Dual-Encoder NDT Scanner With On-Board Position Feedback
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Solution Overview
Problem
Existing non-destructive testing (NDT) methods require operators to manually align and calculate index positions, leading to inefficiencies and inaccuracies, especially in acoustic inspection, as they need to constantly refer to separate instruments for guidance, which distracts from the scanning process.
Innovation Solution
A scanner assembly with integrated encoders and an operator interface allows for simultaneous encoding in two directions, providing real-time feedback on scan and index positions directly on the scanner, enabling flexible and intuitive operation without needing to consult separate instruments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If operators manually align and calculate index positions using separate instruments, then measurement capability is provided, but operator attention is diverted from the scanning process and efficiency is reduced
Solution Approach 1:
The patent combines the encoder and operator interface directly into the scanner assembly, merging previously separate functions (scanning, encoding, and operator interaction) into a single integrated unit. This eliminates the need for operators to refer to separate instruments, maintaining their focus on the scanning process while improving efficiency.
Solution Approach 2:
The integrated operator interface acts as an intermediary between the encoder and the operator, providing all necessary feedback and control capabilities directly at the scanner. This eliminates the need for separate measurement instruments and allows operators to make decisions based on real-time feedback without diverting attention.
2Measurement precision
If separate position encoders and manual marking are used for alignment, then position encoding is achieved, but setup time and complexity increase
Solution Approach 1:
The patent integrates the position encoder directly into the scanner assembly, combining functions that were previously performed by separate encoders and manual marking systems. This integration maintains precise position measurement while eliminating the time-consuming setup procedures associated with separate alignment systems.
Solution Approach 2:
The integrated encoder system provides self-alignment capabilities through direct mechanical coupling with the scanner wheels, eliminating the need for manual marking and external alignment procedures. The system encodes position information automatically as the scanner moves, requiring no additional setup time.
3Productivity
If fixed increment indexing is used for line scans, then scan coverage is achieved, but flexibility is reduced when obstructions prevent indexing to predefined positions
Solution Approach 1:
The patent implements dynamic indexing capabilities where the scanner can operate in both fixed-increment mode and free-hand mode. The system adapts to different inspection scenarios by allowing operators to choose the appropriate mode, providing flexibility to navigate around obstructions while maintaining the ability to perform systematic fixed-increment scans when conditions permit.
Solution Approach 2:
The system allows dynamic changes in indexing parameters, transitioning between fixed increment values and variable positioning. When obstructions are encountered, the system can adjust indexing parameters in real-time, allowing the scanner to skip problematic areas and continue coverage without being constrained by predefined increment values.
4Measurement precision
If operators constantly refer to separate instruments for position feedback, then position information is provided, but scanning accuracy and efficiency are reduced
Solution Approach 1:
The patent merges the operator interface and feedback display directly into the scanner assembly, combining position feedback functionality with the scanning operation itself. This integration provides accurate position information directly at the point of operation, eliminating the need for operators to divert attention to separate instruments and maintaining both accuracy and throughput.
Solution Approach 2:
The integrated operator interface provides real-time feedback on scan position, index location, and scanning status directly to the operator during the scanning process. This continuous feedback loop maintains measurement precision while enabling operators to make immediate adjustments without interrupting the scanning workflow, thereby preserving productivity.
Data Source
AI summary
A non-destructive test apparatus can include a scanner assembly configured to encode movement in, for example, one or two directions. The scanner assembly comprising a carriage comprising one or more respective wheels oriented to rotate in a circumferential scan direction, the carriage housing or otherwise guiding a transducer probe assembly. A first encoder can be configured to generate a first signal representative of displacement of the carriage in the first direction, and the scanner assembly can also include 2024/059948 at least one wheel can be oriented to rotate in an indexing direction, where a second encoder is configured to generate a second signal representative of displacement of the carriage in the second direction in response to rotation of the at least one wheel oriented to rotate in second direction. An operator interface on-board the scanner assembly can receive user input and contemporaneously present a status indication to guide inspection.