Self-Contained Multi-Axis Position Encoder for NDE Scanning Probe
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Solution Overview
Problem
Current nondestructive evaluation (NDE) systems for industrial applications are limited to single-dimensional scanning, making it impractical to perform multi-dimensional scans without motion control systems, which restricts accuracy and flexibility, especially in field settings where transporting equipment may not be feasible.
Innovation Solution
A scanning probe with a self-contained multi-axis position encoder that correlates multi-dimensional probe motion with spatial locations on the test object surface, enabling free-hand, multi-dimensional scanning without the need for external motion control systems, using opto-mechanical or opto-electrical encoders for accurate data correlation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a motion control system is used for multi-dimensional scanning, then scanning accuracy is improved, but device complexity and portability are worsened
Solution Approach 1:
The patent divides the positioning function into two independent parts: a simple motion control system for basic movement and a self-contained multi-axis position encoder attached to the probe for precise position tracking. This segmentation allows the complex positioning task to be handled by the encoder while the motion control system remains simple, resolving the contradiction between accuracy and complexity.
Solution Approach 2:
The position encoder acts as an intermediary device that bridges the simple motion control system and the requirement for high scanning accuracy. It independently tracks probe position and rotation without adding complexity to the motion control system, enabling accurate multi-dimensional scanning while maintaining system simplicity and portability.
2Measurement precision
If a motion control system is used for multi-dimensional scanning, then scanning accuracy is improved, but ease of operation and field deployment are worsened
Solution Approach 1:
The position encoder is self-contained and autonomously tracks probe position and orientation without requiring external motion control infrastructure. This self-service capability enables field technicians to perform accurate multi-dimensional scanning directly at the inspection site without transporting complex motion control equipment, greatly improving ease of operation and field deployment.
3Device complexity
If probe rotation is not compensated, then device complexity is reduced, but measurement precision is worsened
Solution Approach 1:
The patent merges the position tracking and rotation compensation functions into a single integrated position encoder system. The encoder simultaneously measures probe position coordinates and rotation angle, then automatically compensates for rotation effects on position measurements. This unified approach maintains measurement precision without significantly increasing device complexity.
Solution Approach 2:
The position encoder provides real-time feedback on probe rotation angle and uses this information to dynamically compensate for rotation effects on position determination. This feedback mechanism ensures accurate position measurement despite probe rotation, resolving the contradiction between simplicity and precision.
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
Facilitates fast, accurate, and flexible multi-dimensional scanning of test objects, allowing for impromptu field inspections without the need for complex motion control equipment, maintaining NDE accuracy and enabling efficient data processing for internal structural characterizations.
Implementation Method 1
using opto-mechanical or opto-electrical encoders for accurate data correlation
Data Source
AI summary
A scanning probe for an industrial nondestructive evaluation (NDE) ultrasound or eddy current scanning system. The scanning probe gathers reflected waveform data indicative of internal characteristics of the test object. The scanning probe also includes a self-contained multi-axis position encoder that correlates both multi-dimensional probe underside translation and rotation motion across the test sample surface with the multi-dimensional spatial location on the test object surface. The position encoder compensates for probe rotation that would otherwise negatively impact probe position determination accuracy. A data acquisition system combines sets of positional and waveform data for processing by an NDE analyzer.