Robot Ultrasonic Scan Registration to End Item Coordinates
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for translating test data from a testing environment to an end item coordinate system, particularly for ultrasonic scans of three-dimensional parts, are inefficient and inaccurate, often relying on two-dimensional pixel data mapping which does not account for the part's three-dimensional shape.
Innovation Solution
A method and system that utilize a robot with an ultrasonic scanning device, controlled by a computing system, to acquire scan data and translate robot location information to end item location information using common reference points and electronic design models, enabling accurate association of test data with the end item coordinate system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two-dimensional pixel data mapping is used to translate test data, then the translation process is simple, but the accuracy is insufficient and cannot account for three-dimensional part shapes
Solution Approach 1:
The patent transitions from two-dimensional pixel data mapping to three-dimensional coordinate system translation. By establishing a robot coordinate system and transforming robot coordinate data into end item coordinate data through mathematical transformations, the system accurately represents three-dimensional part shapes and provides precise location information for test data points on complex geometries.
Solution Approach 2:
The patent introduces a coordinate transformation system as an intermediary between the robot coordinate system and the end item coordinate system. This intermediary uses common reference points and mathematical transformations to bridge the two coordinate systems, enabling accurate translation of test data locations without direct pixel mapping.
2Manufacturing precision
If pixel data mapping is used for translation, then the process is efficient, but it does not accurately represent three-dimensional part geometries
Solution Approach 1:
The patent replaces the mechanical pixel mapping approach with a mathematical coordinate transformation system. By using robotic positioning data and mathematical transformations between coordinate systems, the system achieves higher accuracy in representing three-dimensional geometries while maintaining computational efficiency through algorithmic processing.
3Adaptability or versatility
If traditional testing coordinate systems are used, then the testing process is straightforward, but the data cannot be effectively integrated with design and manufacturing systems
Solution Approach 1:
The patent creates a universal coordinate transformation framework that serves multiple functions: it translates test data from the robot coordinate system to the end item coordinate system, integrates with design models, and provides location information that can be used across different stages of the product lifecycle including manufacturing, inspection, and maintenance.
Solution Approach 2:
The patent implements feedback mechanisms where test data is translated and associated with design models, allowing the results to be fed back into the design and manufacturing processes. This enables continuous improvement and ensures that testing information is effectively utilized across the product lifecycle.
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
Enables precise integration of test data with the end item coordinate system, facilitating improved product lifecycle management by providing accurate three-dimensional representations of parts, such as aircraft components, through non-destructive inspection.
Implementation Method 1
acquire scan data during a plurality of scans of at least a portion of the part of an end item along a predetermined path plan using an ultrasonic scanning device
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for associating test data for a part under test with an end item coordinate system includes acquiring scan data during a plurality of scans of at least a portion of the part of an end item along a predetermined path plan using an ultrasonic scanning device of a robot. Robot location information associated with the scan data acquired during the plurality of scans is recorded. The robot location information is based on a robot coordinate system. The robot location information is translated to end item location information within the end item coordinate system based on at least three common reference points in the predetermined path plan, an electronic design model of the end item within the end item coordinate system, and the part. A non-destructive inspection (NDI) system for associating the test data with the end item coordinate system is also provided.