Automated Sensor Trajectory Planning for Full Surface Inspection
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Solution Overview
Problem
Current non-destructive control processes for complex surfaces, especially large and intricately shaped parts, face challenges in ensuring complete surface coverage by sensors due to complex geometries and numerous acquisition parameters, leading to dead areas that are difficult to verify using existing methods.
Innovation Solution
A process that simulates sensor movement and trajectory planning, taking into account the part's shape, sensor characteristics, and robotic capabilities, allowing for modification of sensor parameters and control positions to ensure comprehensive surface coverage without interference, using CAD software and robotic simulation tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor movement is simulated using traditional CAD software and robotic simulation tools, then the inspection process can be planned, but the verification of total surface coverage becomes time-consuming and complex due to complex geometries and numerous acquisition parameters
Solution Approach 1:
The patent creates a digital twin (virtual model) of the physical inspection system including the sensor, robot, and part geometry. This virtual copy allows simulation and verification of surface coverage without physical trials, significantly reducing verification time while maintaining accuracy.
Solution Approach 2:
The patent performs preliminary simulation of sensor trajectories and surface coverage before actual inspection. By calculating and verifying coverage in the virtual model beforehand, the system identifies and corrects potential dead areas before physical inspection, avoiding time-consuming rework.
2Reliability
If the sensor trajectory is modified to cover complex surfaces, then complete surface coverage can be achieved, but the robot may interfere with the part during movement
Solution Approach 1:
The patent simulates robot movements and sensor trajectories in advance within the virtual model to identify potential collisions or interferences with the part. Trajectories are optimized beforehand to ensure complete coverage while avoiding interference with protruding elements or complex geometries.
Solution Approach 2:
The digital twin acts as an intermediary between the robot control system and the physical part. It allows virtual testing and optimization of trajectories, serving as a mediator that prevents harmful interference while achieving complete surface coverage.
3Measurement precision
If traditional verification methods are used for sensor coverage, then some inspection can be performed, but dead areas on complex surfaces cannot be fully identified
Solution Approach 1:
The patent uses a digital twin to create a virtual representation of the inspection system and part geometry. This allows precise calculation of sensor fields of view and surface coverage without the complexities of physical verification, achieving high measurement precision while simplifying the verification process.
Solution Approach 2:
The patent replaces physical trial-and-error verification methods with computational simulation. Instead of manually testing sensor coverage on physical models, the system uses software-based calculation and visualization to precisely determine coverage areas and identify dead zones.
Data Source
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AI summary
The invention relates to a method comprising the following steps: determination of a control trajectory for the sensor (13) in relation to the surface (3) according to the characteristics of the robot (15) using a digital model of the part (5); determination of control positions of the sensor (13) along the trajectory; determination, by calculation, of an area (23) of the surface (3) controlled by the sensor (13) at each control position, and verification, by calculation, that the entire area (23) is in a detection field of the sensor (13), without any masked elements, using the characteristics of the sensor (13); verification, by calculation, that all of the surface (3) is controllable for the sensor (13); and, if all of the surface (3) is not controllable, addition of a control position, and/or modification of at least one of the control positions and/or modification of at least one of the characteristics of the sensor (13).