Robotic NDT End Effector for 3D Sensor-to-CAD Correlation
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Solution Overview
Problem
Current non-destructive inspection methods for components, such as aircraft parts, face challenges in accurately correlating two-dimensional metrological data with three-dimensional CAD models, often resulting in gaps and requiring costly, labor-intensive processes involving multiple software packages and additional instrumentation.
Innovation Solution
A non-destructive inspection apparatus with an end effector featuring a linear actuator, gimbals, and a sensor that allows for articulation to maintain contact with the inspection surface while providing precise positional information, enabling accurate correlation of sensor data with three-dimensional coordinates without the need for the end effector to be tangent to the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual typing of three dimensional component coordinate information is used to correlate two dimensional metrological data with three dimensional CAD models, then the correlation process can be completed, but the process becomes costly and labor-intensive
Solution Approach 1:
The patent replaces manual typing operations with an automated robotic system that uses sensors to capture metrological data and automatically correlates it with CAD models. The robotic arm with integrated sensors eliminates the need for manual coordinate input, transforming a labor-intensive process into an automated one while maintaining correlation accuracy.
Solution Approach 2:
The system enables self-service by allowing the robotic inspection apparatus to automatically perform data correlation without human intervention. The robotic system captures its own positional information through sensors and automatically correlates this data with the CAD model, eliminating the need for manual coordination and reducing labor requirements.
2Measurement precision
If a laser-based three dimensional scanner is used to generate surface point cloud data, then three dimensional coordinate information can be obtained, but additional instrumentation and scanning steps are required
Solution Approach 1:
The patent merges the functions of the laser scanner and the inspection robot into a single integrated system. The robotic arm carries the sensor array, and both components work together as one coordinated unit rather than separate systems. This integration eliminates the need for additional laser scanning equipment and reduces the number of separate scanning steps required.
Solution Approach 2:
The robotic inspection system performs multiple functions: it positions the sensor array, captures metrological data, tracks its own position, and correlates data with CAD models. This multi-functional approach replaces the need for dedicated laser scanning equipment, as the robotic system itself provides three dimensional positioning and data capture capabilities.
3Loss of information
If two dimensional metrological data is overlaid onto three dimensional CAD models, then defect location can be identified, but one-to-one correlation of A-scan waveforms cannot be achieved
Solution Approach 1:
The patent transitions from two dimensional data overlay to three dimensional spatial correlation by using the robotic arm's three dimensional positioning capabilities. The system captures the sensor's position in three dimensional space and directly correlates this with the CAD model coordinates, enabling one-to-one correspondence between waveform data and specific locations on the component surface.
Solution Approach 2:
The system uses feedback from the robotic arm's position tracking system to continuously update the correlation between sensor data and CAD model locations. The position tracking provides real-time feedback on the sensor's three dimensional coordinates, allowing the system to maintain accurate one-to-one correlation between each A-scan waveform and its corresponding location on the component.
Data Source
Figure 1A
Figure 1B~1D
Figure 2A~2B
AI summary
A non-destructive inspection apparatus includes a robotic device, an end effector coupled to the robotic device, and a controller coupled to the robotic device and the end effector. The controller is configured to determine, based on an amount of linear actuator extension of a sensor of the end effector and an amount of rotation of the sensor about a first axis of rotation and a second axis of rotation, a displacement of the sensor relative to a center point of the end effector surface so as to determine location information of the sensor, wherein sensor data for a location on a surface of a test article is sensed and correlated with the determined location information of the sensor. The robotic device controls movement of the end effector and is configured to determine, during the movement of the end effector, positional information for the center point of the end effector surface.