Robotic NDT Sensor Positioning for Accurate 3D Data 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 coordinate systems, often resulting in gaps and requiring costly, labor-intensive processes involving multiple software packages and additional instrumentation.
Innovation Solution
A non-destructive inspection apparatus featuring an end effector with a linear actuator and gimbals that allows a sensor to rotate and move relative to the component surface, enabling precise determination of sensor location and correlation of sensor data with three-dimensional coordinates, using a robotic device and controller to manage movement and data correlation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual overlay methods are used to correlate two-dimensional metrological data with three-dimensional CAD models, then data correlation can be achieved, but the process becomes costly, labor intensive, and requires multiple software packages
Solution Approach 1:
The patent combines the two-dimensional sensor data acquisition system with the three-dimensional coordinate system determination into a single integrated robotic inspection system. The robotic device simultaneously collects sensor data and determines positional information, eliminating the need for separate overlay processes and multiple software packages.
Solution Approach 2:
The patent introduces a controller as an intermediary that receives both sensor data and positional information from the robotic device, performs the correlation processing, and outputs the combined results. This mediator handles the complex correlation task centrally, simplifying the overall system architecture.
2Measurement precision
If additional instrumentation and scanning steps are used to generate surface point clouds, then three-dimensional coordinate correlation can be achieved, but the process requires additional capital costs and stretching and alignment operations
Solution Approach 1:
The patent extracts the three-dimensional coordinate determination function from separate scanning instrumentation and integrates it directly into the robotic device that carries the sensor. This eliminates the need for additional laser scanners and separate point cloud generation steps.
Solution Approach 2:
The robotic device is designed to perform multiple functions: it positions the sensor, collects sensor data, determines positional information, and correlates the data with the three-dimensional coordinate system. This multi-functional approach eliminates the need for specialized additional instrumentation.
3Device complexity
If the sensor is fixed on the end effector, then the system structure is simpler, but the system cannot accommodate variations in inspection conditions and achieve precise sensor location determination
Solution Approach 1:
The patent transitions from a fixed sensor mounting to a dynamic mounting system using gimbals that allow the sensor to rotate and adjust its orientation. This dynamic structure enables the sensor to adapt to various inspection conditions while maintaining a relatively simple overall system design.
4Ease of operation
If the sensor position is not precisely tracked, then the system operation is simpler, but gaps appear in data overlays and location accuracy deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the controller continuously receives positional information from the robotic device and uses this information to accurately correlate sensor data with the three-dimensional coordinate system. This feedback loop maintains location accuracy without complicating the overall operation.
Data Source
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.