (153) from the end surface (155) to the part engagement surface (154).

7. The system (100) according to claim 6, further comprising a water channel (166) formed in the body (153) and extending from a first opening (162) in the end surface (155) of the body (153) to a second opening (168) formed in the wall of the sensor cavity (160), the second opening (168) being near an opening (164) in the component engagement surface (154) of the body (153).

8. The system (100) according to claim 6, wherein the component (112) comprises a spar having a varying radius and a varying angle between the web (130) and the flange (128), and wherein the size and shape of the probe housing (116) are selected based on the maximum radius of the spar and the minimum angle between the web (130) and the flange (128) of the spar.

9. The system (100) according to any one of claims 1 - 4, wherein the ultrasonic probe assembly (114) comprises: An ultrasonic sensor array (136); and One or more sensor rods (126) having a first end (138) rigidly coupled to the attachment body (118) and a second end (140) rigidly coupled to the ultrasonic sensor array (136), the one or more sensor rods (126) being configured to hold the ultrasonic sensor array (136) in a fixed position relative to the attachment body (118).

10. A method of non - destructively inspecting a component (112), the method comprising: Position the probe housing (116) and the ultrasonic probe assembly (114) of the system according to any one of claims 1-9 such that a part engagement surface (154) of the probe housing (116) engages with the part (112), wherein the ultrasonic probe assembly (114) is fixedly coupled to an attachment body (118), and the probe housing (116) is movably coupled to the attachment body (118); While traversing the part engagement surface (154) across the surface of the part (112), ultrasonically scan for defects in the part (112); While traversing and scanning the part (112), adjust the distance between the ultrasonic probe assembly (114) and the surface of the part (112); And Bias the probe housing (116) relative to the attachment body to maintain engagement of the part engagement surface (154) with the surface of the part (112).

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