Acoustic Inspection Probe Positioning for Fixture-Induced Tilting
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Solution Overview
Problem
Current inspection techniques fail to compensate for inadvertent pitch and roll of components during acoustic wave transmission, leading to inspection errors due to fixture-induced tilting and discrepancies between actual and theoretical component configurations.
Innovation Solution
The system employs displacement sensors and actuators to adjust the position of wave transducers relative to the component, maintaining a constant gap thickness and aligning the probe with the component's features, using optical sensors to detect profile changes and control pitch and roll adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a fixture is used to fix the component in place during inspection, then the component is stabilized for inspection, but the fixture introduces inadvertent pitch and roll of the component causing inspection errors
Solution Approach 1:
The system uses displacement sensors to continuously monitor the actual position and orientation of the component during inspection, and feeds this information back to adjust the probe position accordingly. This feedback mechanism compensates for the pitch and roll introduced by the fixture, maintaining inspection accuracy despite component instability.
Solution Approach 2:
The system dynamically changes the parameters of the inspection process by adjusting the probe position and orientation based on real-time displacement measurements. Instead of relying on a fixed predetermined model, the system adapts to the actual component configuration and fixture-induced deviations, correcting for pitch and roll through parameter adjustment.
2Ease of operation
If a predetermined model or teach path is used to control wave transducer movement, then the inspection process is simplified, but inspection errors occur when the actual component configuration differs from the theoretical model
Solution Approach 1:
The system performs preliminary measurements using displacement sensors to detect the actual component configuration and fixture-induced deviations before conducting the main inspection. This preliminary action allows the system to establish corrected reference paths that account for real-world variations, combining simplicity with accuracy.
Solution Approach 2:
The system continuously compares actual component features detected during inspection with the predetermined model, and uses displacement sensor data to provide feedback for real-time corrections. This feedback loop allows the system to maintain ease of operation while compensating for configuration differences, ensuring inspection accuracy.
3Measurement precision
If displacement sensors and actuators are added to adjust probe position and compensate for pitch and roll, then inspection accuracy is improved, but device complexity increases
Solution Approach 1:
The system integrates multiple functions into unified components: displacement sensors serve both to measure component position and to provide data for pitch/roll compensation, while the actuator system performs both probe positioning and orientation adjustment. This multi-functionality reduces the need for separate dedicated components, managing complexity while maintaining accuracy.
Solution Approach 2:
The system uses the inspection process itself to generate the data needed for compensation. The wave transducers and displacement sensors work together during the normal inspection operation to detect component features and measure deviations, eliminating the need for separate calibration or measurement steps. The system compensates for errors using the same operational data it collects for inspection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures accurate non-destructive inspection by maintaining consistent acoustic wave transmission conditions, reducing errors caused by component tilting and configuration differences, and eliminating the need for predetermined models or teach paths.
Implementation Method 1
Some techniques for non-destructively inspecting components include the transmission of acoustic waves through the components
Implementation Method 2
at least one displacement sensor configured to detect a position of the at least one wave transducer of the feature inspector relative to the feature of the component
Implementation Method 3
an optical sensor configured to detect changes in a profile of the first and second features of the component
Data Source
AI summary
Described herein is an apparatus for inspecting a component includes a first feature inspector with at least one wave transducer configured to inspect a first feature of the component. The first feature inspector further includes at least one displacement sensor configured to detect a displacement of the at least one wave transducer of the first feature inspector relative to the first feature of the component. The apparatus further includes a second feature inspector with at least one wave transducer configured to inspect a second feature of the component. The second feature inspector further includes at least one displacement sensor configured to detect a displacement of the at least one wave transducer of the second feature inspector relative to the second feature of the component.