Robot NDT Transducer Force Feedback Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing non-destructive testing (NDT) methods, particularly ultrasonic testing, face challenges in maintaining suitable contact with test objects that are rough, irregular, small, or non-homogeneous, leading to suboptimal measurement quality and inefficiencies in manual and automated systems.
Innovation Solution
A robot system equipped with a force-sensing device and controller that generates feedback signals to adjust the position and orientation of the NDT transducer, combining contact force/moment measurements with NDT feedback to ensure adequate contact pressure and optimal measurement quality, allowing for high-quality testing without the need for water immersion or squirter systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual ultrasonic testing is performed with a hand-held transducer, then the inspection can be performed on various test objects, but the inspection process is slow and requires careful attention from an experienced operator
Solution Approach 1:
The automated UT system performs inspection tasks autonomously without requiring continuous operator attention. The robot system automatically positions the transducer, maintains contact force through force feedback control, and collects measurement data, enabling the system to serve itself and eliminating the need for experienced operators to continuously monitor and adjust the inspection process
Solution Approach 2:
The patent replaces manual mechanical operation with an automated robot system that uses force sensors and feedback control to automatically maintain transducer contact with the test object. This substitution of manual mechanical control with automated sensing and control systems dramatically increases inspection speed while reducing operator burden
2Ease of manufacture
If water squirters or water immersion are used for automated ultrasonic testing, then acoustic coupling is maintained without contact, but the system becomes less practical and less cost efficient
Solution Approach 1:
The patent extracts and eliminates the water-based coupling system from the automated UT setup. By using force feedback control to maintain direct contact between the transducer and test object, the system removes the need for water squirters, coupling boxes, or immersion tanks, thereby simplifying the overall system while maintaining acoustic coupling effectiveness
Solution Approach 2:
The patent introduces a force sensing and feedback control system as an intermediary between the transducer and test object. This intermediary mechanism enables precise control of contact force, ensuring adequate acoustic coupling without requiring water-based methods, thus replacing the water intermediary with a controlled mechanical contact system
3Measurement precision
If contact forces are controlled using passive methods like springs, then the transducer maintains contact with the test object, but the system lacks precision in adapting to surface irregularities
Solution Approach 1:
The patent implements active feedback control where force sensors measure the actual contact force between the transducer and test object, and this measurement is fed back to the robot control system. The controller continuously adjusts the transducer position and contact force based on this feedback, enabling precise adaptation to surface irregularities while maintaining optimal acoustic coupling
Solution Approach 2:
The patent transitions from static passive force control (springs) to dynamic active force control. The robot system continuously adjusts its position and applied force in real-time based on feedback from force sensors, enabling the system to adapt dynamically to varying test object geometries and surface conditions, thereby achieving superior measurement precision
4Reliability
If the transducer is separated from the test object by a couplant or water, then acoustic coupling is achieved, but the system requires additional equipment and becomes less cost efficient
Solution Approach 1:
The patent extracts and eliminates the couplant (water or oil) from the acoustic coupling system. By using force feedback control to ensure direct contact between the transducer and test object surface, the system achieves reliable acoustic coupling without requiring any intermediate couplant, thereby reducing equipment complexity and cost
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 system achieves high-quality NDT measurements by adapting to surface irregularities and misalignments, improving measurement accuracy and speed, and reducing the need for precise object positioning and water-based coupling methods.
Implementation Method 1
a force-sensing device configured to provide measurements of contact forces and/or contact moments between the surface of the test object and the NDT transducer
Implementation Method 2
Ultrasonic testing (UT) is based on the propagation of ultrasonic waves in the object or material to be tested and can be used for detecting inhomogeneities of density or elasticity
Implementation Method 3
the controller further comprises a force-sensing module configured to process measurements of the force-sensing device to generate a force feedback signal, and a signal generation module configured to generate the actuation signal based on the predefined trajectory, the NDT feedback signal and the force feedback signal
Data Source
AI summary
A robot system for non-destructive testing (NDT) of a test object, including: a transducer holder and an NDT transducer to perform an NDT on the surface of the test object; a memory to store a predefined trajectory of the NDT transducer; a force-sensing device to provide measurements of the contact forces and/or contact moments between the surface of the test object and the NDT transducer and/or the transducer holder; a controller to generate an actuation signal based on the predefined trajectory; and a positioning device to control the position and/or orientation of the NDT transducer relative to the test object based on the actuation signal. Consequently, the position and/or orientation of the NDT transducer relative to the test object and the contact forces and/or contact moments between the NDT transducer and/or the transducer holder and the test object can be automatically adapted to improve the quality of the NDT measurement.