Robotic Ultrasonic Bond-Line Inspection Without Encoder Drag
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Solution Overview
Problem
Existing ultrasonic inspection methods for adhesively bonded joints are labor-intensive, provide incomplete data, and are hindered by manual manipulation and rotary encoders, which slow down the inspection process and reduce the fiscal benefits of adhesive bonding.
Innovation Solution
An automated ultrasonic inspection system using a robotic arm assembly with a flexible ultrasonic transducer and gimbal mount, capable of multiple-axis motion, to rapidly collect and analyze bond-line data, eliminating the need for rotary encoders and ensuring accurate, high-speed inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual manipulation of ultrasonic inspection probe is used, then inspection accuracy can be maintained, but inspection speed decreases and labor intensity increases
Solution Approach 1:
The patent replaces manual mechanical manipulation of the ultrasonic probe with an automated robotic system. The robotic arm positions and moves the probe according to pre-programmed paths, eliminating the need for operator intervention while maintaining consistent inspection quality and enabling faster inspection cycles.
Solution Approach 2:
The automated inspection system performs the entire inspection process autonomously without requiring operator input during execution. The robotic system self-navigates to inspection positions, maintains proper probe orientation, and collects data continuously, making the process self-service and significantly improving productivity.
2Loss of information
If rotary encoders are integrated with probe housing, then position tracking is enabled, but friction drag slows down probe motion
Solution Approach 1:
The patent eliminates mechanical rotary encoders from the probe housing and replaces them with non-contact optical or magnetic sensing systems. These sensors track probe position and orientation without physical contact, eliminating friction drag while maintaining precise position tracking capability.
Solution Approach 2:
The system introduces an intermediary tracking field (optical or magnetic) between the probe and the positioning system. This field-based intermediary enables position measurement without mechanical contact, eliminating the friction that would otherwise slow probe motion.
3Measurement precision
If probe is presented slowly and deliberately, then data accuracy is ensured, but inspection time increases
Solution Approach 1:
The automated robotic system enables continuous inspection without the start-stop movements inherent in manual operation. The probe moves continuously along programmed paths at optimized speeds, collecting data without interruption. This continuous action maintains data accuracy through consistent positioning while dramatically reducing total inspection time.
Solution Approach 2:
The system dynamically adjusts probe speed and positioning based on inspection requirements. High-speed movement is used in areas requiring less detail, while slower movement is automatically applied in critical areas requiring higher measurement precision, optimizing the balance between speed and accuracy throughout the inspection.
4Reliability
If manual re-positioning is done to verify bond-line imaging, then inspection completeness is improved, but inspection speed decreases
Solution Approach 1:
The automated system incorporates real-time feedback from ultrasonic signals to assess bond-line imaging quality. When anomalies are detected or imaging quality is insufficient, the system automatically triggers re-positioning and re-scanning of affected areas, ensuring inspection completeness without requiring manual verification of every location.
Solution Approach 2:
The robotic system performs preliminary scanning of the entire bond-line area to identify potential problem zones before conducting detailed verification scans. This preliminary action allows the system to focus re-positioning and verification efforts only where needed, maintaining inspection completeness while minimizing unnecessary re-positioning time.
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 provides reliable, rapid, and complete bond-line data analysis, reducing material scrap and enhancing the fiscal benefits of adhesive bonding by increasing production efficiency.
Implementation Method 1
The ultrasonic inspection probe is pressed against the surface, i.e., manually manipulated, to introduce an acoustic pulse into the structure. The probe can measure the acoustic impedance in the structure (i.e., the speed of sound in the structure) as a function of the material density.
Implementation Method 2
An automated ultrasonic inspection system using a robotic arm assembly with a flexible ultrasonic transducer and gimbal mount
Implementation Method 3
An automated ultrasonic inspection system using a robotic arm assembly with a flexible ultrasonic transducer and gimbal mount, capable of multiple-axis motion
Data Source
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AI summary
An inspection system for determining the efficacy and veracity of a bond-line, comprising: a robotic arm assembly providing a gimbal mount for enabling linear and rotary translation about multiple axes; an ultrasonic transducer affixed to the gimbal mount of the robotic arm assembly and comprising a planar array of transducer elements, each transducer element capable of transmitting and receiving reflected ultrasonic energy indicative of changes in acoustic impedance within the bond-line. The reflected energy of each transducer element provides acquired bond-line data indicative of the efficacy of the bond-line while select transducer elements produce orientation data indicative of the orientation of the planar array relative to the contour of the bonded joint. The bond-line and orientation data are combined to determine whether the direction of the transmitted pulse should be altered to validate the bond-line data.