Autonomous Metal Sheet Inspection with Onboard Flaw Data Extraction
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Solution Overview
Problem
Existing autonomous metal-plate inspection apparatuses face challenges in efficiently generating inspection results due to the enormous amount of information in flaw detection data, particularly when using ultrasonic phased array technology.
Innovation Solution
The development of an autonomous metal-plate inspection apparatus that includes a position measurement system based on triangulation, a carriage with a navigational transmitter or receiver, an inspection unit with a flaw detection head, and an inspection-result generation unit. This configuration allows for efficient generation of inspection results even with large amounts of flaw detection data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic phased array technology is used for inspection, then detection precision is improved, but the quantity of data increases enormously
Solution Approach 1:
The patent extracts only the essential inspection results from the enormous amount of flaw detection data generated by ultrasonic phased array technology. The inspection-result generation unit processes the raw data and outputs only the necessary conclusions, separating the essential information from the excessive data volume.
Solution Approach 2:
The patent introduces an inspection-result generation unit as an intermediary between the flaw detection head and the host computer. This intermediary processes the enormous amount of raw inspection data and generates condensed inspection results, acting as a mediator that reduces data transmission requirements while preserving essential information.
2Measurement precision
If large amounts of flaw detection data are transmitted to host computer, then inspection result accuracy is improved, but loss of time increases
Solution Approach 1:
The patent performs preliminary processing of inspection data at the inspection unit before transmission to the host computer. The inspection-result generation unit pre-processes the raw flaw detection data and generates inspection results in advance, reducing the amount of data that needs to be transmitted and processed later.
Solution Approach 2:
The inspection-result generation unit serves as an intermediary that processes data locally, generating inspection results that maintain accuracy while reducing transmission time. This intermediary performs necessary computations before data leaves the inspection unit, minimizing communication delays.
3Productivity
If conventional inspection apparatus is used, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The patent integrates multiple functions into the inspection unit, which performs both flaw detection and inspection-result generation. This multi-functional design improves productivity by eliminating the need for separate processing systems while managing complexity through functional integration.
Solution Approach 2:
The inspection unit performs self-processing of inspection data through the inspection-result generation unit, which autonomously generates inspection results from raw flaw detection data. This self-service capability reduces dependency on external processing systems and improves overall inspection 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
The apparatus can efficiently generate and evaluate inspection results, particularly when employing ultrasonic phased array technology, without the need for transmitting large amounts of flaw detection data to a host computer.
Implementation Method 1
an autonomous metal-plate inspection apparatus using a position measurement system... that performs self-position measurement in an indoor space on the basis of the principle of triangulation
Implementation Method 2
Each flaw detection head has one ultrasonic-wave generation source (transducer)... a flaw detection head uses a plurality of ultrasonic-wave generation sources (transducers)
Implementation Method 3
inspection data is reflection echo (A-scope), which is primary information... information regarding 'the magnitude of a defect' is extracted from a peak height of a defect echo, and information regarding 'the position of the defect in a depth direction' is extracted from an ultrasonic-wave propagation time
Data Source
Figure 1~2
Figure 3A
Figure 3B~4A
AI summary
It is an object of the present invention to provide an autonomous metal-plate inspection apparatus capable of efficiently generating inspection results even when flaw detection data has an enormous amount of information, an inspection method, and a method for manufacturing a metal plate by using the inspection apparatus. Autonomous metal-plate inspection apparatuses 300a and 300b of the present invention includes a carriage 14 that travels on a surface of a metal plate, a navigational transmitter 12b or a navigational receiver 12a, an inspection device 15 that includes flaw detection head 35 including an inspection sensor, which scans an inspection region of the metal plate 10, and an inspection-result generation unit 71 for generating an inspection result, and a control unit that performs, on the basis of a position of the carriage 14 measured by the position measurement system and a target position, which is the position of the carriage 14, control the carriage 14 to autonomously travel to the target position and control the flaw detection head 35 to scan. The inspection-result generation unit 71 generates the inspection result on the basis of inspection information obtained by the inspection sensor and position information of the flaw detection head 35.