Laser Shearography End Effector for Interchangeable Robot Tooling
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Solution Overview
Problem
There is a need for an improved non-destructive testing system that can be used interchangeably with other inspection and repair tools on an industrial robot for composite parts, enabling multiple processes to be conducted by a single robot.
Innovation Solution
A laser shearography end effector is integrated with a frame and a slave tool changer, allowing it to be releasably connected to an industrial robot, with a master tool changer for power and communication, facilitating interchangeable use with other end effectors for inspection and repair operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single industrial robot is used for multiple inspection and repair operations, then versatility and productivity are improved, but device complexity increases due to the need for interchangeable end effectors
Solution Approach 1:
The industrial robot is designed with a universal interface and control system that can accommodate multiple types of end effectors (inspection tools, repair tools, laser shearography systems). The robot controller includes a tool manager that can recognize and control different tool types through standardized communication protocols, allowing one robot to perform diverse functions without requiring separate robotic systems for each operation.
Solution Approach 2:
The system is divided into modular components: the robot platform, the interchangeable end effectors, and the tool changer mechanism. Each end effector is designed as a separate, self-contained module with its own control electronics and communication interface, allowing independent development, maintenance, and replacement without affecting the core robot system.
2Productivity
If multiple inspection and repair tools are integrated into a single robot, then productivity increases, but ease of operation decreases due to the complexity of tool management
Solution Approach 1:
The tool changer system operates automatically without requiring manual intervention. The robot controller autonomously manages tool selection, positioning, and exchange based on program instructions. The system includes automatic tool recognition and calibration features that eliminate manual setup procedures, allowing operators to simply load programs while the system handles all tool management operations.
Solution Approach 2:
The system incorporates real-time feedback mechanisms where the tool manager continuously monitors tool status, positioning, and operational parameters. Sensors detect tool presence, alignment status, and functional state, providing automatic adjustments and alerts to the control system. This feedback loop ensures smooth transitions between different end effectors and maintains optimal operation without operator intervention.
3Measurement precision
If a laser shearography system is integrated with a robot via slave tool changer, then measurement precision is improved, but device complexity increases due to synchronization requirements
Solution Approach 1:
The system performs preliminary synchronization setup during the tool changing process. The control system pre-calibrates timing parameters, establishes coordinate transformations between the robot frame and the laser shearography system frame, and pre-loads synchronization routines into the tool manager. This preliminary configuration ensures that when the tool is in use, precise synchronization occurs automatically without complex real-time calculations.
Solution Approach 2:
The tool manager acts as an intermediary layer between the robot controller and the laser shearography system. It handles all synchronization complexity by translating robot positioning commands into appropriate trigger signals for the shearography system, managing timing offsets, and coordinating data acquisition with robot movement. This intermediary abstraction isolates the complexity from the user while maintaining precise measurement.
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
Enables efficient and versatile inspection and repair of composite parts by allowing a single robot to perform multiple tasks, including non-destructive testing, using a laser shearography system that can be easily switched between different processes.
Implementation Method 1
A laser shearography system supported on the frame for movement with the frame. The laser shearography system includes an excitation system and a laser shearography camera.
Implementation Method 2
laser shearography end effector for inspection in an automated inspection and repair system for composite parts
Data Source
AI summary
A laser shearography end effector for inspection in an automated inspection and repair system for composite parts. A laser shearography system including an excitation system and a laser shearography camera is supported on a frame for movement with the frame. A slave tool changer is secured to the frame for releasably and operatively connecting the inspection tool to an industrial robot such that the industrial robot can move the inspection tool along a work piece as the laser shearography system inspects the work piece and such that the laser shearography end effector is interchangeable with at least one other automatic inspection end effector or repair end effector of the automated inspection and repair system.