Self-adjusting corner scanner for curved part inspection
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Solution Overview
Problem
Non-destructive inspection of curved portions in manufactured parts, such as aircraft components, is challenging due to the difficulty in maintaining the correct height of the sensor array as the radius of curvature changes, which affects the accuracy of the inspection process.
Innovation Solution
An apparatus comprising a frame, a sensor with a concave arcuate surface, a plunger, and a linking mechanism that adjusts the height of the sensor in response to changes in the radius of curvature, ensuring proper positioning and maintaining contact with the part's surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the sensor array is swept across the curvature at a fixed height, then the inspection process is simple, but the accuracy deteriorates when the radius of curvature changes
Solution Approach 1:
The patent implements a dynamic height adjustment mechanism that automatically modifies the sensor array's height above the part surface based on the detected radius of curvature. The system transitions from a static fixed-height approach to a dynamic adaptive approach, where the height is continuously adjusted to maintain optimal inspection conditions regardless of curvature variations.
Solution Approach 2:
The system employs a feedback mechanism where the radius of curvature is first determined through preliminary measurement, and this information is then used to adjust the sensor array height before the actual inspection. This closed-loop feedback ensures that the inspection accuracy is maintained by adapting to the specific geometric characteristics of each inspected feature.
2Measurement precision
If the sensor array height is adjusted to maintain correct positioning, then the inspection accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical height adjustment mechanisms with a computational approach. Instead of using intricate mechanical linkages or actuators to physically adjust the sensor array height, the system determines the optimal height through radius of curvature calculations and uses this information to position the sensor array, thereby achieving accurate inspection with reduced mechanical complexity.
3Measurement precision
If the radius of curvature is determined and used to adjust sensor height, then the inspection accuracy is improved, but the inspection time increases
Solution Approach 1:
The patent implements a preliminary measurement step where the radius of curvature is determined before the actual inspection process. This preliminary action allows the system to pre-calculate and set the optimal sensor array height in advance, so that when the inspection begins, the sensor is already positioned correctly, minimizing any time penalty and enabling efficient sequential inspection of multiple features.
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 non-destructive inspection of parts with varying curvature radii without damaging the part, ensuring consistent signal reflection and transmission, and allowing for inspection in any orientation.
Implementation Method 1
transmitting a form of energy, such as ultrasonic waves, at the part and recording the reflected or perhaps refracted energy to form an image or profile of the part
Data Source
AI summary
An apparatus for inspecting a curved portion of a manufactured part comprises a frame, a sensor, a plunger, and a linking mechanism. The frame may include a first contact wall and an opposing second contact wall. Each contact wall may contact a planar portion of the part adjacent to the curved portion and may be oriented at an angle corresponding to an angle of the planar portions of the part adjacent to the curved portion. The sensor may transmit at least one signal to and receive at least one signal from the part. The plunger may contact the surface of the part and move as a radius of curvature of the part changes. The linking mechanism may couple to the plunger and may adjust the height of the sensor above a surface of the part in response to motion of the plunger.