Robotic Inspection Arm with Telescoping Scanner for Limited Access
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Solution Overview
Problem
Conventional nondestructive inspection (NDI/NDE) methods face challenges in accessing and inspecting complex aerospace structures, often requiring part removal or expensive redesigns due to limited access, and suffer from reduced sensitivity due to 'lift-off' issues when sensors are not completely seated on non-flat surfaces.
Innovation Solution
An extended reach inspection apparatus comprising a robotic manipulator arm with a telescoping extension mechanism and a scanner device, including a probe with a bias means to maintain sensor contact and prevent lift-off, allowing for effective inspection in limited access areas by moving the scanner device between retracted and extended positions and rotating it in a circular path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional NDE tools are used to inspect limited access areas, then part removal or expensive redesigns are required, but the device complexity and cost increase significantly
Solution Approach 1:
The manipulator arm is divided into multiple segments (proximal end arm segment, intermediate arm segments, distal end arm segment) that can be articulated independently through movable joints, enabling the tool to navigate complex geometries and reach limited access areas without requiring part removal or redesign
2Adaptability or versatility
If the sensor is rotated or moved along a non-flat surface, then the inspection coverage increases, but lift-off occurs reducing detection sensitivity
Solution Approach 1:
The scanner device incorporates a dynamic positioning system with a movable joint that allows the sensor to self-adjust its angle and position in real-time, maintaining optimal contact with the surface throughout the full range of motion and eliminating lift-off issues during rotation or movement along non-flat surfaces
Solution Approach 2:
The system uses feedback mechanisms to monitor sensor-to-surface distance and automatically adjusts the sensor position to maintain consistent contact, ensuring adequate sensitivity for defect detection over the full range of motion
3Area of stationary object
If the scanner device is positioned at a distance from the robotic arm, then the inspection coverage area increases, but the control precision decreases
Solution Approach 1:
The distal end arm segment is equipped with localized control features including a movable joint and telescoping extension mechanism that provide precise positioning control specifically at the scanner device location, maintaining high positioning accuracy even when the scanner is extended to cover large inspection areas
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 solution enables accurate detection of defects over a full range of motion with improved sensitivity, reducing the need for part removal or redesign and enhancing the effectiveness of NDI/NDE in complex structures by maintaining sensor contact and preventing lift-off.
Implementation Method 1
a bias means received in the opening in-between the first end of the probe and the sensor to urge the sensor away from the first end of the probe
Data Source
AI summary
An extended reach inspection apparatus may include a scanner device and a robotic manipulator arm. The robotic manipulator arm may include a plurality of arm segments including a distal end arm segment and a proximal end arm segment. A movable joint may couple the distal end arm segment to the robotic manipulator arm. A telescoping extension mechanism may be coupled to the distal end arm segment. The scanner device is mounted to the telescoping extension mechanism for moving the scanner device between a retracted position proximate the robotic manipulator arm and an extended position at a distance from the robotic manipulator arm. A control handle may be coupled to the proximal end arm segment of the plurality of arm segments for manipulating the robotic manipulator arm.