Robotic Part Inspection With Feedback-Guided Sensor Positioning
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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 are inefficient and prone to errors.
Innovation Solution
A 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 precision and efficiency, incorporating a controllable lens and illumination mechanism to optimize the inspection process.
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 turbine 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 components. The robot mechanism positions and moves the sensor automatically, eliminating manual operations and significantly improving both precision and time efficiency.
Solution Approach 2:
The inspection system performs self-positioning and self-adjustment through feedback control. The robot mechanism automatically adjusts its position and orientation based on sensor input and pre-programmed paths, enabling the system to inspect itself and the workpiece without continuous human intervention, thereby reducing inspection time while maintaining high precision.
2Productivity
If automated inspection systems are implemented, then inspection efficiency is improved, but the systems are inefficient and error-prone compared to manual methods
Solution Approach 1:
The patent incorporates a feedback control unit that receives sensor input and adjusts the robot mechanism's position and orientation accordingly. This closed-loop feedback system ensures accurate positioning, consistent inspection quality, and automatic correction of deviations, thereby improving both efficiency and reliability while reducing error rates.
Solution Approach 2:
The system dynamically adjusts inspection parameters such as sensor position, orientation, and potentially sensor type based on real-time feedback and pre-programmed inspection paths. This flexibility allows the automated system to adapt to different inspection scenarios and maintain high reliability across various component types and defect conditions.
3Measurement precision
If 2D image-based inspection is used, then damage detection can be performed, but it is not suitable for determining damage in absolute units and requires complex pose determination
Solution Approach 1:
The patent transitions from 2D image-based inspection to 3D inspection capabilities through the use of sensors that can capture spatial information in multiple dimensions. The robot mechanism's precise positioning in three-dimensional space, combined with appropriate sensors, enables direct measurement of damage in absolute units without requiring complex 2D-to-3D reconstruction and pose determination algorithms.
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.