Robotic Ultrasonic Inspection for Parallel Surface Crack Detection
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Solution Overview
Problem
Existing inspection systems for industrial surfaces face challenges in detecting corrosion or damage, particularly cracks and corrosion parallel to the sensing direction, often requiring system shutdowns, safety procedures, and exposing personnel to hazards, leading to incomplete inspections with human error and inadequate coverage.
Innovation Solution
A robotic inspection system with self-aligning and self-stabilizing sensor sleds that traverse industrial surfaces, maintaining perpendicular contact and orientation to ensure thorough and accurate inspections, even on contoured surfaces, using a modular sled array system with adjustable sensor spacing and pivot points for obstacle navigation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inspection systems are used, then personnel can perform inspections, but safety hazards and system shutdowns are required
Solution Approach 1:
The robotic inspection system performs inspections autonomously without requiring human intervention or system shutdowns. The robot navigates, positions sensors, and collects data independently, eliminating the need for personnel exposure to hazardous environments and avoiding production downtime associated with traditional inspection methods.
Solution Approach 2:
The patent replaces manual mechanical inspection operations with an automated robotic system equipped with sensors and navigation capabilities. This substitution eliminates human exposure to hazards while maintaining inspection effectiveness, resolving the contradiction between safety and productivity.
2Measurement precision
If manual inspection methods are used, then inspections can be performed, but human error and incomplete coverage occur
Solution Approach 1:
The robotic inspection system incorporates real-time feedback mechanisms where sensor data is continuously collected, analyzed, and used to adjust inspection parameters. This ensures complete coverage and accurate detection of defects while eliminating human error through automated data processing and decision-making algorithms.
Solution Approach 2:
The system dynamically adjusts inspection parameters such as sensor positioning, scanning speed, and detection thresholds based on real-time conditions. This adaptability ensures consistent inspection quality and complete coverage regardless of surface variations or environmental factors, overcoming limitations of manual methods.
3Device complexity
If sensors are positioned fixedly, then system complexity is reduced, but detection of parallel cracks and corrosion is difficult
Solution Approach 1:
The robotic inspection system employs dynamic sensor positioning where sensors can move and reorient themselves during the inspection process. This dynamic capability allows sensors to detect cracks and corrosion in various orientations including parallel defects, while the robot's control system manages the complexity through automated positioning algorithms.
Solution Approach 2:
The system adds spatial dimensions to sensor positioning by enabling multi-axis movement and rotation of sensors on the robotic platform. This dimensional freedom allows detection of defects in any orientation without requiring overly complex fixed sensor arrays, as the robot can physically reposition sensors to optimal detection angles.
4Reliability
If robotic inspection systems are implemented, then safety and coverage improve, but couplant loss and reconfiguration time increase
Solution Approach 1:
The robotic inspection system performs preliminary actions by pre-positioning sensors and pre-loading couplant before inspections begin. The robot carries sufficient couplant and configures sensor arrays in advance, minimizing reconfiguration time during operations and reducing overall inspection downtime while maintaining comprehensive coverage.
Solution Approach 2:
The system uses composite sensor arrays that integrate multiple sensor types and functions into unified modules. This modular composite design allows rapid reconfiguration by swapping entire functional units rather than individual sensors, reducing reconfiguration time while maintaining comprehensive inspection capabilities.
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 accurate, efficient, and safe inspections of industrial surfaces, reducing human error and improving coverage while minimizing couplant loss and down-time, allowing for real-time data processing and rapid reconfiguration of sensor arrays.
Implementation Method 1
a sensor sled including an ultrasonic sensor
Data Source
AI summary
Systems, methods, and apparatus for ultra-sonic inspection of a surface are described. An example system may include an inspection robot structured to move in a direction of travel on an inspection surface. The inspection robot may include a payload including a first ultrasonic (UT) phased array and a second UT phased array, the first UT phased array and the second UT phased array being arranged in a parallel configuration. The inspection robot may include a rastering device structured to move the payload in a direction of inspection, the direction of inspection being distinct from the direction of travel and the direction of inspection being distinct from the parallel configuration of the first UT phased array and the second UT phased array.