Integrated CMM and Eddy Current Inspection Probe
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Solution Overview
Problem
Current inspection methods for machine components, such as rotor blades, require separate processes for external and internal geometry measurements and defect detection, which are time-consuming, expensive, and not suitable for in-situ inspection, and fail to directly link non-destructive examination data with geometry information.
Innovation Solution
An integrated inspection probe combining coordinate measuring machine (CMM) and eddy current (EC) capabilities, along with proximity sensors, to simultaneously measure external dimensions and internal/sub-surface defects, and display measurement data linked to geometry information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate inspection processes are used for external geometry and internal defects, then measurement accuracy is maintained, but inspection time increases significantly
Solution Approach 1:
The patent combines multiple inspection functions (external geometry measurement via CMM, internal defect detection via ultrasound, and surface defect detection via eddy current) into a single integrated inspection probe that can perform all measurements simultaneously during one inspection process, eliminating the need for separate inspection processes while maintaining measurement accuracy through coordinated operation of all sensor types
2Reliability
If multiple separate inspection processes are used, then comprehensive defect detection is achieved, but equipment cost and complexity increase
Solution Approach 1:
The inspection probe is designed as a universal multi-functional device that integrates coordinate measuring machine capabilities, ultrasound sensing, and eddy current sensing into a single probe assembly, allowing one device to perform external geometry measurement, internal defect detection, and surface defect detection that previously required multiple separate inspection systems
Solution Approach 2:
Multiple inspection functions (external geometry measurement via CMM, internal defect detection via ultrasound, and surface defect detection via eddy current) are merged into a single integrated inspection probe that can perform all measurements simultaneously during one inspection process, eliminating the need for separate inspection processes while maintaining measurement accuracy through coordinated operation of all sensor types
3Extent of automation
If NDE data is scanned along pre-programmed tool path, then automation is achieved, but adaptability to actual geometry deviations is lost
Solution Approach 1:
The system continuously measures actual component geometry during inspection and uses this feedback information to dynamically adjust the inspection tool path in real-time, allowing the automated inspection process to adapt to actual geometry deviations from the nominal CAD model while maintaining automated operation throughout the inspection process
4Measurement precision
If EC probe is maintained in tight contact with surface contour, then measurement accuracy is improved, but setup complexity increases for complicated geometries
Solution Approach 1:
The inspection system uses dynamic probe positioning control that automatically adjusts the probe's position and orientation in real-time based on the measured surface geometry, allowing the EC probe to maintain optimal contact with complex surface contours during automated inspection without requiring complicated manual setup procedures for each specific component geometry
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 reduces inspection time, enhances accuracy, and enables real-time 3D imaging of defects and geometry, improving CMM productivity and allowing for accurate internal and surface defect measurements.
Implementation Method 1
eddy current (EC) sensor is typically used for identifying surface or near surface defects
Implementation Method 2
proximity sensors can be used to determine the surface normality and a distance between the sensor and the component to be inspected
Data Source
AI summary
A method for integrating a measurement device for use in measuring a machine component includes providing a coordinate measuring machine (CMM) and combining eddy current (EC) capabilities and CMM capabilities to form an inspection probe. The method further includes installing the inspection probe on the CMM so that the inspection probe measures external boundaries of the machine component with the CMM capabilities and substantially simultaneously measures at least one of internal boundaries, internal defects, surface defects, and material properties of the machine component with the EC capabilities, which are directly linked to actual component dimensional information provided by CMM. The inspection data can be simultaneously linked to and/or displayed with a CAD model to enable a direct comparison between the inspection data and the nominal requirements specified on the CAD model.