Multi-Arm Scanner Assembly for Weld Inspection
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Solution Overview
Problem
Existing non-destructive testing (NDT) methods using independent acoustic probe assemblies face challenges such as increased weight, material, and cost, as well as reduced throughput due to complex setup and rework requirements.
Innovation Solution
A scanner assembly with multiple arms and corresponding probe assemblies is used to position acoustic probe assemblies for full inspection coverage of structures like longitudinal welds, allowing for semi-automated or automated inspection without colliding with the leading edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple independent acoustic probe assemblies are used to achieve full inspection coverage, then inspection coverage is improved, but device complexity and cost increase
Solution Approach 1:
The scanner assembly is divided into multiple arms (first arm, second arm, etc.) that can independently position individual probe assemblies. Each arm-probe combination acts as a segmented unit that contributes to the overall inspection coverage, allowing the system to achieve complete coverage while maintaining modular complexity rather than using one large complex assembly
Solution Approach 2:
Each arm assembly is designed with universal functionality to hold and position an acoustic probe assembly. The arms can be configured to inspect different regions of the object, and the same arm structure serves multiple inspection functions, reducing the need for specialized complex structures for each probe position
2Area of stationary object
If independent acoustic probe assemblies are used, then inspection coverage is improved, but weight and material increase
Solution Approach 1:
Multiple probe assemblies are merged into a single integrated scanner assembly that shares common structural elements, support mechanisms, and control systems. The arms are mechanically coupled to a common support frame, allowing weight sharing and eliminating redundant structural components that would exist if probes were completely independent
Solution Approach 2:
The probe assemblies are nested within or attached to the arm structures, with probes positioned at the ends of arms that can be retracted or extended. This nesting arrangement allows compact storage when not in use and reduces the overall material required compared to having separate independent probe assemblies
3Area of stationary object
If complex setup procedures are used to achieve full coverage, then inspection coverage is improved, but productivity decreases
Solution Approach 1:
The arms are designed with dynamic movement capabilities, allowing them to pivot, extend, and reposition probe assemblies automatically during inspection. This dynamic positioning eliminates the need for complex manual setup procedures and enables rapid reconfiguration for different inspection scenarios, significantly improving productivity
Solution Approach 2:
The scanner assembly incorporates automatic positioning and alignment mechanisms that allow the system to self-adjust and self-position the probe assemblies without requiring complex external setup procedures. The automated arm movements and probe positioning reduce setup time and enable faster inspection throughput
4Area of stationary object
If probe assemblies approach the leading edge of the object, then inspection coverage is improved, but risk of damage increases
Solution Approach 1:
The system incorporates preliminary positioning and alignment actions that carefully guide the probe assemblies toward the leading edge of the object before actual inspection begins. The arms are pre-positioned and the probes are gradually approached to the inspection zone, allowing controlled deployment that minimizes collision risk while maximizing coverage
Solution Approach 2:
The arm structures serve as intermediary elements between the support frame and the probe assemblies, providing mechanical cushioning and controlled movement. The arms can absorb shocks and provide controlled deceleration as probes approach the leading edge, reducing the risk of damage from sudden impacts or collisions
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 enables more complete coverage of structures during NDT, reduces the risk of damage to the probe assembly or the structure, and improves inspection throughput by allowing a single scanner assembly to achieve full inspection coverage.
Implementation Method 1
use of an acoustic inspection technique, such as where one or more electroacoustic transducers are used to insonify a region on or within the object under test, and acoustic energy that is scattered or reflected can be detected and processed
Data Source
AI summary
Apparatus and techniques as shown and described herein can be used to provide non-destructive inspection using a scanner assembly that can have one or more arms that can be used to position a probe assembly such that full inspection coverage of a structure can be achieved in a semi-automated or automated manner using as few as a single scanner assembly. Such apparatus and techniques can include a scanner assembly having multiple arms and corresponding probe assemblies, such as can be used to perform acoustic inspection of a longitudinal weld structure.