Ultrasonic NDT Calibration Scan for Robot Alignment Accuracy
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Solution Overview
Problem
Current non-destructive testing (NDT) systems using multi-axis robots face challenges in accurately determining the relative position of ultrasonic sensors in real-time, particularly when inspecting large parts like aircraft components, leading to potential misalignment and inaccurate defect measurement during ultrasonic inspections.
Innovation Solution
A calibration system comprising two multi-axis robotic devices with end effectors equipped with emitters and receivers, which perform a calibration scan to measure deviations along a scan path and determine corrected spatial locations for precise alignment, ensuring accurate ultrasonic signal transmission and defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multi-axis robots are used to conduct inspections, then large parts can be accommodated with a large inspection envelope, but the ability to determine the exact position of the sensor in real-time deteriorates
Solution Approach 1:
The system uses ultrasonic time-of-flight measurements between sensors on different robots to provide real-time feedback on relative position and orientation. This feedback loop enables continuous correction of position data, allowing the robots to maintain accurate spatial awareness despite operating independently in a large inspection envelope.
Solution Approach 2:
Ultrasonic waves serve as an intermediary medium to establish spatial relationships between the two independently moving robots. By measuring the time of flight of ultrasonic signals between sensors on different robots, the system creates a virtual reference frame that mediates the position determination without requiring direct mechanical coupling or centralized coordination.
2Adaptability or versatility
If multi-axis robots move independently, then operational flexibility increases, but the ability to verify location relative to each other deteriorates
Solution Approach 1:
The system continuously measures the time of flight of ultrasonic signals between robots to provide real-time feedback on relative positioning. This enables independent robots to verify their locations relative to each other without compromising operational flexibility, as each robot can autonomously adjust based on the feedback from the other robot's position.
Solution Approach 2:
The patent replaces mechanical coupling or centralized mechanical guidance systems with an acoustic field-based positioning system. Ultrasonic waves substitute for physical mechanical connections, allowing robots to move independently while maintaining reliable relative location verification through acoustic signal exchange rather than mechanical constraints.
3Difficulty of detecting and measuring
If ultrasonic signals are transmitted through the part, then internal defects can be detected, but misalignment between sensors leads to inaccurate measurements
Solution Approach 1:
The system uses feedback from time-of-flight measurements to continuously monitor and adjust sensor alignment. By comparing the expected ultrasonic signal travel time with actual measurements, the system can detect misalignment and correct it in real-time, ensuring accurate defect measurements while maintaining the ability to detect internal defects through through-transmission ultrasonic testing.
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
The system enhances the accuracy of ultrasonic NDT inspections by correcting scan path deviations, allowing for precise alignment and improved defect measurement, thereby overcoming limitations of traditional multi-axis robots in NDT applications.
Implementation Method 1
the ultrasonic signal from the sensor passes through the part from one robot to another
Implementation Method 2
the receiver measures a time of flight of an ultrasonic signal from the emitter
Data Source
AI summary
A non-destructive testing calibration system includes a first multi-axis robotic device having a first end effector, a second multi-axis robotic device having a second end effector. A calibration assembly includes an emitter arranged on the first end effector and a receiver arranged on the second end effector, where the emitter and the receiver exchange a calibration signal between the first robotic device and the second robotic device. A data processor and a memory storing instructions, which when executed causes the data processor to perform operations comprising: performing a calibration scan, where the calibration scan includes a plurality of measurement points along a scan path of the emitter and the receiver; measuring the deviation between the emitter and the receiver at each measurement point along the scan path; and determining a corrected scan path based on the deviation between the emitter and receiver at each measurement point during the calibration scan.