Automated Eddy Current Inspection Path for Weld Probe Alignment
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Solution Overview
Problem
Automated Eddy Current Inspection (ECI) systems for friction-welded aircraft components face challenges due to variations in blade positioning, leading to inaccuracies in probe placement and limited inspection value, as the nominal tool paths do not account for fabrication and positioning tolerances, resulting in potential misalignment of the inspection probe with the welds.
Innovation Solution
A computer-implemented method and system for automated part inspection that includes a corrective machine tool program to adjust the inspection tool path, ensuring constant contact and orientation, and calibration processes to accurately determine the probe's position and orientation, using ECI to inspect welds by adjusting voltage and angle to match predetermined signal amplitudes and phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated ECI systems use nominal tool path positioning, then the inspection process is automated and efficient, but the probe is misplaced due to fabrication and positioning tolerances, reducing inspection accuracy
Solution Approach 1:
The system performs preliminary scanning of the part surface to capture actual geometry and weld locations before generating the inspection tool path. This preliminary action allows the system to adapt the nominal tool path to the actual part variations, ensuring accurate probe placement while maintaining automation.
Solution Approach 2:
The system dynamically adjusts tool path parameters based on measured part geometry. By changing the positioning parameters from fixed nominal values to measured actual values, the system compensates for fabrication and positioning tolerances, achieving both automation and precision.
2Productivity
If the inspection probe follows a nominal tool path, then the inspection process is simple and fast, but the probe does not accurately locate the welds due to positioning variations, limiting inspection value
Solution Approach 1:
A preliminary scanning phase is performed to map the actual weld locations and part geometry. This preliminary action enables subsequent inspection to follow accurate paths without sacrificing speed, as the adaptation has already been completed.
Solution Approach 2:
The system uses feedback from the preliminary scan data to adjust the inspection tool path. The measured actual geometry feeds back into the tool path generation process, creating an adaptive system that maintains both speed and reliability.
3Measurement precision
If manual inspection is performed with an inspector manipulating a portable eddy current instrument, then probe placement accuracy is maintained, but the inspection process is time-consuming and less efficient
Solution Approach 1:
The automated system performs the adaptation function that would otherwise require manual intervention. By using automated scanning and tool path generation based on measured geometry, the system achieves manual-level accuracy without the time cost of manual operation.
Solution Approach 2:
The system replaces manual mechanical manipulation with automated measurement and control. The inspection probe is positioned automatically based on measured geometry rather than manual operator skill, maintaining accuracy while dramatically improving efficiency.
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 enhances the accuracy of automated ECI by ensuring precise probe placement and orientation, maintaining constant contact and pressure, and adjusting for variations in part geometry, thereby improving the inspection's effectiveness and reliability.
Implementation Method 1
Eddy Current Inspection (ECI) is typically used
Data Source
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AI summary
A system and method for automated part inspection are provided. The method comprises receiving a corrective machine tool program comprising instructions for causing a Numerical Control machine tool to machine at least one finished surface of a part, the corrective machine tool program differing from a nominal machine tool program; determining from the machine tool program a desired position and a desired orientation of an inspection tool relative to the at least one finished surface; and generating an inspection tool path program defining a movement of the inspection tool relative to the part, the inspection tool path program comprising instructions for placing the inspection probe at the desired position and the desired orientation and acquiring at least one measurement of the at least one new finished surface.