Multimodal Inspection Probe for Simultaneous CMM and NDE Measurement
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Solution Overview
Problem
Current methods for inspecting rotor blades and other machine components with internal geometry or narrow openings are time-consuming, expensive, and require multiple separate processes, as they cannot simultaneously measure external and internal geometry and defects, leading to inefficiencies and inaccuracies.
Innovation Solution
A multimodal measurement probe integrating a coordinate measuring machine (CMM) with non-destructive examination (NDE) sensors like ultrasonic and eddy current probes, allowing simultaneous measurement of external boundaries and internal defects, with adaptive control and data processing to optimize sensor usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate inspection processes (CT, UT, CMM) are used to measure internal and external geometry, then measurement completeness is improved, but inspection time and process complexity increase significantly
Solution Approach 1:
The patent combines multiple inspection methods (CMM probe, UT sensor, EC sensor) into a single integrated inspection probe that can perform all measurements simultaneously. The probe integrates mechanical positioning with ultrasonic and eddy current sensing capabilities, allowing internal and external geometry measurement in one continuous operation rather than separate processes.
Solution Approach 2:
The inspection probe is designed as a universal device that performs multiple functions: it measures external dimensions via CMM contact probe, detects internal defects via ultrasonic sensors, and identifies surface cracks via eddy current sensors. This multi-functional probe eliminates the need for multiple specialized devices and sequential inspection processes.
2Measurement precision
If multiple separate inspection processes are used, then measurement accuracy for different features is improved, but setup time and operational complexity increase
Solution Approach 1:
The patent merges the functionality of CMM, ultrasonic, and eddy current inspection systems into a single integrated probe assembly. This combines the accuracy of contact-based dimensional measurement with the defect-detection capabilities of non-contact NDE methods, while simplifying the overall inspection process by eliminating multiple setup procedures.
3Adaptability or versatility
If CMM probe is used for complex cavity geometry, then measurement capability is improved, but probe bending and setup complexity increase
Solution Approach 1:
The patent combines the CMM probe with ultrasonic and eddy current sensors in an integrated assembly. This allows the system to measure complex cavity geometries using the probe's positioning capability while simultaneously detecting internal defects through the integrated NDE sensors, eliminating the need for separate probe bending operations and reducing setup complexity.
4Measurement precision
If different sensors are used for different measurement types, then measurement specialization is improved, but inspection speed and coordination difficulty increase
Solution Approach 1:
The patent merges specialized sensors (CMM probe for dimensional measurement, ultrasonic sensor for internal defect detection, eddy current sensor for surface crack detection) into a single integrated probe. This allows all measurement types to be performed simultaneously during one continuous inspection operation, dramatically increasing productivity while maintaining the measurement specialization benefits of each sensor type.
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 faster, more accurate inspection of both external and internal geometries and defects, reducing setup time and improving productivity by providing real-time 3D imaging and direct data linkage to CAD models, enhancing dimensional and defect measurement accuracy.
Implementation Method 1
Nondestructive examination (NDE) sensors including ultrasound (UT) sensors
Implementation Method 2
eddy current (EC) sensors
Data Source
AI summary
A method for integrating a measurement device for use in measuring a machine component includes providing a coordinate measuring device, such as a coordinate measuring machine (CMM), and integrating with a plurality of nondestructive examination (NDE) capabilities with a plurality of coordinate measuring device capabilities to form an inspection probe. The method further includes integrating the NDE inspection probe with the coordinate measuring device such that the inspection probe substantially simultaneously measures a plurality of NDE measurements and external/internal geometry and defects of machine component, which are linked to actual component dimensional information provided by CMM. The inspection data can be simultaneously linked to and/or displayed together with a CAD model to enable a direct comparison between the inspection data and the nominal requirements carried on the CAD model.