Robotic NDT Calibration for Large-Scale Internal Imaging
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Solution Overview
Problem
Existing non-destructive testing (NDT) systems face challenges in accurately determining the relative position of the source and imaging detector of penetrating ionizing radiation for large-scale objects, such as tanks and aircraft fuselages, due to obstructed visibility, which is crucial for precise 3D internal structure measurement.
Innovation Solution
A method involving robotic arms with a source and imaging detector, controlled by a server, uses delta changes in position and orientation to calibrate the relative positions through goniometric calculations, utilizing collimated beams and imaging detector movements to determine the exact alignment without direct visibility, facilitated by mechanical connections or laser measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If robotic arms are used to carry radiation source and imaging detector for large-scale objects, then measurement capability is enabled, but relative position determination becomes difficult due to visibility obstruction
Solution Approach 1:
The patent applies preliminary action by performing calibration measurements before the actual inspection of large-scale objects. The robotic arms first determine their relative positions using calibration objects or methods, establishing accurate geometric relationships in advance. This preliminary calibration enables subsequent measurements to be performed without requiring direct visibility between source and detector during the actual inspection of obscured large-scale objects.
Solution Approach 2:
The patent introduces intermediary elements (calibration objects, reference markers, or intermediate measurement points) that facilitate the determination of relative positions between robotic arms. These intermediaries serve as mediators to establish geometric relationships when direct line-of-sight measurement is blocked by the large-scale object being inspected.
2Measurement precision
If calibration is performed using reference objects for robotic CT scanners, then position accuracy is achieved, but the method becomes time-consuming and computationally intensive
Solution Approach 1:
The patent replaces complex mechanical calibration procedures with computational methods. Instead of relying solely on physical reference objects and mechanical positioning, the system uses computational algorithms to process images and determine relative positions. This substitution reduces the time required for calibration while maintaining or improving position accuracy through sophisticated image processing and geometric calculations.
Solution Approach 2:
The patent changes the calibration approach by transforming physical calibration parameters into computational parameters. Rather than relying on fixed mechanical reference objects, the system uses variable parameters such as image coordinates, detection thresholds, and geometric transformations to establish relative positions. This parameter transformation enables more efficient calibration that is less time-consuming while maintaining precision.
3Manufacturing precision
If robotic arms with good position repeatability are used, then movement precision is achieved, but accuracy for determining relative position is insufficient
Solution Approach 1:
The patent implements feedback mechanisms that continuously monitor and adjust the relative positions of robotic arms during calibration. By using detection systems to monitor the actual positions of radiation source and imaging detector, the system receives feedback information and computes corrections to the relative position determination. This feedback loop compensates for the limitations of position repeatability and improves overall measurement precision.
Solution Approach 2:
The patent replaces direct mechanical measurement of relative positions with optical or detection-based measurement systems. Instead of relying solely on mechanical position repeatability, the system uses detection of radiation patterns, image analysis, or other non-mechanical measurement methods to determine relative positions with higher accuracy, thereby overcoming the limitations of mechanical positioning systems.
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
Enables precise calibration of NDT systems for large-scale objects, allowing accurate 3D internal structure measurement by determining the relative positions of the radiation source and detector, overcoming visibility obstructions and improving measurement efficiency.
Implementation Method 1
a source of penetrating ionizing radiation... a collimated beam of penetrating ionizing radiation passes through the initial area of the large-scale object from the source of penetrating ionizing radiation to the imaging detector of ionizing radiation
Implementation Method 2
An ionizing radiation detector is an imaging detector that not only detects the incidence of penetrating ionizing radiation, but can assign it to a specific pixel of its area sensor
Data Source
AI summary
The calibration method for non-destructive measurement of the internal structure of large-scale objects (4), comprising robotic arm (1) equipped with a source (2) of penetrating ionizing radiation, robotic arm (7) equipped with an imaging detector (6) of ionizing radiation, and a server for synchronized control of the robotic arms connected for communication to the robotic arms (1, 7). Any robotic arm (1, 7) changes its position at least once by a defined delta change. The change in the position of incidence of the beam (5) on the imaging detector (6) is measured, or the change in the position of the robotic arm (7) with the imaging detector (6) is measured to maintain the initial position of incidence of the collimated beam (5). The defined delta change and the associated changes are used to calculate the relative position of the source (2) in relation to the imaging detector (6).