Ultrasound inspection system and method

Abstract

To provide systems and methods for automatically inspecting a structure using ultrasonic waves.SOLUTION: A system 100 for inspecting a structure 102 includes a laser ultrasound device 104 configured to direct laser light 194, which generates ultrasonic waves within the structure 102, onto a surface 112 of the structure 102, and to generate an array of ultrasound data representative of the ultrasonic waves. The system includes a robotic arm 110 configured to move the laser light 194 across the surface 112. The system 100 includes a multiplex controller configured to receive the array of ultrasound data for an inspection location 116. The system 100 includes a motion-control module configured to control movement of the laser light 194, a motion-tracking module configured to determine the inspection location 116, and an inspection module configured to process the array of ultrasound data to inspect the structure at the inspection location 116.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure generally relates to nondestructive testing. More specifically, it relates to systems and methods for automatically inspecting structures using ultrasonic waves.

Background Art

[0002] In the manufacture of aircraft, vehicles, and other structures, inspection of the parts used to form those structures is typically performed to determine whether those parts will have the desired parameters for the desired performance. Further, when aircraft, vehicles, and other structures are in use, those structures and parts can be inspected as part of normal maintenance.

[0003] Generally, nondestructive tests are performed on these parts. Nondestructive tests are used to evaluate the characteristics of a part without making the part unusable during operation. Ultrasonic testing is a type of nondestructive testing. Ultrasonic testing is often used to perform inspections of aircraft parts including composite materials. Ultrasonic testing involves transmitting sound waves through a test object such as an aircraft part or structure.

[0004] Different types of characteristics may be evaluated using different types of sound waves. In conventional ultrasonic inspection, different types of sound waves can be generated within a part and detected by using different types of ultrasonic inspection devices or by scanning the part multiple times. However, using multiple types of ultrasonic inspection devices or inspecting a part multiple times can consume an undesirable amount of time, energy, and resources. Further, it can be difficult to integrate ultrasonic data received from different types of ultrasonic inspection devices.

[0005] Therefore, there is a need for systems and methods for inspecting structures that take into account at least some of the above problems. Accordingly, those skilled in the art continue to make research and development efforts in the field of pressure vessel assemblies.

Summary of the Invention

[0006] Examples of systems for inspecting structures, methods for inspecting structures, and robotic control systems for automatically inspecting structures are disclosed. The following is a non-exclusive list of examples of the subject matter covered by this disclosure, whether or not they are claimed.

[0007] In one example, the disclosed system includes a laser ultrasonic device configured to direct a laser beam that generates ultrasonic waves within a structure towards the surface of the structure and to generate an array of ultrasonic data representing the ultrasonic waves. The system further includes a robotic arm configured to move the laser beam across the surface of the structure. The system also includes a multiplex controller coupled to the laser ultrasonic device, configured to trigger the generation of ultrasonic waves within the structure at an inspection location on the structure and to receive an array of ultrasonic data from the laser ultrasonic device for the inspection location. The system further includes a computer system coupled to the robotic arm and the multiplex controller. The computer system includes a motion control module configured to control the movement of the laser beam across the surface of the structure. The computer system further includes a motion tracking module configured to determine when the laser beam is at the inspection location. The computer system also includes an inspection module configured to process the array of ultrasonic data to inspect the structure at the inspection location.

[0008] In one example, the method of the present disclosure includes: (1) moving the optical head of a laser ultrasonic device with respect to the surface of a structure using a robotic arm, wherein the optical head is configured to transmit laser light that generates ultrasonic waves within the structure and detects a response to the ultrasonic waves; (2) determining that the optical head is at an inspection location on the structure; (3) using a multiplex controller to trigger the generation of ultrasonic waves within the structure at the inspection location on the structure; (4) generating an array of ultrasonic data representing the ultrasonic waves based on the response; (5) receiving the array of ultrasonic data for the inspection location with the multiplex controller; and (6) processing the array of ultrasonic data to inspect the structure at the inspection location.

[0009] In one example, the disclosed robot control system includes a robot controller coupled to a robot arm, configured to control the position of the robot arm. The robot control system further includes a multiplex controller coupled to a laser ultrasonic device, configured to control the laser ultrasonic device. The robot control system also further includes a computer system coupled to the robot arm and the multiplex controller. The computer system includes at least one processor and, in response to execution by at least one processor, the computer system (1) causes the computer system to generate a scan path for the movement of the optical head of a laser ultrasonic device across the surface of a structure based on a three-dimensional model of the structure; (2) causes the computer system to determine trigger positions along the scan path corresponding to inspection positions on the structure; (3) causes the computer system to command a robot controller to use a robot arm to move the optical head along the scan path relative to the surface of the structure; (4) causes the computer system to determine when the optical head is at a trigger position; (5) causes the robot controller to command the robot controller to position the optical head at an initial device-position relative to the surface of the structure at the trigger position; (6) causes the computer system to command a multiplex controller to trigger the generation of ultrasound within the structure at the inspection position and to receive an array of ultrasonic data representing the ultrasound; and (7) includes a memory for storing at least one computer-readable program that processes the array of ultrasonic data supplied by the multiplex controller to inspect the structure.

[0010] Other examples of the disclosed systems, methods, and robot control systems will become apparent from the following detailed description, the accompanying drawings, and the claims listed separately. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic diagram showing an example of an inspection environment in which a structural inspection system operates. [Figure 2] This is a schematic block diagram of an example of the above-mentioned inspection environment. [Figure 3]This is a schematic plan view illustrating an example of a safe zone in the inspection environment where the above system operates. [Figure 4] This is an exemplary schematic block diagram of a part of a system for inspecting structures, including a laser ultrasonic device and an ultrasonic transducer device. [Figure 5] This is an exemplary schematic block diagram of a part of a system for inspecting structures, including a laser ultrasonic device and an ultrasonic transducer device. [Figure 6] This is an exemplary schematic block diagram of a part of a system for inspecting structures, including a laser ultrasonic device and a second laser ultrasonic device. [Figure 7] This is an exemplary schematic block diagram of a part of a system for inspecting structures, including a laser ultrasonic device and a second laser ultrasonic device. [Figure 8] This is an illustrative schematic block diagram of a part of the system, including the alignment device. [Figure 9] This is a flowchart illustrating one example of a method for inspecting structures. [Figure 10] This is an illustrative schematic block diagram of a robotic control system for automatically inspecting structures. [Figure 11] This is a schematic diagram of an example aircraft. [Figure 12] This is a flowchart illustrating the manufacturing and maintenance methods for aircraft. [Modes for carrying out the invention]

[0012] The following detailed descriptions refer to the accompanying drawings illustrating specific examples described herein. Other examples having different structures and operations do not deviate from the scope of this disclosure. Similar reference numerals may represent the same feature, element, or component in different drawings. Throughout this disclosure, any one of several items may be referred to individually as an item, or several items may be referred to collectively as an item, or referred to by the same reference numeral. In this specification, a feature, element, component, or step described in the singular form following the term "one ("a" or "an")" should be understood not to exclude multiple features, elements, components, or steps unless expressly stated to exclude them.

[0013] Exemplary and non-exclusive examples of the subject matter of this disclosure are provided below, which may or may not be claimed. References to “examples” in this specification mean that one or more features, structures, elements, components, properties, and / or operating steps described in relation to that example are included in at least one aspect, embodiment, and / or implementation of the subject matter of the invention of this disclosure. Thus, the phrases “one example,” “another example,” “one or more examples,” and similar wording throughout this disclosure may or may not refer to the same example. Furthermore, the subject matter of the invention characterizing any one example may or may not include the subject matter of the invention characterizing any other example. Furthermore, the subject matter of the invention characterizing any one example may or may not be combined with the subject matter of the invention characterizing any other example.

[0014] Referring to Figures 1-8 as an example, this disclosure relates to a system 100 for inspecting a structure 102. System 100 enables automated laser ultrasonic non-destructive testing and evaluation of the structure 102, resulting in increased capabilities of the laser ultrasonic inspection equipment.

[0015] Refer to Figures 1 and 2, which show an example of an inspection environment 190. An inspection environment 190 includes a system 100 and a structure 102. An inspection environment 190 is an example of an operating environment used by the system 100 to inspect, evaluate, or test the structure 102. In one or more examples, the system 100 includes a laser ultrasonic device 104, a robotic arm 110, a multiplex controller 114, and a computer system 118. In one or more examples, the structure 102 includes any articles, objects, parts, or components that are inspected, evaluated, or tested using the system 100. In one or more examples, the structure 102 is a composite structure.

[0016] The laser ultrasonic device 104 is configured to direct a laser beam 194 (Figure 1) towards the surface 112 of the structure 102. The laser beam 194 is configured to generate ultrasonic waves 106 within the structure 102. For example, the laser beam 194 has energy that causes the ultrasonic waves 106 to propagate through the structure 102. The laser beam 194 is also used to detect the response 208 (Figure 2) to the ultrasonic waves 106. For example, the laser beam 194 is also transmitted to the surface 112 in a manner that does not generate ultrasonic waves within the structure 102, and a portion of the laser beam 194 that is returned to the laser ultrasonic device 104 and detected contains information used to identify the response 208 to the ultrasonic waves 106. The laser ultrasonic device 104 is further configured to generate an array 108 (Figure 2) of ultrasonic data representing the ultrasonic waves 106.

[0017] In one or more examples, the laser ultrasonic device 104 includes an optical head 196. The optical head 196 is configured to emit laser light 194 (Figure 1) in the form of pattern 212 (Figure 1) onto the surface 112 of the structure 102. In one or more examples, the optical head 196 functions as a laser transmitter configured to direct the laser light 194 onto the surface 112, and a laser receiver is configured to receive a portion of the laser light 194 that is returned (e.g., reflected) from the surface 112 and used to detect a response 208.

[0018] The robotic arm 110 is configured to move the laser beam 194 across the surface 112 of the structure 102. In one or more examples, the optical head 196 is coupled to an end of the robotic arm 110, such as in the form of an end effector (as shown, for example, in FIG. 1). In one or more examples, the robotic arm 110 is configured to move the optical head 196 about several axes with respect to the surface 112 of the structure 102 such that the pattern 212 of the laser beam 194 is moved across the surface 112 (e.g., along the scan path 160). In one or more examples, the robotic arm 110 is a scanning robotic arm. For example, the robotic arm 110 is a robotic movement system commercially available from KUKA Robotics. In other examples, different types of movement systems, such as a gantry robot or other suitable automated movement system 240 (as shown, for example, in FIGS. 4 - 7), are used to move the optical head 196.

[0019] In one or more examples, the optical head 196 is configured to transmit (e.g., emit and / or direct) a generation laser light 202 (FIG. 2) to the surface 112 of the structure 102. The generation laser light 202 is an example of the laser beam 194 (FIG. 1) and is also referred to as an excitation laser light. In one or more examples, the generation laser light 202 is transmitted in a manner that forms a first pattern 218 (FIG. 2) on the surface 112 of the structure 102. The first pattern 218 of the generation laser light 202 is several regions of the surface 112 irradiated by the generation laser light 202. The regions of the surface 112 can have any shape, such as circular, elliptical, square, diagonal, or other shapes. In one or more examples, the first pattern 218 of the generation laser light 202 takes the form of points. In one or more examples, the first pattern 218 of the generation laser light 202 takes the form of a continuous line segment or a discontinuous line segment. For example, a continuous line segment is a series of continuous regions, and a discontinuous line segment is a series of discontinuous regions. In other examples, the first pattern 218 has a shape similar to a rectangle or other suitable shape.

[0020] The generated laser beam 202 is configured to generate ultrasonic waves 106 within the structure 102 when the generated laser beam 202 encounters the structure 102. For example, the ultrasonic waves 106 are generated when the generated laser beam 202 is transmitted to the surface 112. In one or more examples, the energy of the generated laser beam 202 causes thermoplastic expansion in the structure 102. Due to the thermoplastic expansion, ultrasonic waves 106 are generated within the structure 102. The ultrasonic waves 106 are ultrasonic signals having a frequency that depends on a particular implementation, such as the material used to form the structure 102, the pulse width of the generated laser beam 202, and other factors. In one or more examples, the generated laser beam 202 takes the form of a pulsed laser beam. The generated laser beam 202 has an arbitrary appropriate wavelength, such as about 1053 nm.

[0021] The laser ultrasonic device 104 is configured to detect the material response to the ultrasonic waves 106 traveling within the structure 102. Generally, the material response includes ultrasonic signals or ultrasonic waves that result from scattering, reflection, modulation, and other changes to the ultrasonic waves 106 traveling within the structure 102. In one or more examples, the material response to the ultrasonic waves 106 is detected by transmitting a detection laser beam 204 (FIG. 2) to the surface 112 of the structure 102 and detecting a response 208 (FIG. 2) formed by the detection laser beam 204.

[0022] In one or more examples, the optical head 196 is configured to transmit (e.g., emit and / or direct) detection laser light 204 (Figure 2) onto the surface 112 of the structure 102. Detection laser light 204 is an example of laser light 194 (Figure 1). In one or more examples, this detection laser light 204 is transmitted in such a way that it forms a second pattern 220 (Figure 2) on the surface 112 of the structure 102. The second pattern 220 of the detection laser light 204 is several areas of the surface 112 that are illuminated by the detection laser light 204. The areas of the surface 112 can have any shape, such as circular, elliptical, square, oblique, or other shapes. In one or more examples, the second pattern 220 of the detection laser light 204 takes the form of points. In one or more examples, the second pattern 220 of the detection laser light 204 takes the form of continuous or discontinuous line segments. In other examples, the second pattern 220 has a shape resembling a rectangle or other suitable shape. In one or more examples, the second pattern 220 substantially aligns with or overlaps with the first pattern 218.

[0023] The detection laser beam 204 is configured to form a response 208 (Figure 2). The response 208 is a portion of the detection laser beam 204 that is deflected by the ultrasonic wave 106, travels through the structure 102 to the surface 112, reflects from the surface 112 of the structure 102 and returns to the optical head 196. For example, the ultrasonic wave 106 undergoes changes such as scattering, reflection, and modulation as it travels through the structure 102, causing mechanical vibrations on the surface 112. These mechanical vibrations on the surface 112 are detected by the response 208. In one or more examples, the detection laser beam 204 has any suitable wavelength, such as about 1550 nm.

[0024] In one or more examples, the laser ultrasonic device 104 includes a generating laser unit 198 and a detection laser unit 200. The generating laser unit 198 is configured to generate and transmit a generating laser beam 202 (Figure 2). The detection laser unit 200 is configured to generate and transmit a detection laser beam 204 (Figure 2) and to detect the detection laser beam 204 returned in response 208.

[0025] In one or more examples, the generating laser unit 198 is optically coupled to the optical head 196 via an optical communication link 206 (Figure 1) to transmit the generated laser light 202 to the optical head 196. In one or more examples, the generating laser unit 198 is separate from the optical head 196. For example, the generating laser unit 198 is optical fiber based and includes a generating laser light source 224 (Figure 1) and several generating laser optical fibers 214 (Figure 1), such as an array of generating laser optical fibers 214.

[0026] In one or more examples, the generating laser unit 198 is optically coupled to the optical head 196 via an optical communication link 206 (Figure 1) to transmit the generated laser light 202 to the optical head 196. In one or more examples, the generating laser unit 198 is separate from the optical head 196. For example, the generating laser unit 198 is optical fiber based and includes a generating laser light source 224 (Figure 1) and several generating laser optical fibers 214 (Figure 1), such as an array of generating laser optical fibers 214.

[0027] In one or more examples, the generating laser light source 224 includes a laser generator, a laser diode array, or another light source for the generated laser light 202. In one or more examples, the generating laser light source 224 is a diode pump laser that generates and emits pulsed laser light.

[0028] In one or more examples, the detection laser unit 200 is optically coupled to the optical head 196 via an optical communication link 206 (Figure 1) to transmit detection laser light 204 to the optical head 196 and receive a response 208 from the optical head 196. In one or more examples, the detection laser unit 200 is located away from the optical head 196. For example, the detection laser unit 200 is optical fiber based and includes a detection laser light source 226 (Figure 1), an interferometer 228, and several detection laser optical fibers 216 (Figure 1), such as an array of detection laser optical fibers 216.

[0029] The detection laser light source 226 is configured to generate detection laser light 204 (Figure 2). The interferometer 228 is configured to identify information from the detection laser light 204 that forms a response 208. Furthermore, the interferometer 228 is configured to generate an array 108 of ultrasonic data representing the ultrasonic wave 106. The interferometer 228 is also configured to transmit the array 108 of ultrasonic data to the multiplex controller 114. The detection laser optical fiber 216 is configured to receive the detection laser light 204 from the detection laser light source 226 and transmit the detection laser light 204 to the optical head 196. In one or more examples, the plurality of detection laser optical fibers 216 form at least a portion of the optical output 232 of the optical head 196 (as shown, for example, in Figures 4-7) so that the detection laser beam 204 is directed onto the surface 112 of the structure 102 in the form of a second pattern 220. The detection laser optical fibers 216 are also configured to receive the detection laser beam 204 from the optical head 196, which forms a response 208, and to transmit the response 208 to the interferometer 228. In one or more examples, the plurality of detection laser optical fibers 216 receive the return portion of the detection laser beam 204 which forms a response 208 corresponding to each region of the surface 112 of the structure 102 forming the second pattern 220.

[0030] In one or more examples, the detection laser light source 226 includes a laser generator, a laser diode array, or another light source for the detection laser light 204. In one or more examples, the generating laser light source 224 is a diode pump laser that generates and emits pulsed laser light. In one or more examples, the interferometer 228 includes several interferometers. In one or more examples, the interferometer 228 is a Sagnac interferometer.

[0031] The computer system 118 is coupled to and communicates with the robot arm 110 and the multiplex controller 114. The computer system 118 is configured to provide operation commands to the robot arm 110 and the multiplex controller 114. The multiplex controller 114 provides a communication and control interface between the computer system 118, the laser ultrasonic device 104, and the robot arm 110 during inspection operations. For example, the multiplex controller 114, in accordance with the commands of the computer system 118 and based on the position information of the robot arm 110, controls the timing of transmitting the generated laser beam 202 (Figure 2) to the surface 112 of the structure 102 to generate ultrasound 106. In another example, the multiplex controller 114 receives an array of ultrasound data 108 and transmits the array of ultrasound data 108 to the computer system 118 for processing.

[0032] In one or more examples, the multiplex controller 114 is configured to trigger the generation of ultrasound 106 within the structure 102 at the inspection position 116 of the structure 102. The multiplex controller 114 is further configured to receive an array 108 of ultrasound data for the inspection position 116 from the laser ultrasound device 104. The use of the multiplex controller 114 allows control of the operation of the generating laser unit 198 and the detection laser unit 200 using a single controller. The use of the multiplex controller 114 also facilitates signal processing of multiple data channels corresponding to the array 108 of ultrasound data provided by the detection laser unit 200 during inspection.

[0033] The multiplex controller 114 is coupled to the laser ultrasonic device 104 (e.g., a generating laser unit 198 and a detection laser unit 200). In one or more examples, the generating laser unit 198 is coupled to and communicates with the multiplex controller 114 via a data communication link 210 (Figure 1), such as several wired connections, several wireless connections, or a combination thereof. In one or more examples, the detection laser unit 200 is coupled to and communicates with the multiplex controller 114 via a data communication link 210, such as several wired connections, several wireless connections, or a combination thereof.

[0034] In one or more examples, the multiplex controller 114 includes a trigger module 126. The trigger module 126 is configured to transmit a trigger signal 128 (Figure 2) to a laser ultrasonic device 104. The trigger signal 128 is configured to trigger the generation of ultrasound 106 within the structure 102 at the inspection position 116. For example, the multiplex controller 114 transmits the trigger signal 128 to the generating laser unit 198 when the optical head 196 is over the inspection position 116. In response to the trigger signal 128, the generating laser unit 198 generates a generating laser beam 202 (Figure 2) and transmits it to the optical head 196 for transmission to the surface 112 of the structure 102 at the inspection position 116.

[0035] In one or more examples, the multiplex controller 114 includes an array receiver 130. The array receiver 130 is configured to receive an array 108 of ultrasonic data from the laser ultrasonic device 104. The array receiver 130 includes multiple receiver elements, such as a phased array of receiver elements. The array receiver 130 enables the multiplex controller 114 to receive the array 108 of ultrasonic data from the detection laser unit 200 (e.g., interferometer 228) using multiple individual data channels, such as up to 128 channels. For example, detection laser light 204 is transmitted from an optical head 196, such as from an array of detection laser optical fibers 216 (Figure 1), as an array of detection laser beams that form an array of detection spots (e.g., a second pattern 220) on the surface 112 of the structure 102. The interferometer 228 receives and detects the response 208 associated with each of the array of detection laser beams of detection laser light 204. The interferometer 228 generates an array 108 of ultrasonic data corresponding to the ultrasonic signal responses detected at different spots on the surface 112 to the ultrasonic waves 106 that have propagated through the structure 102 and returned to the surface 112. The array of ultrasonic data 108 corresponding to the response 208 associated with each of the array of detected laser beams is transmitted from the interferometer 228 along multiple individual data channels to the array receiver 130 of the multiplex controller 114. Thus, the array receiver 130 of the multiplex controller 114 can simultaneously receive responses 208 from different spots on the surface 112 and link the responses 208 in a timely manner.

[0036] In one or more examples, the multiplex controller 114 is configured to synchronize the transmission of a trigger signal 128 (Figure 2) with the reception of an array of ultrasonic data 108 (Figure 2). The synchronization of the transmission of the trigger signal 128 with the reception of the array of ultrasonic data 108 is primarily due to the difference between the speed of the laser beam 194 (Figure 1) (e.g., generated laser beam 202) (Figure 2) transmitted from the optical head 196 and the processing speed of the array receiver 130 that receives the array of ultrasonic data 108. For example, without such synchronization, the generated laser beam 202 may generate an ultrasonic wave 106, which may be detected by the detection laser beam 204, before the multiplex controller 114 is ready to receive the array of ultrasonic data 108 from the laser ultrasonic device 104.

[0037] In one or more examples, the synchronous operation of the transmitter (e.g., the trigger module 126 and / or generating laser unit 198 shown in Figure 2) to the receiver (e.g., the array receiver 130 and / or detection laser unit 200 shown in Figure 2) is essential to compensate for various electronic delays that may occur in one or both of the transmitting and / or receiving electronics of the multiplex controller 114, generating laser unit 198, and / or detection laser unit 200. For example, since the transmitting and / or receiving electronics are different modules and are physically external to each other, the synchronous operation ensures that they work together. In other words, the synchronous operation prevents the transmitter from emitting before the receiver is ready to receive the ultrasonic data. Furthermore, in one or more examples, the activation signal 170 links the multiplex controller 114 to a robot position generated from a 3D model 164, and the multiplex controller 114 links to the generating laser unit 198 via the synchronous operation. This is a configuration illustrating how different modules form system 100.

[0038] In one or more examples, the multiplex controller 114 includes a clock 132 (Figure 2). The clock 132 is configured to delay the transmission of a trigger signal 128 from the trigger module 126 by a predetermined period. In one or more examples, a computer system 118 is configured or adapted to generate an activation signal 170 (Figure 2) that is transmitted to the multiplex controller 114. In response to the activation signal 170, the multiplex controller 114 generates a trigger signal 128 and prepares to receive an array of ultrasonic data 108. The clock 132 delays the transmission of the trigger signal 128 to the laser ultrasonic device 104 (e.g., generating laser unit 198) by a predetermined period until the array receiver 130 of the multiplex controller 114 is ready to receive the array of ultrasonic data 108. In one or more examples, the predetermined period of delay is approximately 20 microseconds (µs). In one or more examples, the clock 132 is implemented using hardware, software, firmware, or a combination thereof (e.g., a timing module). Delaying the transmission of the trigger signal 128 using clock 132 is an example of implementing the synchronous operation described above.

[0039] In one or more examples, the multiplex controller 114 includes a signal conditioner module 134 (Figure 2). The signal conditioner module 134 is configured to apply appropriate signal conditioning to the trigger signal 128 provided to the generating laser unit 198 to generate the generated laser beam 202 (Figure 2). In one or more examples, the signal conditioner module 134 is configured to modify at least one of the period, waveform, and voltage of the trigger signal 128 for use by the laser ultrasonic device 104.

[0040] In one or more examples, the signal adjustment module 134 is configured to modify the trigger signal 128 to delay its transmission to the laser ultrasonic device 104 by a predetermined period. For example, the signal adjustment module 134 modifies one or more parameters of the trigger signal 128 so that the laser ultrasonic device 104 (e.g., generating laser unit 198) receives the trigger signal 128 after the array receiver 130 of the multiplex controller 114, which receives the array of ultrasonic data 108, is ready. Delaying the transmission of the trigger signal 128 using the signal adjustment module 134 is an example of implementing the synchronous operation described above.

[0041] In one or more examples, the multiplex controller 114 includes an analog / digital ("A / D") module 192. The analog / digital module 192 is configured to convert analog signals or data, such as those output by the laser ultrasonic device 104 or other ultrasonic device, into digital signals or data suitable for processing by the computer system 118. The analog / digital module 192 is any suitable type of analog-to-digital converter.

[0042] In one or more examples, the multiplex controller 114 includes various other operating and control elements. In one or more examples, the multiplex controller 114 is a phased array ultrasound receiver that provides data acquisition and data analysis capabilities for fully automated ultrasound operation. In one or more examples, the multiplex controller 114 is implemented using hardware, software, firmware, or a combination thereof. For example, the multiplex controller 114 is the FOCUS PX device commercially available from Olympus.

[0043] In one or more examples, the multiplex controller 114 allows for a simple and easy expansion of the system 100 to accommodate additional ultrasound devices, as described in more detail herein and illustrated in Figures 4-7. For example, multiple response signals (e.g., response 208) generated from each of the multiple ultrasound devices are received and processed by the same multiplex controller 114.

[0044] Referring to Figure 3, this schematically illustrates an example of system 100 operating within a safety zone 138, in which a robotic arm 110 moves the optical head 196 of the laser ultrasonic device 104 against the surface 112 of the structure 102 during the inspection operation. In one or more examples, the laser ultrasonic device 104 includes an integral shutoff mechanism that terminates the transmission of laser light 194 to prevent injury to the eyes of a human operator 242 located within the inspection environment 190.

[0045] In one or more examples, system 100 includes a safety sensor 136. The safety sensor 136 is coupled to and communicates with a computer system 118. The safety sensor 136 is configured to detect intrusion of the laser ultrasonic device 104 into a safety zone 138. The computer system 118 is configured to automatically shut off the power supply to the laser ultrasonic device 104 in response to the safety sensor 136 detecting intrusion of the laser ultrasonic device 104 into the safety zone 138.

[0046] In one or more examples, the safety sensor 136 is configured to detect operator 242's intrusion into the safety zone 138. The computer system 118 is configured to automatically shut off power to the laser ultrasonic device 104 in response to the safety sensor 136 detecting operator 242's intrusion into the safety zone 138.

[0047] The use of safety zone 138 and automatic stopping of laser beam 194 ensure that a sufficient nominal eye obstruction distance is maintained during inspection operations by preventing the output of laser beam 194 from exceeding the minimum safety threshold formed by safety zone 138. The minimum threshold distance 246 between the output of laser beam 194 and the human operator 242 may depend on various factors such as the classification of the laser generating the laser beam 194 and / or the wavelength and power of the laser beam 194. In one or more examples of the fiber optic-based lasers of system 100, the minimum threshold distance 246 is approximately 2 meters.

[0048] In one or more examples, the inspection environment 190 includes an inspection station 244. The inspection station 244 is used to inspect, test, or otherwise evaluate a structure 102 using the system 100. The inspection station 244 is associated with or includes a robotic arm 110; at least a portion of a laser ultrasonic device 104 (e.g., an optical head 196 coupled to the robotic arm 110); the structure 102 to be inspected; safety sensors 136; and any other machine tools or support tools used in connection with the inspection operation. Generally, during the inspection operation, the robotic arm 110, the optical head 196, and the structure 102 are located inside the inspection station 244, while the operator 242 is located outside the inspection station 244.

[0049] In one or more examples, the safety zone 138 includes an outer boundary 248 defining the perimeter of the inspection station 244 and an inner boundary 250 spaced apart from the outer boundary 248. Generally, the safety zone 138 is a three-dimensional volume of space where a potential eye hazard may exist for at least a portion of the inspection operation.

[0050] In one or more examples, the safety zone 138 is established by or associated with a single safety sensor 136. In one or more examples, the safety zone 138 is established by or associated with multiple safety sensors 136 (as illustrated, for example, in Figure 3).

[0051] In one or more examples, the safety zone 138 corresponds to the field of view or sensing zone of the safety sensor 136. For example, the safety sensor 136 has an intrinsic or adjustable three-dimensional spatial volume corresponding to the safety sensor 136, within which the safety sensor 136 can detect the presence of the robot arm 110, the optical head 196, and / or the operator 242.

[0052] In one or more examples, the inner boundary 250 of the safety zone 138 corresponds to the field of view or sensing zone of the safety sensor 136 (e.g., the inner set of safety sensors). For example, the safety sensor 136 has an intrinsic or adjustable two-dimensional region space corresponding to the safety sensor 136, and across this region, the safety sensor 136 can detect the presence of the robot arm 110 and / or optical head 196. As an example, the safety sensor 136 generates a laser light curtain 252 that forms the inner boundary 250 of the safety zone 138.

[0053] In one or more examples, the outer boundary 248 of the safety zone 138 is formed by a safety structure 254 (e.g., a safety cage) constructed around the perimeter of the inspection station 244. The safety structure 254 provides a physical barrier between the operator 242 and the safety zone 138. Alternatively, in one or more examples, the outer boundary 248 of the safety zone 138 corresponds to the field of view or sensing zone of a safety sensor 136 (e.g., the outer set of safety sensors). For example, the safety sensor 136 has a two-dimensional domain space corresponding to the safety sensor 136, across which the safety sensor 136 can detect the presence of the operator 242. As an example, the safety sensor 136 generates a laser beam curtain 252 that forms the outer boundary 248 of the safety zone 138.

[0054] The safety sensor 136 includes or takes the form of any suitable type of sensing device configured to at least partially detect the presence of the robot arm 110, the optical head 196, and / or the operator 242 within the safety zone 138. Examples of the safety sensor 136 include, but are not limited to, optical cameras, optical sensors, infrared cameras, infrared sensors, laser sensors, through-beam sensors, area scanners, and / or combinations thereof.

[0055] The use of safety sensors 136 and optionally safety structures 254 to form a safety zone 138 allows the inspection station 244 to be made movable and / or resizable depending on the specific implementation or inspection needs. Thus, the inspection station 244 is portable and adjustable, which beneficially provides operational flexibility to the system 100.

[0056] In one or more examples, the system 100 includes a movable platform 256. The robotic arm 110 is coupled to a movable platform 256. The movable platform 256 is configured to move the robotic arm 110 relative to a structure 102, for example, within an inspection station 244. In one or more examples, the movable platform 256 is a component of a moving system 240 (Figures 4-7). In one or more examples, the movable platform 256 is configured to move along a track 258 located within the inspection station 244. The use of the movable platform 256 provides the system 100 with greater flexibility and portability.

[0057] Refer to Figures 4 and 5, which schematically show some examples of a system 100 incorporating an ultrasonic transducer device 140 during inspection. In one or more examples, system 100 uses a multiplex controller 114 to integrate laser-based ultrasonic inspection and transducer-based ultrasonic inspection for inspecting a structure 102. In one or more examples, system 100 includes an ultrasonic transducer device 140.

[0058] As shown in Figure 4, in one or more examples, the ultrasonic transducer device 140 is configured to generate a second array of ultrasonic data 142 representing the ultrasound 106. A multiplex controller 114 is coupled to the ultrasonic transducer device 140. The multiplex controller 114 is configured to receive the second array of ultrasonic data 142 for the inspection position 116 from the ultrasonic transducer device 140.

[0059] In one or more examples, the ultrasonic transducer device 140 includes at least one ultrasonic transducer. In one or more examples, the ultrasonic transducer device 140 includes an array of ultrasonic transducers (e.g., a two-dimensional array). The ultrasonic transducer device 140 is configured to detect the response to the ultrasonic waves 106 generated by the generated laser light 202. For example, the ultrasonic transducer is configured to receive an ultrasonic signal propagating through the structure 102 in response to the ultrasonic waves 106.

[0060] In one or more examples, the use of an ultrasonic transducer device 140 enables the detection of ultrasound 106 and inspection of the structure 102 from a secondary position, thereby providing additional data (e.g., a second array of ultrasound data 142 for the inspection position 116) used to evaluate the structure 102. For example, as shown in Figure 4, the ultrasonic transducer device 140 is positioned at the inspection position 116 relative to a second surface 234 of the structure 102, such as on the opposite side of the laser ultrasound device 104. In one or more examples, the laser ultrasound device 104 detects the ultrasound 106 propagating through the structure 102 and returning to the surface 112, and the ultrasonic transducer device 140 detects the ultrasound 106 propagating through the structure 102 to the second surface 234.

[0061] In one or more examples, the array receiver 130 (Figure 2) of the multiplex controller 114 is configured to receive a second array of ultrasonic data 142 from the ultrasonic transducer device 140. The array receiver 130 enables the multiplex controller 114 to receive an array of ultrasonic data 108 from the laser ultrasonic device 104 and a second array of ultrasonic data 142 from the ultrasonic transducer device 140 using multiple individual data channels. Thus, the array receiver 130 of the multiplex controller 114 makes it possible to simultaneously detect responses to the ultrasound 106 at different spots on surface 112 and the second surface 234 and to link these responses in a timely manner.

[0062] As shown in Figure 5, in one or more examples, an ultrasonic transducer device 140 is configured to generate a second ultrasonic wave 144 within the structure 102. The ultrasonic transducer device 140 is further configured to generate a third ultrasonic data array 146 representing the second ultrasonic wave 144. A multiplex controller 114 is configured to trigger the generation of the second ultrasonic wave 144 within the structure 102 at a second inspection location 148 of the structure 102. The multiplex controller 114 is further configured to receive the third ultrasonic data array 146 for the second inspection location 148 from the ultrasonic transducer device 140.

[0063] In one or more examples, the ultrasonic transducer device 140 is configured to detect a response to a second ultrasonic wave 144 generated by the ultrasonic transducer device 140. For example, at least one of the ultrasonic transducers (e.g., transmitting transducers) of the ultrasonic transducer device 140 is configured to transmit an ultrasonic signal to a structure 102 that generates a second ultrasonic wave 144 within the structure 102. At least one of the ultrasonic transducers (e.g., receiving transducers) of the ultrasonic transducer device 140 is configured to receive an ultrasonic signal that has propagated through the structure 102 and returned in response to the second ultrasonic wave 144.

[0064] In one or more examples, the use of the ultrasonic transducer device 140 enables the detection of a second ultrasound 144 (e.g., a different type of ultrasound), inspection of the structure 102 at a second inspection position 148, and / or inspection of the structure 102 from a secondary position, thereby providing additional data used to evaluate the structure 102 (e.g., an array of third ultrasound data 146 for the second inspection position 148). For example, as shown in Figure 5, the ultrasonic transducer device 140 is positioned at a second inspection position 148 relative to a second surface 234 of the structure 102, such as on the opposite side of the laser ultrasound device 104. In one or more examples, the laser ultrasound device 104 detects the ultrasound 106 propagating through the structure 102 and returning to the surface 112, and the ultrasonic transducer device 140 detects the ultrasound 114 propagating through the structure 102 and returning to the second surface 234.

[0065] In one or more examples, the trigger module 126 (Figure 2) of the multiplex controller 114 is configured to transmit a second trigger signal 236 to the ultrasonic transducer device 140. The second trigger signal 236 is configured to trigger the generation of a second ultrasonic wave 144 within the structure 102 at a second inspection position 148. For example, the multiplex controller 114 transmits the second trigger signal 236 to the transmitting transducer of the ultrasonic transducer device 140 when the ultrasonic transducer device 140 is over the second inspection position 148. In response to the second trigger signal 236, the transmitting transducer transmits an ultrasonic signal to the surface 112 of the structure 102 at the second inspection position 148.

[0066] In one or more examples, the array receiver 130 (Figure 2) of the multiplex controller 114 is configured to receive a third array of ultrasonic data 146 from the ultrasonic transducer device 140. The array receiver 130 enables the multiplex controller 114 to receive an array of ultrasonic data 108 from the laser ultrasonic device 104 and a third array of ultrasonic data 146 from the ultrasonic transducer device 140 using multiple individual channels. Thus, the array receiver 130 of the multiplex controller 114 makes it possible to simultaneously detect the responses to the ultrasonic 106 and the second ultrasonic 114 at different spots on surface 112 and the second surface 234 and to link these responses in a timely manner.

[0067] In one or more examples, multiple ultrasound devices (e.g., one or more laser ultrasound devices 104 and one or more ultrasound transducer devices 140) are synchronized to a single multiplex controller 114, for example, as described above. For example, the multiplex controller 114 sequences its inputs (#1, #2, #3, etc.) after a corresponding one of the multiple ultrasound devices is triggered. In this example, there is one trigger signal for each of the multiple ultrasound devices (e.g., trigger signal 128 and a second trigger signal 236, as shown in Figure 5).

[0068] In one or more examples, system 100 includes a mobile system 240. The mobile system 240 is configured to move the ultrasonic transducer device 140 relative to the structure 102, such as across a second surface 234, during inspection operations. In one or more examples, the mobile system 240 includes or takes the form of a robot, such as a scanning robot arm similar to the robot arm 110 associated with the laser ultrasonic device 104.

[0069] In the example shown in Figure 5, the inspection position 116 and the second inspection position 148 are different. However, in other examples, the inspection location 116 and the second inspection location 148 are approximately the same or at least partially overlapping. In such examples, the laser ultrasonic device 104 detects the ultrasound 106 propagating through the structure 102 and returning to the surface 112, and the second ultrasound 144 propagating through the structure 102 and returning to the surface 112. The ultrasonic transducer device 140 detects the second ultrasound 144 propagating through the structure 102 and returning to the second surface 234, and the ultrasound 106 propagating through the structure 102 to the second surface 234. In one or more examples, the ultrasound 106 and the second ultrasound 144 are different types of ultrasound. The example shown in Figure 5 depicts an ultrasonic transducer device 140 positioned at a second inspection position 148 relative to a second surface 234 of the structure 102, but in other examples, the ultrasonic transducer device 140 may be positioned at a second inspection position 148 relative to surface 112 of the structure 102 or another surface of the structure 102 during the inspection operation.

[0070] Refer to Figures 6 and 7, which schematically show some examples of the system 100 incorporating a second laser ultrasonic device 150. In one or more examples, the system 100 utilizes a multiplex controller 114 to integrate multiple laser-based ultrasonic inspections for inspecting a structure 102. In one or more examples, the system 100 includes a second laser ultrasonic device 150.

[0071] As shown in Figure 6, in one or more examples, the second laser ultrasound device 150 is configured to generate a fourth array of ultrasound data 152 representing ultrasound 106. A multiplex controller 114 is coupled to the second laser ultrasound device 150. The multiplex controller 114 is configured to receive the fourth array of ultrasound data 152 for the inspection position 116 from the second laser ultrasound device 150.

[0072] In one or more examples, the second laser ultrasonic device 150 includes at least a second detection laser unit and a second optical head configured to generate detection laser light 204, transmit it to a second surface 234, and receive the return portion of the detection laser light 204 that forms a response 208, similar to the detection laser unit 200 and optical head 196 of the laser ultrasonic device 104. For example, the second laser ultrasonic device 150 is configured to detect an ultrasonic signal propagating through a structure 102 in response to an ultrasonic wave 106.

[0073] In one or more examples, the use of a second laser ultrasonic device 150 enables the detection of ultrasound 106 and inspection of the structure 102 from a secondary position, thereby providing additional data (e.g., a fourth array of ultrasound data 152 for the inspection position 116) used to evaluate the structure 102. For example, as shown in Figure 6, the second laser ultrasonic device 150 is positioned at the inspection position 116 relative to a second surface 234 of the structure 102, such as on the opposite side of the laser ultrasonic device 104. In one or more examples, the laser ultrasonic device 104 detects the ultrasound 106 propagating through the structure 102 and returning to the surface 112, and the second laser ultrasonic device 150 detects the ultrasound 106 propagating through the structure 102 to the second surface 234.

[0074] In one or more examples, the array receiver 130 (Figure 2) of the multiplex controller 114 is configured to receive a fourth array of ultrasonic data 152 from a second laser ultrasonic device 150. The array receiver 130 enables the multiplex controller 114 to receive an array of ultrasonic data 108 from the laser ultrasonic device 104 and a fourth array of ultrasonic data 152 from the second laser ultrasonic device 150 using multiple individual data channels. Thus, the array receiver 130 of the multiplex controller 114 makes it possible to simultaneously detect responses to ultrasonic waves 106 at different spots on surface 112 and the second surface 234 and to link these responses in a timely manner.

[0075] In one or more examples, the multiplex controller 114 is configured to synchronize the transmission of a trigger signal 128 to the laser ultrasonic device 104 with the reception of a fourth ultrasonic data array 152 from the second laser ultrasonic device 150. The synchronization of the transmission of the trigger signal 128 with the reception of the ultrasonic data array 152 is primarily due to the difference between the speed of the generated laser light 202 transmitted from the optical head 196 and the processing speed of the array receiver 130 that receives the fourth ultrasonic data array 152.

[0076] As shown in Figure 7, in one or more examples, a second laser ultrasonic device 150 is configured to generate a third ultrasonic wave 154 within the structure 102. The second laser ultrasonic device 150 is further configured to generate a fifth ultrasonic data array 156 representing the third ultrasonic wave 154. A multiplex controller 114 is configured to trigger the generation of the third ultrasonic wave 154 within the structure 102 at a third inspection position 158 of the structure 102. The multiplex controller 114 is further configured to receive the fifth ultrasonic data array 156 for the third inspection position 158 from the second laser ultrasonic device 150.

[0077] In one or more examples, the second laser ultrasonic device 150 includes a second generating laser unit configured to generate a generating laser beam 202 that generates a third ultrasonic wave 154 within the structure, similar to the generating laser unit 198 of the laser ultrasonic device 104, and transmit it to the second surface 234. For example, the second laser ultrasonic device 150 is configured to detect an ultrasonic signal propagating through the structure 102 in response to the third ultrasonic wave 154 generated by the second laser ultrasonic device 150.

[0078] In one or more examples, the use of a second laser ultrasonic device 150 enables the detection of a third ultrasound 154 (e.g., a different type of ultrasound), inspection of the structure 102 at a third inspection position 158, and / or inspection of the structure 102 from a secondary position, thereby providing additional data used to evaluate the structure 102 (e.g., an array of fifth ultrasound data 156 for the third inspection position 158). For example, as shown in Figure 7, the second laser ultrasonic device 150 is positioned at a second inspection position 148 relative to a second surface 234 of the structure 102, such as on the opposite side of the laser ultrasonic device 104. In one or more examples, the laser ultrasonic device 104 detects the ultrasound 106 propagating through the structure 102 and returning to the surface 112, and the second laser ultrasonic device 150 detects the third ultrasound 154 propagating through the structure 102 and returning to the second surface 234.

[0079] In one or more examples, the trigger module 126 (Figure 2) of the multiplex controller 114 is configured to transmit a third trigger signal 238 to the second ultrasonic device 150. The third trigger signal 238 is configured to trigger the generation of a third ultrasonic wave 154 within the structure 102 at a third inspection position 158. For example, the multiplex controller 114 transmits the third trigger signal 238 to the second generating laser unit of the second laser ultrasonic device 150 when the second optical head of the second laser ultrasonic device 150 is over the third inspection position 158.

[0080] In one or more examples, the array receiver 130 (Figure 2) of the multiplex controller 114 is configured to receive an array 156 of fifth ultrasonic data from a second laser ultrasonic device 150. The array receiver 130 enables the multiplex controller 114 to receive an array 108 of ultrasonic data from the laser ultrasonic device 104 and an array 156 of fifth ultrasonic data from the second ultrasonic device 150 using multiple individual channels. Thus, the array receiver 130 of the multiplex controller 114 makes it possible to simultaneously detect responses to ultrasonic waves 106 and the third ultrasonic wave 154 at different spots on surface 112 and the second surface 234 and to link these responses in a timely manner.

[0081] In one or more examples, the multiplex controller 114 is configured to synchronize the transmission of a third trigger signal 238 to a second laser ultrasonic device 150 with the reception of a fifth ultrasonic data array 156 from the second laser ultrasonic device 150. The synchronization of the transmission of the third trigger signal 238 and the reception of the fifth ultrasonic data array 156 is primarily due to the difference between the speed of the generated laser light 202 transmitted from the second optical head of the second laser ultrasonic device 150 and the processing speed of the array receiver 130 that receives the fifth ultrasonic data array 156. In one or more examples, the synchronization operation is performed using a clock 132 (Figure 2) and / or a signal adjustment module 134, as described above, to implement a transmission delay of a predetermined period.

[0082] In one or more examples, multiple ultrasound devices (e.g., one or more laser ultrasound devices 104 and one or more second laser ultrasound devices 150) are synchronized to a single multiplex controller 114, for example, as described above. For example, the multiplex controller 114 sequences its inputs (#1, #2, #3, etc.) after a corresponding one of the multiple ultrasound devices is triggered. In this example, there is one trigger signal for each of the multiple ultrasound devices (e.g., trigger signal 128 and a third trigger signal 238, as shown in Figure 7).

[0083] In one or more examples, the moving system 240 is configured to move the second optical head of the second laser ultrasonic device 150 relative to the structure 102 so that the detection laser beam 204 and the generation laser beam 202 move across the second surface 234 during the inspection operation. In one or more examples, the moving system 240 includes or takes the form of a robot, such as a scanning robot arm similar to the robot arm 110 associated with the laser ultrasonic device 104.

[0084] In the example shown in Figure 7, the inspection position 116 and the third inspection position 158 are different. However, in other examples, the inspection position 116 and the third inspection position 158 are approximately the same or at least partially overlap. In such examples, the laser ultrasonic device 104 detects the ultrasound 106 propagating through the structure 102 and returning to the surface 112, and the third ultrasound 154 propagating through the structure 102 and returning to the surface 112. The second laser ultrasonic device 150 detects the third ultrasound 154 propagating through the structure 102 and returning to the second surface 234, and the ultrasound 106 propagating through the structure 102 to the second surface 234. In one or more examples, the ultrasound 106 and the third ultrasound 154 are different types of ultrasound. The example shown in Figure 7 depicts a second laser ultrasonic device 150 positioned at a third inspection position 158 relative to a second surface 234 of the structure 102, but in other examples, the second laser ultrasonic device 150 may be positioned at a third inspection position 158 relative to surface 112 of the structure 102 or another surface of the structure 102 during the inspection operation.

[0085] It should be understood that system 100 can inspect any number of inspection positions (e.g., inspection position 116, second inspection position 148, third inspection position 158, fourth inspection position, etc.) by incorporating or utilizing any number of feasible laser ultrasonic devices (e.g., laser ultrasonic device 104, second laser ultrasonic device 150, third laser ultrasonic device, etc.) and ultrasonic transducer devices (e.g., ultrasonic transducer device 140, second ultrasonic transducer device, third ultrasonic transducer device, etc.). Advantageously, system 100 allows for the simultaneous collection of scan data and enables the multiplex controller 114 to receive ultrasonic data output from all devices.

[0086] Therefore, the use of the multiplex controller 114 enables the reception and processing of ultrasonic data from different types of ultrasonic testing equipment and links the ultrasonic data from different ultrasonic testing equipment to the same clock (e.g., clock 132). In addition, the use of the multiplex controller 114 facilitates modular functionality to the system 100 by enabling different types of ultrasonic testing equipment to inspect the same structure 102.

[0087] In one or more examples, multiple ultrasound devices (e.g., one or more laser ultrasound devices 104, one or more ultrasound transducer devices 140, and / or one or more second laser ultrasound devices 150) are synchronized to a single multiplex controller 114, for example, as described above. For example, the multiplex controller 114 sequences its inputs (#1, #2, #3, etc.) after a corresponding one of the multiple ultrasound devices is triggered. In this example, there is one trigger signal for each of the multiple ultrasound devices (e.g., trigger signal 128, a second trigger signal 236, and / or a third trigger signal 238, as shown in Figures 5 and 7).

[0088] Referring here to Figure 2, the computer system 118 is configured or adapted to provide the multiplex controller 114 with operational commands to control the laser ultrasonic device 104 and any other ultrasonic inspection devices such as the ultrasonic transducer device 140 (Figures 4 and 5) and / or the second laser ultrasonic device 150 (Figures 6 and 7). The computer system 118 is also configured or adapted to provide the robot arm 110 with operational commands to move the laser beam 194 (Figure 1) across the surface 112 of the structure 102 according to a predetermined scan path 160. The computer system 118 is further configured to inspect the structure 102 by processing the ultrasonic data array 108 and any other ultrasonic data such as the second ultrasonic data array 142 (Figure 4), the third ultrasonic data array 146 (Figure 5), the fourth ultrasonic data array 152 (Figure 6), and the fifth ultrasonic data array 156 (Figure 7).

[0089] In one or more examples, the computer system 118 includes a motion control module 120. The motion control module 120 is configured to control the movement of laser beams 194 relative to the surface 112 of the structure 102. For example, the motion control module 120 commands the robot arm 110 to move the optical head 196 to a desired position (e.g., three-dimensional arrangement and angular direction) relative to the surface 112 of the structure 102, so that the laser beams 194 transmitted from the optical head 196 have a predetermined offset distance 272 (e.g., as shown in Figure 8) and a predetermined collision angle 274. In one or more examples, the predetermined offset distance 272 between the optical outputs 232 (Figure 8) of the optical head 196 determines the focal position of the laser beams 194 (e.g., generated laser beam 202 and / or detected laser beam 204) on the surface 112 of the structure 102. In one or more examples, a predetermined collision angle 274 (Figure 8) of the laser beam 194 (e.g., the generated laser beam 202 and / or the detected laser beam 204) is perpendicular to the surface 112 of the structure 102.

[0090] In one or more examples, the motion control module 120 is configured to command the moving system 240 to control the movement of the ultrasonic transducer device 140 (e.g., Figures 4 and 5) relative to the structure 102. In one or more examples, the motion control module 120 is configured to command the moving system 240 to control the movement of laser light transmitted from a second laser ultrasonic device 150 (e.g., Figures 6 and 7).

[0091] In one or more examples, the computer system 118 includes a motion tracking module 122. The motion tracking module 122 is configured to determine when the optical head 196, and thus the laser beam 194, is in the inspection position 116. For example, the motion tracking module 122 is configured to receive position information of the robot arm 110 relative to the structure 102, such as position information of the tool center point of the robot arm 110 corresponding to the position (e.g., alignment and angular direction) of the laser beam 194 (Figure 1) transmitted to the surface 112 of the structure 102. In one or more examples, the motion tracking module 122 is configured to generate an activation signal 170 and transmit the activation signal 170 to the multiplex controller 114 in response to position information of the robot arm 110 indicating that the laser beam 194 is in the inspection position 116. Thus, the activation signal 170 is triggered by the position of the optical head 196 relative to the surface 112 of the structure 102. In one or more examples, the activation signal 170 is based on a 3D model 164 of the structure 102 (as shown, for example, in Figure 2).

[0092] In one or more examples, the motion tracking module 122 is configured to determine when the ultrasonic transducer device 140 (e.g., Figures 4 and 5) is at the inspection position 116 (e.g., Figure 4) or the second inspection position 148 (e.g., Figure 5). For example, the motion tracking module 122 is configured to receive position information of the mobile system 240 corresponding to the position of the ultrasonic transducer device 140 relative to the structure 102.

[0093] In one or more examples, the motion tracking module 122 is configured to determine when the laser beam transmitted from the second laser ultrasonic device 150 (e.g., Figures 6 and 7) is at the inspection position 116 (e.g., Figure 6) or the third inspection position 158 (e.g., Figure 7). For example, the motion tracking module 122 is configured to receive position information of the mobile system 240 corresponding to the position of the laser beam transmitted over the structure 102.

[0094] In one or more examples, the computer system 118 includes a path planning module 162. The path planning module 162 is configured to generate a scan path 160 for the movement of a laser beam 194 (Figure 1) across the surface 112 of a structure 102. In one or more examples, the scan path 160 is generated based on a three-dimensional model 164 of the structure 102. In one or more examples, the scan path 160 is a pre-planned path based on a three-dimensional model 164 of the structure 102.

[0095] In one or more examples, the three-dimensional model 164 of the structure 102 is generated by one of several different methods. In one or more examples, the three-dimensional model 164 is a nominal model representing the design shape of the structure 102. For example, the three-dimensional model 164 is generated using computer-aided design (CAD) implemented on a computer, such as computer system 118.

[0096] In one or more examples, the path planning module 162 is configured to determine trigger positions 166 along a scan path 160. The trigger positions 166 correspond to inspection positions 116 of the structure 102. In one or more examples, the path planning module 162 determines multiple trigger positions 166 along the scan path 160 corresponding to multiple if inspection positions. In one or more examples, the path planning module 162 sets multiple trigger positions 166 at predetermined intervals, such as predetermined distance intervals. For example, each of the trigger positions 166 may be set at intervals of 2 millimeters (mm), 4 mm, etc.

[0097] The path planning module 162 is also configured to determine the initial device position 168 of the optical head 196 of the laser ultrasonic device relative to the surface 112 of the structure 102 at the inspection position 116 for the generation of ultrasound 106 within the structure 102 and the generation of an array 108 of ultrasound data. For example, the path planning module 162 determines the initial device position 168 (e.g., position and angular direction) of the optical head 196 relative to the surface 112 of the structure 102 (e.g., position and angular direction) at the trigger position 166, which is a proper or appropriate position such that the optical head 196 is at a predetermined offset distance 272 (Figure 8) from the surface 112 and the laser beam 194 is at a predetermined collision angle 274 (Figure 8) from the surface 112.

[0098] The initial device position 168 is a relatively precise and accurate position of the optical head 196 of the laser ultrasonic device 104 relative to the surface 112. In one or more examples, the precision and accuracy of the initial device position 168 are achieved by creating a 3D model of the robot motion path (e.g., the scan path 160 shown in Figure 1). For example, the robot motion plan is created from the 3D model (e.g., the 3D model 164 shown in Figure 2) using vector software. Determined by the path planning module 162 and / or controlled by the motion control module 120, the initial device position 168 of the optical head 196 of the laser ultrasonic device 104 positions the laser ultrasonic device 104 at an initial motion position within a predetermined threshold of known and / or desired direction and / or offset relative to the surface 112 of the structure 102. In one or more examples, the initial device position 168 of the optical head 196 of the laser ultrasonic device 104 is within ±3 degrees of a known direction (e.g., a desired collision angle 274) relative to the surface 112 of the structure 102, and can therefore be referred to herein as the “precise” position. This precise and accurate initial positioning of the optical head 196 of the laser ultrasonic device 104 relative to the surface 112 serves as an enabler for the system 100.

[0099] In one or more examples, the motion control module 120 controls the movement of the optical head 196 of the laser ultrasonic device 104 using the scan path 160 and the initial device position 168. For example, the motion control module 120 commands the robotic arm 110 to move the optical head 196 across the surface 112 of the structure 102 so that the laser beam 194 moves across the surface 112 along the scan path 160. The motion control module 120 uses the initial device position 168 to command the robotic arm 110 to properly position the optical head 196 relative to the surface 112 so that a predetermined offset distance 272 and a predetermined collision angle 274 are maintained (e.g., constant) at each of the trigger positions 166 as the optical head 196, and thus the laser beam 194, moves along the scan path 160.

[0100] In one or more examples, the motion tracking module 122 is configured to use trigger positions 166 to determine when the optical head 196 of the laser ultrasonic device 104 is at an inspection position 116, and to send an activation signal 170 to the multiplex controller 114 when the optical head 196 is at the inspection position 116. In one or more examples, the motion tracking module 122 tracks the optical head 196 as it moves along the scan path 160 using position information provided in response to the movement of the robot arm 110. When the position information of the robot arm 110 indicates that the optical head 196 is at a trigger position 166, the motion tracking module 122 sends an activation signal 170 to the multiplex controller 114. For example, each trigger position 166 is located at a predetermined distance from one another along the scan path 160. When the position information of the robot arm 110 indicates that the optical head 196 has moved a predetermined distance, an activation signal 170 is sent to the multiplex controller 114.

[0101] In one or more examples, the movement and / or operation of additional or secondary ultrasound equipment (e.g., an ultrasonic transducer device 140 and / or a second laser ultrasound device 150) is controlled in substantially the same manner or technique as the control of the movement and / or operation of the laser ultrasound device 104 described herein. For example, the positioning of an arm-end tool (EOAT) of a robotic mobile system (e.g., a mobile system 240 and / or a robotic arm 110) is used to control the position, arrangement, orientation and movement of each of the multiple ultrasound equipment (e.g., the laser ultrasound device 104, the ultrasonic transducer device 140 and / or a second laser ultrasound device 150).

[0102] In one or more examples, the computer system 118 includes an inspection module 124 configured to process an array of ultrasonic data 108 to inspect, evaluate, or test a structure 102 at an inspection location 116. In one or more examples, the inspection module 124 is configured to process the array of ultrasonic data 108, as well as any other ultrasonic data such as a second array of ultrasonic data 142 (Figure 4), a third array of ultrasonic data 146 (Figure 5), a fourth array of ultrasonic data 152 (Figure 6), and a fifth array of ultrasonic data 156 (Figure 7), in order to generate information about the structure 102. The information described above characterizes the structure 102 and includes, but is not limited to, the thickness of the structure 102, the material composition of the structure 102, an indication of whether there are any undesirable inconsistencies or abnormalities on and / or in the structure 102, and / or other types of information, parameters, characteristics and / or properties of the structure 102, such as porosity. The above information may be output and / or displayed in any one of several forms, including A-Scan, B-Scan, C-Scan, frequency images, graphical indicators, or other forms.

[0103] Referring further to Figure 2, in one or more examples, the system 100 includes a profiler 172. The profiler 172 is configured to generate data used to generate a three-dimensional model 164 of the structure 102. In one or more examples, the "as-built" geometry of the structure 102 being inspected may differ from the design geometry and, consequently, from the nominal model. Thus, the use of the profiler 172 provides a more accurate representation of the geometry of the structure 102 when generating the scan path 160. In one or more examples, the scan path 160 is dynamically calculated based on the three-dimensional model 164 generated from the profiler data.

[0104] In one or more examples, the profiler 172 generates three-dimensional point cloud data that is provided to a computer, such as a computer system 118, and used to generate a three-dimensional model 164 of the structure 102. In one or more examples, the profiler 172 includes or takes the form of any suitable sensor device capable of generating three-dimensional data representing the “as-built” shape of the surface 112 of the structure 102. For example, the profiler 172 includes at least one of the following: a laser profiler, a laser scanner, a structured optical scanner, a camera, a stereo vision system, etc.

[0105] Herein, we refer to Figures 2 and 8 schematically showing some examples of a system 100 that utilizes a positioning device 174 for positioning a laser beam 194 on the surface 112 of a structure 102. In one or more examples, the system 100 includes a positioning device 174. The positioning device 174 is configured to determine the real device position 176 (Figure 2) of the laser ultrasonic device 104 relative to the surface 112 of the structure 102. The real device position 176 refers to, for example, the actual position of the optical head 196 of the laser ultrasonic device 104 relative to the surface 112, following the initial positioning of the optical head 196, and is therefore also referred to herein as the actual device position. The positioning device 174 is further configured to modify at least one operating parameter of the laser ultrasonic device 104 based on the actual device position 176.

[0106] In one or more examples, the motion control module 120 performs the initial positioning of the laser beam 194 relative to the surface 112 of the structure 102 by providing motion commands to the robot arm 110 to position the optical head 196 at an initial device position 168. The alignment device 174 performs the final positioning of the laser beam 194 relative to the surface 112 of the structure 102 so that the laser beam 194 is within a desired working tolerance for the inspection operation. For example, the alignment device 174 modifies at least one motion parameter of the optical head 196 so that the laser beam 194 is within approximately ±2 degrees of a desired collision angle 274 (e.g., perpendicular to the surface 112) and within ±2.5 mm of a desired offset distance 272.

[0107] As shown in Figure 8, in one or more examples, the alignment device 174 includes a positioning sensor 260 and a positioning device 262. The positioning sensor 260 is configured to direct positioning light 264 onto a surface 112 of the structure 102, for example, an area of ​​the surface 112 surrounding an inspection position 116. The positioning sensor 260 is further configured to receive a portion of the positioning light 264 that is reflected from the surface 112 and returns to the positioning sensor 260. The spatial position (e.g., three-dimensional arrangement and angular direction) of the surface 112 surrounding the inspection position 116 is determined (e.g., estimated or measured) based on an evaluation of the reflected portion of the positioning light 264 collected by the positioning sensor 260.

[0108] In one or more examples, the positioning sensor 260 determines its position relative to the surface 112 of the structure 102 using one of a variety of three-dimensional scanning techniques, such as time-of-flight or triangulation. For example, the positioning sensor 260 includes at least one of a three-dimensional scanner, a laser scanner, a structured optical scanner, etc. In one or more examples, the positioning sensor 260 is configured to generate position data 270 (e.g., multiple data points) representing the three-dimensional position of a region of the surface 112 illuminated by the positioning light 264.

[0109] Position data 270 is used to computationally determine the position of the illuminated portion of the surface 112 relative to the positioning sensor 260. In one or more examples, the alignment device 174 is coupled to the end of the robot arm 110 (as shown, for example, in Figure 1) so that the position of the optical head 196 relative to the surface 112 can be computationally determined based on the position of the positioning sensor 260 relative to the surface 112. Thus, the actual device position 176 is determined by the computer system 118 based on the acquired position data 270. The actual device position 176 serves as position feedback used to compensate if the offset distance 272 between the optical output 232 of the optical head 196 and the collision angle 274 of the laser beam 194 relative to the surface 112 is outside the range of acceptable error during inspection.

[0110] In one or more examples, the positioning device 262 is configured to compensate if the offset distance 272 between the optical head 196 and the optical output 232 is outside the acceptable range of error by selectively positioning the focal point of the laser beam 194 on the surface 112. In one or more examples, the positioning device 262 is configured to compensate if the collision angle 274 of the laser beam 194 is outside the acceptable range of error by selectively directing the projection angle of the laser beam 194 from the optical output 232.

[0111] The selective placement of the focal point of the laser beam 194 and / or the selective angular direction of the projection angle of the laser beam 194 can be achieved by any one or a combination of various methods. In one or more examples, the optical head 196 includes at least one laser optics 268 associated with the laser beam 194. For example, the laser optics 268 includes one or more optical elements associated with transmitting the generated laser beam 202 and one or more optical elements associated with transmitting the detected laser beam 204. In one or more examples, the positioning device 262 is configured to operate the laser optics 268 to selectively adjust the depth of focus of the laser beam 194 so that the focal point of the laser beam 194 is on the surface 112, in order to compensate for an offset distance outside the tolerance range between the optical output 232 of the optical head 196 and the surface 112 of the structure 102. In one or more examples, the positioning device 262 is configured to operate the laser optics 268 to selectively adjust the projection angle of the laser beam 194 so that the laser beam 194 is perpendicular to the surface 112, in order to compensate for collision angles outside the tolerance range between the laser beam 194 and the surface 112 of the structure 102.

[0112] Alternatively, in one or more examples, the positioning device 262 is coupled to the optical head 196 and is configured to make slight adjustments to the position and / or angular direction of the optical head 196 to correct the offset distance between the optical output 232 of the optical head 196 and the surface of the structure 102, which is outside the tolerance range, and / or to correct the collision angle 274 between the laser beam 194 and the surface 112 of the structure 102, which is outside the tolerance range.

[0113] For example, referring here to Figure 9, this disclosure relates to a method 1000 for inspecting a structure 102. In one or more examples, the implementation of method 1000 utilizes one or more examples of a system 100 (such as those shown in Figures 1-8) for inspecting the structure 102. Method 1000 enables automated laser ultrasonic non-destructive testing and evaluation of the structure 102, resulting in increased capabilities of the laser ultrasonic testing equipment.

[0114] Referring in general to Figures 1 and 2, and more particularly to Figure 9, in one or more examples, method 1000 includes the step (block 1002) of moving the optical head 196 of a laser ultrasonic device 104 against the surface 112 of a structure 102. In one or more examples, a robotic arm 110 is used to move the optical head 196. The optical head 196 is configured to transmit laser light 194. The laser beam 194 (e.g., the generating laser beam 202) is configured to generate ultrasonic waves 106 within the structure 102. The laser beam 194 (e.g., the detection laser beam 204) is configured to detect the response 208 to the ultrasonic waves 106.

[0115] In one or more examples, according to method 1000, the step of moving the optical head 196 (block 1002) includes the step of moving the optical head 196 along a scan path 160 based on a three-dimensional model 164 of the structure 102 (block 1004). The step of moving the optical head 196 (block 1002) further includes the step of positioning the optical head 196 at an initial device position 168 with respect to the surface 112 of the structure 102 for the generation of ultrasound 106 within the structure 102 and the generation of an array 108 of ultrasound data (block 1006).

[0116] In one or more examples, method 1000 includes the step of generating a scan path 160 for a laser beam 194 to travel across the surface 112 of a structure 102. For example, the scan path 160 is generated based on a three-dimensional model 164 of the structure 102.

[0117] In one or more examples, method 1000 includes the step (block 1008) of determining that the optical head 196 is at an inspection position 116 of the structure 102. In one or more examples, according to method 1000, the step (block 1008) of determining that the optical head 196 is at an inspection position 116 includes the step (block 1010) of determining that the optical head 196 is at a trigger position 166 along the scan path 160, which corresponds to the inspection position 116.

[0118] In one or more examples, method 1000 includes the step of determining a trigger position 166 along a scan path 160 that corresponds to an inspection position of the structure 102.

[0119] Referring in general to Figures 2 and 8, and in particular to Figure 9, in one or more examples, Method 1000 includes the step (block 1012) of determining the actual device position 196 of the optical head 176 relative to the surface 112 of the structure 102. Method 1000 further includes the step (block 1014) of changing at least one operating parameter of the optical head 196 based on the actual device position 176.

[0120] Referring in general to Figures 1 and 2, and more particularly to Figure 9, in one or more examples, Method 1000 includes the step (block 1016) of triggering the generation of ultrasonic waves 106 within the structure 102 at an inspection position 116 of the structure 102. In one or more examples, a multiplex controller 114 is used to trigger the generation of ultrasonic waves 106. Ultrasonic waves 106 are generated within the structure 102 by transmitting a laser beam 194 (e.g., generating laser beam 202) to the surface 112 of the structure 102 at the inspection position 116.

[0121] In one or more examples, method 1000 includes the step (block 1018) of generating an array of ultrasonic data 108 representing an ultrasonic wave 106 based on a response 208. The response 208 is formed by transmitting a laser beam 194 (e.g., detection laser beam 204) to the surface 112 of the structure 102 at the inspection position 116 and detecting the return portion of the laser beam 194 (e.g., detection laser beam 204).

[0122] In one or more examples, method 1000 includes the step (block 1020) of receiving an array 108 of ultrasound data from the inspection position 116. In one or more examples, a multiplex controller 114 receives the array 108 of ultrasound data from a laser ultrasound device 104 (e.g., from a detection laser unit 200).

[0123] In one or more examples, method 1000 includes a step of synchronizing (block 1022) the generation of ultrasound 106 (block 1016) and the reception of an array of ultrasound data 108 (block 1020). In one or more examples, a multiplex controller 114 synchronizes the generation of ultrasound 106 and the reception of an array of ultrasound data 108.

[0124] In one or more examples, method 1000 includes the step of processing an array of ultrasonic data 108 (block 1024). The array of ultrasonic data 108 is transmitted from the multiplex controller 114 to the computer system 118 for processing. In one or more examples, the array of ultrasonic data 108 is processed to inspect, evaluate, or test a structure 102 at an inspection location 116. Method 1000 includes the step of inspecting the structure 102 (block 1026).

[0125] Referring in general to Figure 3, and more particularly to Figure 9, in one or more examples, Method 1000 includes the step of detecting the entry of the optical head 196 into the safety zone 138 (block 1028) and the step of automatically shutting off the power supply to the laser ultrasonic device 104 in response to the detection of the entry of the optical head 196 into the safety zone 138 (block 1030).

[0126] Referring in general to Figures 2 and 4, and more particularly to Figure 9, in one or more examples, Method 1000 includes the step of positioning an ultrasonic transducer device 140 relative to a structure 102 (block 1032). The ultrasonic transducer device 140 is configured to generate a second array of ultrasonic data 142 representing ultrasonic waves 106. In one or more examples, Method 1000 includes the step of receiving the second array of ultrasonic data 142 for an inspection position 116 (block 1034). In one or more examples, a multiplex controller 114 receives the second array of ultrasonic data 142. In one or more examples, Method 1000 includes the step of processing the second array of ultrasonic data 142 for inspection of the structure 102 at the inspection position 116 (block 1036). In one or more examples, the ultrasonic data array 108 and the second ultrasonic data array 142 are integrated and processed together to inspect, evaluate, or test a structure 102 (e.g., block 1026) at the inspection location 116.

[0127] Referring generally to Figures 2 and 5, in one or more examples, an ultrasonic transducer device 140 is configured to generate a second ultrasonic wave 144 within a structure 102. The ultrasonic transducer device 140 is configured to generate a third ultrasonic data array 146 representing the second ultrasonic wave 144. In one or more examples, method 1000 includes the step of receiving the third ultrasonic data array 146 for a second inspection location 148. In one or more examples, a multiplex controller 114 receives the third ultrasonic data array 146. In one or more examples, method 1000 includes the step of processing the third ultrasonic data array 146 to inspect the structure 102 at the second inspection location 148. In one or more examples, the ultrasonic data array 108 and the third ultrasonic data array 146 are integrated and processed together to inspect, evaluate, or test the structure 102 (e.g., block 1026) at the inspection location 116.

[0128] Referring in general to Figures 2 and 6, and in particular to Figure 9, in one or more examples, Method 1000 includes the step of positioning a second laser ultrasonic device 150 relative to a structure 102 (block 1038). The second laser ultrasonic device 150 is configured to generate a fourth ultrasonic data array 152 representing ultrasonic waves 106. In one or more examples, Method 1000 includes the step of receiving the fourth ultrasonic data array 152 for an inspection position 116 (block 1040). In one or more examples, a multiplex controller 114 receives the fourth ultrasonic data array 152. In one or more examples, Method 1000 includes the step of processing the fourth ultrasonic data array 152 for inspection of the structure 102 at the inspection position 116 (block 1042). In one or more examples, the ultrasonic data array 108 and the fourth ultrasonic data array 152 are integrated and processed together to inspect, evaluate, or test the structure 102 at the inspection location 116 (e.g., block 1026).

[0129] Referring generally to Figures 2 and 7, in one or more examples, a second laser ultrasonic device 150 is configured to generate a third ultrasonic wave 154 within a structure 102. The second laser ultrasonic device 150 is configured to generate a fifth ultrasonic data array 156 representing the third ultrasonic wave 154. In one or more examples, method 1000 includes the step of receiving the fifth ultrasonic data array 156 for a third inspection location 158. In one or more examples, a multiplex controller 114 receives the fifth ultrasonic data array 156. In one or more examples, method 1000 includes the step of processing the fifth ultrasonic data array 156 to inspect the structure 102 at the third inspection location 158. In one or more examples, the ultrasonic data array 108 and the fifth ultrasonic data array 156 are integrated and processed together to inspect, evaluate, or test the structure 102 (e.g., block 1026) at the inspection location 116.

[0130] Referring next to Figure 10, as an example, the present disclosure also relates to a robotic control system 180 for automatically inspecting a structure 102. In one or more examples, the robotic control system 180 is implemented using system 100 (for example, shown in Figures 1-8) and / or according to method 1000 (for example, shown in Figure 9).

[0131] In one or more examples, the robot control system 180 includes a robot controller 182. The robot controller 182 is coupled to and communicates with a robot arm 110. The robot controller 182 is configured to control the position of the robot arm 110.

[0132] In one or more examples, the robot control system 180 includes a multiplexer 114. The multiplexer 114 is coupled to a laser ultrasonic device 104. The multiplexer 114 is configured to control the laser ultrasonic device 104. In one or more examples, the multiplexer 114 is also coupled to and communicates with a robot arm 110, for example, via a robot controller 182.

[0133] In one or more examples, the robot control system 180 includes a computer system 118. The computer system 118 is coupled to and communicates with a robot controller 182. The computer system 118 is coupled to and communicates with a multiplex controller 114. The computer system 118 includes at least one processor 184 and a memory 186 that stores at least one computer-readable program 188 that causes the computer system 118 to perform an action in response to execution by the at least one processor 184.

[0134] In one or more examples, in response to execution by at least one processor 184, program 188 causes computer system 118 to generate a scan path 160 for the movement of the optical head 196 of laser ultrasonic device 104 across the surface 112 of structure 102, based on a three-dimensional model 164 of structure 102.

[0135] In one or more examples, in response to execution by at least one processor 184, the program 188 causes the computer system 118 to determine a trigger position 166 along the scan path 160 that corresponds to an inspection position 116 of the structure 102.

[0136] In one or more examples, in response to execution by at least one processor 184, program 188 instructs computer system 118 to use robot arm 110 to move the optical head 196 of laser ultrasonic device 104 along scan path 160 against the surface 112 of structure 102.

[0137] In one or more examples, in response to execution by at least one processor 184, program 188 causes computer system 118 to determine when the laser ultrasonic device 104 is in the trigger position 166.

[0138] In one or more examples, in response to execution by at least one processor 184, program 188 instructs computer system 118 to position the optical head 196 of laser ultrasonic device 104 at an initial device position 168 relative to the surface 112 of structure 102 at trigger position 166.

[0139] In one or more examples, in response to execution by at least one processor 184, program 188 instructs computer system 118 to use laser ultrasonic device 104 to trigger the generation of ultrasound 106 within structure 102 at inspection position 116. In response to execution by at least one processor 184, program 188 further instructs computer system 118 to receive an array of ultrasound data 108 representing the ultrasound 106 from laser ultrasonic device 104.

[0140] In one or more examples, in response to execution by at least one processor 184, program 188 causes computer system 118 to process array 108 of ultrasonic data provided by multiplex controller 114 to inspect structure 102.

[0141] As shown in Figure 10, the robot control system 180 implements a computer system 118 using a data processing system. The computer system 118 is used to process data such as the position data of the robot arm 110, the position data of the optical head 196, and ultrasonic data from the laser ultrasonic device 104 and any other ultrasonic inspection device coupled to the multiplex controller 114, as described above. In one or more examples, the computer system 118 includes a communication framework 276 that provides communication between the processor 184, the storage device 278, the communication unit 280, the input / output unit 282, and the display 284. In one or more examples, the communication framework 276 is implemented as a bus system.

[0142] The processor 184 is configured to execute instructions for software to perform several operations. In one or more examples, the processor 184 includes several processor units, multiprocessor cores, and / or some other type of processor, depending on the implementation. In one or more examples, the processor 184 takes the form of a hardware unit (such as a circuit system, an application-specific integrated circuit (ASIC), a programmable logic device, or some other appropriate type of hardware unit).

[0143] Instructions for the operating system, applications, and / or programs executed by the processor 184 are stored in the storage device 278. The storage device 278 communicates with the processor 184 via the communication framework 276. A storage device, also referred to herein as a computer-readable storage device, is any hardware capable of storing information temporarily and / or permanently. This information may include, but is not limited to, data, program code, and / or other information.

[0144] Memory 186 and fixed storage device 286 are examples of storage device 278. In one or more examples, memory 186 takes the form of random access memory or some type of volatile or non-volatile storage device. Fixed storage device 286 includes any number of components or devices. For example, fixed storage device 286 may include a hard drive, flash memory, rewritable optical disk, rewritable magnetic tape, or any combination thereof. The medium used by fixed storage device 286 may be removable or not.

[0145] The communication unit 280 enables the computer system 118 to communicate with the multiplex controller 114, the robot controller 182, and other data processing systems and / or devices. The communication unit 280 may provide communication using physical and / or wireless communication links.

[0146] The input / output unit 282 is capable of receiving inputs from the multiplex controller 114, robot controller 182, and other devices connected to the computer system 118, and transmitting outputs to them.

[0147] The display 284 is configured to display information to the user. For example, the display 284 displays information characterizing the structure 102 after processing and evaluating the array of ultrasonic data 108 (Figure 2) and any additional ultrasonic data.

[0148] In one or more examples, one or more operations of various examples of system 100 (e.g., Figures 1-8) and / or one or more operational steps of various examples of method 1000 (e.g., Figure 9) are executed by processor 184 using computer implementation instructions. These instructions may be referred to as program code, computer-available program code, or computer-readable program code, and may be read and executed by one or more processor units within processor unit 184.

[0149] In these examples, program code 288 is arranged in functional form on a selectively removable computer-readable medium 290, which can be loaded or transferred to a computer system 118 for execution by a processor 184. The program code 288 and the computer-readable medium 290 together form a computer program product 292. In one or more examples, the computer-readable medium 290 may be a computer-readable storage medium 294 or a computer-readable signaling medium 296.

[0150] Throughout this disclosure, various components of System 100, the multiplex controller 114, and / or the computer system 118 are referred to as modules. In this disclosure, the term “module” includes hardware, software, or a combination of hardware and software. For example, a module may include one or more circuits configured to perform or execute a described function. For other examples, a module may include a processor, a storage device (e.g., memory), and a computer-readable storage medium having instructions that, when executed by the processor, cause the processor to perform or execute a described function. In one or more examples, a module takes the form of a computer program product 292, which is a combination of program code 288 and a computer-readable medium 290.

[0151] Referring here to Figures 11 and 12, examples of system 100, method 1000, and robot control system 180 may relate to or be used in the context of an aircraft manufacturing and maintenance method 1100, as shown in the flowchart of Figure 11, and an aircraft 1200, as schematically shown in Figure 12. For example, the aircraft 1200 and / or the aircraft manufacturing and maintenance method 1100 may utilize a structure 102 that is inspected according to method 1000 and / or using system 100 and / or robot control system 180 as described herein and shown in Figures 1-10.

[0152] This disclosure acknowledges that composite structures can be advantageous in aircraft manufacturing for reducing aircraft weight and providing long service lives for various components of the aircraft. In the manufacture of composite structures, layers of composite material are typically laid up on a tool. Often, each layer of composite material includes fiber sheets impregnated or pre-impregnated with a matrix material (commonly called a prepreg). Different layers of composite material may be laid up in different orientations, and different numbers of layers may be used depending on the performance requirements of the composite structure being manufactured. In certain circumstances, inconsistencies may occur in a composite structure during its manufacture or during its service life. Due to the spacing of the layers constituting the composite structure, inspection of the composite structure may be more difficult than desired, depending on the location and type of the inconsistency. Furthermore, some inconsistencies may not be detectable even with conventional non-destructive testing techniques. In one or more examples, structure 102 is a composite structure. Examples of system 100, method 1000, and robot control system 180 improve the capabilities of laser ultrasonic inspection and ultrasonic transducer inspection for inspecting and evaluating structures 102.

[0153] Referring to Figure 12, an example of the aircraft 1200 may include a fuselage 1202 having an interior 1206. The aircraft 1200 also includes several high-level systems 1204. Examples of high-level systems 1204 include one or more of the propulsion system 1208, electrical system 1210, hydraulic system 1212, and environmental system 1214. In other examples, the aircraft 1200 may include any number of other types of systems, such as a communication system, flight control system, guidance system, and weapons system. In one or more examples, a structure 102 inspected according to method 1000 and / or using system 100 and / or robotic control system 180 forms components of the fuselage 1202, such as wings, fuselage, and stringers.

[0154] Referring to Figure 11, in the pre-manufacturing stage, Method 1100 includes the specification and design of the aircraft 1200 (block 1102) and material procurement (block 1104). In the manufacturing stage of the aircraft 1200, the components and subassemblies of the aircraft 1200 are manufactured (block 1106) and the system integration of the aircraft 1200 is performed (block 1108). Subsequently, the aircraft 1200 is licensed and delivered (block 1110) and put into operation (block 1112). Periodic maintenance and upkeep (block 1114) includes the modification, reconfiguration, and modification of one or more systems of the aircraft 1200.

[0155] Each process of Method 1100 shown in Figure 11 may be carried out or performed by a system integrator, a third party, and / or an operator (e.g., a customer). In this specification, a system integrator may include, but is not limited to, any number of spacecraft manufacturers and subcontractors of key systems; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military organization, flight operations organization, etc.

[0156] Examples of the system 100, method 1000, and / or robotic control system 180 shown and described herein may be used during any one or more stages of the manufacturing and maintenance method 1100 shown in the flowchart of Figure 11. In one example, inspection of a structure 102 according to method 1000 and / or using system 100 and / or robotic control system 180 may form part of the manufacturing of components and subassemblies (block 1106) and / or system integration (block 1108). Furthermore, a structure 102 inspected according to method 1000 and / or using system 100 and / or robotic control system 180 may be used in a similar manner to components or subassemblies prepared during the operation of the aircraft 1200 (block 1112). Furthermore, structures 102 inspected in accordance with Method 1000 and / or using System 100 and / or the robotic control system 180 may be used during the System Integration (Block 1108) and Authorization and Delivery (Block 1110). Similarly, inspections of structures 102 in accordance with Method 1000 and / or using System 100 and / or the robotic control system 180 may be used, for example, during the operation of the aircraft 1200 (Block 1112) and during maintenance and servicing (Block 1114).

[0157] While examples from aerospace have been provided, the examples and principles disclosed herein can also be applied to other industries such as the automotive industry, the space industry, the construction industry, and other design and manufacturing industries. Therefore, in addition to aircraft, the examples and principles disclosed herein can also be applied to structural component assemblies and systems for other types of vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.) and individual structures, as well as to manufacturing methods for other types of vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.) and individual structures.

[0158] Where used herein, a system, apparatus, device, structure, article, element, component, or hardware "configured to perform" a particular function does not merely have the potential to perform that function after further modification, but is actually capable of performing that function without any modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware "configured to perform" a particular function is specifically selected, created, implemented, used, programmed and / or designed for the purpose of performing that particular function. Wherein herein, the expression "configured to" indicates an existing feature of the system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform a particular function without further modification. Wherein this disclosure a system, apparatus, device, structure, article, element, component, or hardware described as "configured to perform" a particular function, it may also be described as "adapted" and / or "operable" to perform that function, either additionally or alternatively.

[0159] Unless otherwise indicated, terms such as “first,” “second,” and “third” are used solely as symbols in this specification and are not intended to impose any order, position, or hierarchical requirements on the items they refer to. Furthermore, a reference to, for example, an item “second” does not require or exclude the existence of, for example, an item “first” or a lesser numbered item, and / or, for example, an item “third” or a more higher numbered item.

[0160] In this disclosure, terms such as “inspect,” “inspect,” “evaluate,” “evaluate,” “test,” “test,” and similar terms used to refer to inspecting, evaluating, and / or testing the structure 102 refer to non-destructive testing (NDT), non-destructive evaluation (NDE), non-destructive testing (NDI), non-destructive evaluation (NDE), and other inspection techniques used to analyze and / or evaluate the characteristics, parameters and / or properties of a structure, material or component without permanently altering or damaging the article under test.

[0161] In one or more examples, the structure 102 comprises or is formed from several materials. In one or more examples, the structure 102 is a composite structure formed from two or more composite materials, such as a fiber-reinforced polymer formed from a matrix material and a reinforcing material. In other examples, the structure 102 is formed from a metallic material, a plastic material, or other suitable type of material. In one or more examples, the matrix material includes a thermosetting resin (e.g., epoxy), a thermoplastic polymer (e.g., polyester, vinyl ester, nylon), or other types of matrix material. In one or more examples, the reinforcing material includes fibers (e.g., glass fibers, carbon fibers, aramid fibers), or other types of reinforcing material. In one or more examples, the fibers are unidirectional fibers or take the form of woven or nonwoven fabrics, textiles, or tapes. In one or more examples, the structure 102 is a laminated structure. The laminated structure comprises or is formed from multiple material layers. In one or more examples, the structure 102 comprises multiple layers of composite material.

[0162] In this disclosure, the term “surface,” as in relation to the surface 112 of the structure 102, has its usual meaning and refers to any portion of the outer surface of the structure 102 to which the laser beam 194 and / or positioning light 264 are transmitted during the inspection operation.

[0163] In this disclosure, the term “inspection location,” as in relation to the inspection location 116 of the structure 102, refers to a portion of the surface 112 or a predetermined surface area of ​​the surface 112 that is intended to be illuminated by light during a laser ultrasonic testing operation at any given location along the scan path 160.

[0164] In this disclosure, the term "position" of an item refers to the arrangement of the item in three-dimensional space with respect to a fixed reference frame (for example, the reference frame 266 shown in Figure 1) and the angular direction of the item in three-dimensional space with respect to the fixed reference frame.

[0165] As used herein, the phrase "several" refers to one or more items.

[0166] In this specification, the phrase "at least one of" when used with the enumerated items means that different combinations of one or more of the enumerated items may be used, and that only one of each enumerated item is required. For example, "at least one of item A, item B, and item C" includes, but is not limited to, "item A" or "item A and item B." This example also includes "item A, item B, and item C" or "item B and item C." As other examples, "at least one of" includes, but is not limited to, "two item A, one item B, and ten item C," "four item B, seven item C," and other appropriate combinations. As used herein, the terms "and / or" and the " / " symbol include any and all combinations of one or more of the enumerated items in question.

[0167] In this disclosure, the terms “joined,” “joined,” and similar terms refer to two or more elements that are connected, linked, fixed, attached, connected, communicated, or otherwise related to one another (e.g., mechanically, electrically, fluidly, optically, or electromagnetically). In various examples, these elements may be directly related or indirectly related. For example, element A may be directly related to element B. In another example, element A may be indirectly related to element B, for example, through another element C. It should be understood that not all relationships between the various elements disclosed are necessarily represented. Therefore, other connections may exist that are not shown in the drawings.

[0168] In this specification, the term "approximately" refers to or represents a state that is close to the described state but not exactly so, yet still performs the desired function or achieves the desired result. For example, "approximately" refers to a state that is within a certain acceptable tolerance or accuracy range, such as being within 10% of the described state. However, the term "approximately" does not exclude a state that is exactly as described. In this specification, the term "substantially" refers to a state that is essentially the described state, performing the desired function or achieving the desired result.

[0169] Figures 1-8, 10, and 12 referenced above may represent functional elements, features, or their constituent elements, and do not necessarily represent any specific structure. Accordingly, modifications, additions, and / or omissions can be made to the illustrated structures. Furthermore, those skilled in the art will see that not all elements, features, and / or their components shown and illustrated in Figures 1-8, 10, and 12 referenced above are required to be included in all examples, and not all elements, features, and / or their components depicted herein are necessarily shown in each example. Accordingly, some of the elements, features, and / or components shown and illustrated in Figures 1-8, 10, and 12 may be combined in various ways without requiring the inclusion of other features, other drawings, and / or accompanying disclosures shown and illustrated in Figures 1-8, 10, and 12, although such combinations are not explicitly shown herein. Similarly, additional features not limited to those presented in the examples can be combined with some or all of the features shown and described herein. Unless otherwise specified, the schematic diagrams of the examples shown in Figures 1-8, 10, and 12 referenced above do not imply any structural limitations with respect to the examples. Rather, it should be understood that even if one exemplary structure is shown, modifications to that structure may be made as needed. Accordingly, modifications, additions, and / or omissions can be made to the illustrated structures. Furthermore, elements, features, and / or components that serve similar or at least substantially similar purposes are labeled with the same numbers in Figures 1-8, 10, and 12, respectively, and such elements, features, and / or components may not be described in detail herein with respect to each of Figures 1-8, 10, and 12. Similarly, not all elements, features, and / or components are labeled in each of Figures 1-8, 10, and 12, but the reference numbers associated with them may be used herein for consistency.

[0170] In Figures 9 and 11 referenced above, blocks may represent operations, steps, and / or parts thereof, and the lines connecting the various blocks do not imply any particular order or dependency of operations or parts thereof. It should be understood that not all dependencies between the various operations disclosed are necessarily represented. Figures 9 and 11 and the accompanying disclosures illustrating the operations of the methods of this disclosure as described herein should not be interpreted as necessarily determining the sequence in which the operations are performed. Rather, it should be understood that even if an exemplary order is shown, the sequence of operations may be changed as needed. Accordingly, the illustrated operations may be modified, added to, and / or omitted, and certain groups of operations may be performed in different orders or simultaneously. Furthermore, those skilled in the art will understand that it is not necessary to perform all the operations described.

[0171] Furthermore, throughout this Specification, references to features, advantages, or similar terms used herein do not imply that all features and advantages that may be realized by the examples disclosed herein are present in or are present in any single example. Rather, terms referring to features or advantages should be understood to mean that a particular feature, advantage, or characteristic described in relation to an example is included in at least one example. Accordingly, descriptions of features, advantages, and similar terms used throughout this Disclosure may, but may not, refer to the same example.

[0172] Furthermore, this disclosure includes embodiments according to the following examples.

[0173] Example 1. In a system (100) for inspecting a structure (102), A laser ultrasonic device (104) configured to direct a laser beam (194) that generates ultrasonic waves (106) within a structure (102) towards the surface (112) of the structure (102), and to generate an array (108) of ultrasonic data representing the ultrasonic waves (106); A robotic arm (110) configured to move a laser beam (194) across the surface (112) of a structure (102); A multiplex controller (114) is coupled to a laser ultrasonic device (104) and is configured to trigger the generation of ultrasound (106) within the structure (102) at the inspection position (116) of the structure (102), and to receive an array (108) of ultrasound data for the inspection position (116) from the laser ultrasonic device (104); A computer system (118) coupled to a robotic arm (110) and a multicontroller (114). And, A motion control module (120) configured to control the movement of a laser beam (194) relative to the surface (112) of a structure (102); A motion tracking module (122) configured to determine when the laser beam (194) is at the inspection position (116); and An inspection module (124) configured to process an array of ultrasonic data (108) and inspect a structure (102) at an inspection location (116). Computer systems including (118) and A system (100) equipped with the following.

[0174] Example 2. The system (100) described in Example 1, The multiple controller (114) A trigger module (126) configured to transmit a trigger signal (128) to a laser ultrasonic device (104) to trigger the generation of ultrasound (106) within a structure (102) at the inspection position (116); An array receiver (130) configured to receive an array (108) of ultrasound data from a laser ultrasound device (104) and Equipped with, The multiplex controller (114) is further configured to synchronize the transmission of a trigger signal (128) with the reception of an array of ultrasonic data (108). System (100).

[0175] Example 3. The system (100) according to Example 2, further comprising a multiplex controller (114) and a clock (132) configured to delay the transmission of a trigger signal (128) from a trigger module (126) by a predetermined period.

[0176] Example 4. The system (100) of Example 2, further comprising a signal adjustment module (134) configured to modify at least one of the period, waveform, and voltage of a trigger signal (128) for use with a laser ultrasonic device (104).

[0177] Example 5. The system (100) according to Example 4, wherein the signal adjustment module (134) is further configured to modify the trigger signal (128) to delay the transmission of the trigger signal (128) to the laser ultrasonic device (104) by a predetermined period.

[0178] Example 6. The system (100) according to Example 1, further comprising a safety sensor (136) coupled to a computer system (118) and configured to detect intrusion of a laser ultrasonic device (104) into a safety zone (138), The system (100) according to Embodiment 1, further configured such that the computer system (118) automatically shuts off the power supply to the laser ultrasonic device (104) in response to a safety sensor (136) that detects the laser ultrasonic device (104) entering a safety zone (138).

[0179] Example 7. The system (100) according to Example 1, further comprising an ultrasonic transducer device (140) configured to generate a second array (142) of ultrasonic data representing an ultrasonic wave (106), A system (100) in which a multiplex controller (114) is coupled to an ultrasonic transducer device (140) and is further configured to receive a second array (142) of ultrasonic data for an examination position (116) from the ultrasonic transducer device (140).

[0180] Example 8. The system (100) described in Example 7, The ultrasonic transducer device (140) is further configured to generate a second ultrasonic wave (144) within the structure (102) and to generate a third ultrasonic data array (146) representing the second ultrasonic wave (144). A system (100) further configured such that a multiplex controller (114) triggers the generation of a second ultrasonic wave (144) within the structure (102) at a second inspection position (148) of the structure (102), and receives a third array of ultrasonic data (146) for the second inspection position (148) from an ultrasonic transducer device (140).

[0181] Example 9. The system (100) of Example 1, further comprising a second laser ultrasound device (150) configured to generate a fourth array of ultrasound data (152) representing ultrasound (106), wherein a multiplex controller (114) is coupled to the second laser ultrasound device (150) and further configured to receive the fourth array of ultrasound data (152) for the inspection position (116) from the second laser ultrasound device (150).

[0182] Example 10. The system (100) described in Example 9, A second laser ultrasonic device (150) is further configured to generate a third ultrasonic wave (154) within the structure (102) and to generate a fifth ultrasonic data array (156) representing the third ultrasonic wave (154); A system (100) further configured such that a multiplex controller (114) triggers the generation of a third ultrasonic wave (154) within the structure (102) at a third inspection position (158) of the structure (102), and receives a fifth array of ultrasonic data (156) for the third inspection position (158) from a second laser ultrasonic device (150).

[0183] Example 11. The system (100) described in Example 1, The laser ultrasonic device (104) is coupled to a robotic arm (110) and includes an optical head (196) configured to transmit laser light (194) to the surface (112) of a structure (102); The computer system (118) Based on a three-dimensional model (164) of the structure (102), a scan path (160) is generated for the movement of a laser beam (194) across the surface (112) of the structure (102); Determine the trigger position (166) along the scan path (160) corresponding to the inspection position (116); and The system further includes a path planning module (162) configured to determine the initial device position (168) of the optical head (196) relative to the surface (112) of the structure (102) at a trigger position (166) for generating ultrasonic waves (106) within the structure (102) and generating an array (108) of ultrasonic data; The motion control module (120) controls the movement of the optical head (196) using the robot arm (110) using the scan path (160) and the initial device position (168); The motion tracking module (122) is configured to determine when the optical head (196) is in the inspection position (116) using the trigger position (166), and to transmit an activation signal (170) to the multiplex controller (114) when the optical head (196) is in the inspection position (116). System (100).

[0184] Example 12. The system (100) according to Example 11, further comprising a laser profiler (172) configured to generate a three-dimensional model (164) of a structure (102).

[0185] Example 13. The system (100) according to Example 11, further comprising a positioning device (174) configured to determine the actual device position (176) of the laser ultrasonic device (104) relative to the surface (112) of a structure (102), and to change at least one operating parameter of the laser ultrasonic device (104) based on the actual device position (176).

[0186] Example 14. In a method (1000) for inspecting a structure (102), A step of moving the optical head (196) of a laser ultrasonic device (104) relative to the surface (112) of a structure (102) using a robotic arm (110), wherein the optical head (196) is configured to transmit laser light (194) that generates ultrasonic waves (106) within the structure (102) and detects a response (208) to the ultrasonic waves (106); A step of determining that the optical head (196) is at the inspection position (116) of the structure (102); A step of using a multiplex controller (114) to trigger the generation of ultrasonic waves (106) within the structure (102) at the inspection position (116) of the structure (102); A step of generating an array (108) of ultrasound data representing the ultrasound (106) based on the response (208); The steps of receiving an array (108) of ultrasound data for the examination position (116) by a multiplex controller (114); and A step of processing an array of ultrasonic data (108) to inspect a structure (102) at the inspection location (116). Method (1000), including the above.

[0187] Example 15. The method according to Example 14 (1000), further comprising the step of synchronizing the step of triggering the generation of ultrasound (106) using a multiplex controller (114) and the step of receiving an array of ultrasound data (108).

[0188] Example 16. Steps include detecting the intrusion of the optical head (196) into the safety zone (138); In response to the step of detecting the intrusion of the optical head (196) into the safety zone (138), the power supply to the laser ultrasonic device (104) is automatically stopped. The method of Example 14 (1000) further includes the following.

[0189] Example 17. A positioning step of positioning an ultrasonic transducer device (140) with respect to a structure (102), wherein the ultrasonic transducer device (140) is configured to generate a second array of ultrasonic data (142) representing ultrasonic waves (106); The steps include: receiving a second array of ultrasound data (142) for the examination position (116) by a multiplex controller (114); and The step of processing an array of ultrasound data (108) and a second array of ultrasound data (142) to inspect a structure (102) at the inspection location (116). The method according to Example 14, further comprising (1000).

[0190] Example 18. The step of moving the optical head (196) of the laser ultrasonic device (104) is, The steps include: moving the optical head (196) along a scan path (160) based on a three-dimensional model (164) of the structure (102); The process includes the steps of positioning an optical head (196) at an initial device position (168) relative to the surface (112) of the structure (102) for the generation of ultrasonic waves (106) within the structure (102) and the generation of an array (108) of ultrasonic data; and The step of determining that the laser ultrasound device (104) is at the inspection position (116) is the step of determining that the optical head (196) is at the trigger position (166) along the scan path (160) corresponding to the inspection position (116). The method according to Example 14, including (1000).

[0191] Example 19. The steps include determining the actual device position (176) of the optical head (196) relative to the surface (112) of the structure (102); A step of changing at least one operating parameter of the optical head (196) based on the actual device position (176) and The method according to Example 18, further comprising (1000).

[0192] Example 20. A robot controller (182) coupled to a robot arm (110) and configured to control the position of the robot arm (110); A multiplex controller (114) is coupled to a laser ultrasonic device (104) and configured to control the laser ultrasonic device (104); A robot control system (180) for automatically inspecting a structure (102), comprising a computer system (118) coupled to a robot controller (182) and a multiplex controller (114), the computer system (118) including at least one processor (184) and a memory (186) that stores at least one computer-readable program (188), The memory (186), when executed by at least one processor (184), provides to the computer system (118): Based on a three-dimensional model (164) of the structure (102), a scan path (160) is generated for the movement of the optical head (196) of the laser ultrasonic device (104) across the surface (112) of the structure (102); Determine the trigger position (166) along the scan path (160) corresponding to the inspection position (116) of the structure (102); The robotic arm (110) is used to instruct the robotic controller (182) to move the optical head (196) along the scan path (160) relative to the surface (112) of the structure (102); Determine when the optical head (196) is in the trigger position (166); The trigger position (166) commands the robot controller (182) to position the optical head (196) at the initial device position (168) relative to the surface (112) of the structure (102); The system triggers the generation of ultrasound (106) within the structure (102) at the inspection position (116), and instructs the multiplex controller (114) to receive an array of ultrasound data (108) representing the ultrasound (106) from the laser ultrasound device (104); A robot control system (180) processes an array of ultrasonic data (108) provided by a multiplex controller (114) and instructs it to inspect a structure (102).

[0193] Features, advantages, and characteristics described in one embodiment may be combined in any suitable manner in one or more other embodiments. Those skilled in the art will recognize that the embodiments described herein may be carried out without the presence of one or more specific features or advantages of a particular embodiment. Further features and advantages that are not present in all embodiments may be recognized in other embodiments. Furthermore, while various examples of System 100, Method 1000, and Robot Control System 180 have been shown and described, those skilled in the art will find that changes may occur when reading this specification. This application includes such modifications and is limited only by the claims.

Claims

1. A system (100) for inspecting a structure (102), comprising: a laser ultrasound device (104) configured to direct a laser beam (194) toward a surface (112) of the structure (102) to generate ultrasound waves (106) within the structure (102) and to generate an array of ultrasound data (108) representative of the ultrasound waves (106); a robotic arm (110) configured to move the laser beam (194) across the surface (112) of the structure (102); a multiplexing controller (114) coupled to the laser ultrasonic device (104) and configured to trigger generation of the ultrasonic waves (106) within the structure (102) at an inspection location (116) of the structure (102) and to receive the array of ultrasonic data (108) for the inspection location (116) from the laser ultrasonic device (104); a computer system (118) coupled to the robotic arm (110) and the multiplex controller (114), a motion control module (120) configured to control movement of the laser beam (194) relative to the surface (112) of the structure (102); a motion tracking module (122) configured to determine when the laser beam (194) is at the inspection position (116); and a computer system (118) including an inspection module (124) configured to process the array of ultrasound data (108) to inspect the structure (102) at the inspection location (116); A system (100) comprising:

2. The multiplex controller (114) a trigger module (126) configured to transmit a trigger signal (128) to the laser ultrasonic device (104) to trigger generation of the ultrasonic waves (106) within the structure (102) at the inspection location (116); an array receiver (130) configured to receive the array of ultrasound data (108) from the laser ultrasound device (104); and The system (100) of claim 1, wherein the multiplexing controller (114) is further configured to synchronize transmission of the trigger signal (128) with reception of the array of ultrasound data (108).

3. 3. The system of claim 1, wherein the multiplexing controller further comprises a clock configured to delay transmission of the trigger signal from the trigger module by a predetermined period.

4. 4. The system (100) of claim 1, wherein a signal conditioning module (134) is further configured to modify the trigger signal (128) to delay transmission of the trigger signal (128) to the laser ultrasound device (104) by a predetermined period.

5. 5. The system (100) of claim 1, further comprising a safety sensor (136) coupled to the computer system (118) and configured to detect intrusion of the laser ultrasonic device (104) into a safety zone (138), The system (100), wherein the computer system (118) is further configured to automatically shut off power to the laser ultrasonic device (104) in response to the safety sensor (136) detecting entry of the laser ultrasonic device (104) into the safety zone (138).

6. 6. The system (100) of claim 1, further comprising an ultrasound transducer device (140) configured to generate a second array of ultrasound data (142) representative of the ultrasound waves (106), comprising: The system (100), wherein the multiplexing controller (114) is coupled to the ultrasonic transducer device (140) and is further configured to receive the second array of ultrasonic data (142) for the inspection position (116) from the ultrasonic transducer device (140).

7. the ultrasonic transducer device (140) is further configured to generate second ultrasonic waves (144) within the structure (102) and to generate a third array of ultrasonic data (146) representative of the second ultrasonic waves (144); 7. The system (100) of claim 1, wherein the multiplexing controller (114) is further configured to trigger generation of the second ultrasonic waves (144) within the structure (102) at a second inspection location (148) of the structure (102) and to receive the third array of ultrasonic data (146) for the second inspection location (148) from the ultrasonic transducer device (140).

8. 8. The system (100) of any one of claims 1 to 7, further comprising a second laser ultrasound device (150) configured to generate a fourth array of ultrasound data (152) representative of the ultrasound waves (106), The system (100), wherein the multiplexing controller (114) is coupled to the second laser ultrasonic device (150) and is further configured to receive the fourth array of ultrasonic data (152) for the inspection location (116) from the second laser ultrasonic device (150).

9. A method (1000) for inspecting a structure (102), comprising: moving an optical head (196) of a laser ultrasound device (104) relative to a surface (112) of the structure (102) using a robotic arm (110), the optical head (196) being configured to transmit a laser light (194) that generates ultrasonic waves (106) within the structure (102) and detects a response (208) to the ultrasonic waves (106); determining that the optical head (196) is in an inspection position (116) of the structure (102); triggering generation of the ultrasonic waves (106) within the structure (102) at the inspection location (116) of the structure (102) using a multiplexing controller (114); generating an array of ultrasound data representative of the ultrasound waves based on the responses; receiving, by the multiplexing controller (114), the array of ultrasound data (108) for the inspection location (116); and Processing the array of ultrasound data to inspect the structure at the inspection location. A method (1000) comprising:

10. 10. The method (1000) of claim 9, further comprising: detecting an intrusion of an optical head (196) into a safety zone (138); and automatically shutting off power to the laser ultrasonic device (104) in response to detecting the intrusion of the optical head (196) into the safety zone (138).

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