Automated NDI Inspection System with Integrated Positional Sensing
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Solution Overview
Problem
Current non-destructive inspection (NDI) systems face challenges in accurately and efficiently acquiring both NDI data and positional data, especially for complex structures, due to limitations in sensor positioning and data acquisition frequency, leading to time-consuming and labor-intensive manual scanning and limited accuracy.
Innovation Solution
An inspection system equipped with a robot having a movable arm carrying non-destructive inspection sensors and positional sensors, capable of acquiring data independently of motion control programs, allowing for simultaneous data acquisition and recording positional data at high frequencies, including three-dimensional positioning, to generate precise images of structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual scanning is used with trained technicians moving sensors over the structure, then inspection quality depends on technician performance, but the process is time-consuming and labor-intensive
Solution Approach 1:
The system uses automated sensors that independently acquire both NDI data and positional data without requiring continuous human intervention. The sensors self-coordinate their data collection, eliminating the need for technicians to manually track and record defect locations while maintaining high inspection quality through consistent automated measurement protocols.
Solution Approach 2:
The patent replaces the mechanical manual scanning process with an automated system where sensors are moved by a positioning mechanism (such as a robotic arm or automated cart). This substitution eliminates human labor intensity and time consumption while maintaining measurement precision through controlled, repeatable sensor positioning and automated data correlation.
2Reliability
If sensors are moved manually by technicians, then location information must be tracked by the same technician watching the display, but this increases human error and reduces efficiency
Solution Approach 1:
The system merges the NDI sensor and positional tracking into a single integrated unit. The sensor simultaneously captures both the structural inspection data and its own positional information, eliminating the need for separate tracking systems and reducing coordination complexity. This unified approach ensures that defect locations are automatically and accurately recorded without requiring technicians to manually correlate data with position.
3Productivity
If automated scanning systems are implemented, then inspection efficiency increases, but accurate association of NDI data with positional information becomes more difficult
Solution Approach 1:
The system incorporates real-time feedback mechanisms where the sensor continuously reports its positional data alongside NDI measurements. This feedback loop ensures that each inspection data point is automatically correlated with its precise location, maintaining high measurement precision even as inspection speed increases. The system adjusts and verifies positioning information continuously throughout the automated scanning process.
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 system enables rapid and precise acquisition of NDI data with associated positional information, enhancing the detection and localization of flaws in complex structures, reducing human error and increasing inspection efficiency.
Implementation Method 1
a pulse-echo (PE), through-transmission (TT), or shear-wave sensor may be used to obtain ultrasonic data, such as for thickness gauging, detection of laminar defects and porosity, and/or crack detection in the structure
Implementation Method 2
at least one positional sensor for acquiring positional data of the non-destructive inspection sensor
Data Source
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AI summary
A system and method for inspecting a structure are provided. The system includes at least one non-destructive inspection ("NDF) sensor capable of acquiring data indicative of at least a portion of the structure, and at least one positional sensor for acquiring positional data of the NDI sensor. The system also includes a mechanism operable to trigger the NDI sensor and/or the positional sensor to acquire data such that data indicative of the structure and the positional data are acquired at approximately the same time. The system further includes a movable arm carrying the sensors and movably attached to a base. The system includes a data acquisition system capable of communicating with the sensors such that the data acquisition system generates information indicative of at least a portion of the structure based on the data acquired by the sensors.