Robotic Part Inspection With Feedback-Guided Defect Detection
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Solution Overview
Problem
Current methods for inspecting mechanical components like turbine blades are tedious, time-consuming, imprecise, and error-prone, especially when dealing with complex shapes and operational stresses that cause damage such as erosion and corrosion, and existing automated systems lack efficiency and accuracy.
Innovation Solution
An automated robotic inspection system that uses a robot mechanism to support the part, with a sensor and feedback control unit that adjusts the position and pose based on real-time and past sensor input to enhance inspection focus and accuracy, incorporating a controllable lens, illumination, and filter systems to optimize inspection results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection or NDE techniques are used, then inspection can be performed on complex mechanical components, but the process is tedious, time-consuming, imprecise, and error-prone
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated robotic system that uses sensors (optical, acoustic, or other non-contact sensors) to inspect turbine blades. The robot mechanism positions and orients the blade while sensors automatically detect damage, eliminating the need for manual visual or contact-based NDE techniques.
Solution Approach 2:
The inspection system uses feedback control where sensor input automatically controls the robot mechanism's movement and orientation. The system self-adjusts based on real-time sensor data, with the feedback control unit modifying the robot's path and sensor positioning without human intervention, making the system self-regulating and autonomous.
2Productivity
If automated inspection systems are implemented, then inspection speed and consistency improve, but system complexity increases
Solution Approach 1:
The robotic inspection system is designed to be versatile and adaptable to different inspection scenarios. The robot mechanism can handle various blade types and configurations, and the sensor system can detect multiple defect types (cracks, erosion, corrosion) using the same basic platform, reducing the need for multiple specialized systems.
Solution Approach 2:
The system incorporates feedback control where sensor input real-time controls the robot mechanism's position and orientation. This closed-loop control automates complex positioning tasks, reducing the need for complex pre-programming while maintaining high inspection efficiency and adaptability.
3Reliability
If feedback control with past sensor input is used, then inspection accuracy and defect detection reliability improve, but processing and control complexity increases
Solution Approach 1:
The feedback control unit receives sensor input and uses it to control the robot mechanism's movement and sensor positioning. The system incorporates past sensor input to inform current inspection decisions, creating a closed-loop system that continuously adjusts based on accumulated data, thereby improving detection reliability while automating complex control decisions.
Solution Approach 2:
The system stores past sensor input and uses this historical data to guide current inspection actions. By analyzing previous sensor readings and inspection results, the system can pre-adjust inspection parameters, focus on high-probability defect areas, and optimize the inspection path before actual detection occurs.
Data Source
AI summary
A method for robotic inspection of a part, includes the steps of: supporting the part with a robot mechanism; obtaining part-related sensor input with a sensor positioned to inspect the part supported by the robot mechanism; and controlling movement of the robot mechanism relative to the sensor, wherein the controlling is done by a feedback control unit which receives the sensor input, and the feedback control unit is configured to control the robot mechanism based upon the sensor input.