Ultrasonic NDT Calibration Scan Path Correction for Robot Alignment
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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 sensors during ultrasonic inspections, leading to potential misalignment and inaccurate defect measurement in large components like aircraft parts.
Innovation Solution
A calibration system comprising two multi-axis robotic devices with end effectors equipped with emitters and receivers, performing a calibration scan to measure deviations along a scan path and determining 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 the inspection envelope can accommodate large parts, but the ability to determine the exact position of the sensor relative to the part deteriorates
Solution Approach 1:
The system employs a feedback mechanism where the actual sensor position is continuously measured using laser trackers or other positioning systems, and this information is fed back to update the corrected scan path. This allows the system to compensate for deviations between the planned and actual sensor positions, maintaining measurement precision while using multi-axis robots for large part inspection.
Solution Approach 2:
The patent replaces purely mechanical positioning systems with a hybrid system that incorporates optical measurement technologies (laser trackers, cameras) and computational correction. This substitution allows the system to achieve high positioning accuracy without relying solely on mechanical precision, enabling the use of multi-axis robots for large inspection envelopes.
2Extent of automation
If multi-axis robots are used for ultrasonic inspection, then automation is improved, but the alignment accuracy between emitter and receiver deteriorates
Solution Approach 1:
The system uses real-time feedback from positioning systems to monitor and adjust the relative positions of emitters and receivers mounted on multi-axis robots. This feedback loop ensures that alignment accuracy is maintained throughout the automated inspection process, compensating for robotic positioning variations.
Solution Approach 2:
The system performs preliminary calibration scans to establish the relationship between robot positions and sensor locations before actual inspection. This preliminary action creates a corrected scan path that accounts for systematic errors in robot positioning, ensuring accurate emitter-receiver alignment during automated operation.
3Device complexity
If traditional multi-axis robots are used, then device complexity is reduced, but the ability to maintain alignment within tolerance deteriorates
Solution Approach 1:
The system introduces an intermediary computational layer that processes positioning data and generates corrected scan paths. This intermediary software component acts as a mediator between the simple multi-axis robot hardware and the precision requirements, maintaining alignment tolerance without adding mechanical complexity to the robotic system.
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
Enhances the accuracy of ultrasonic NDT inspections by correcting scan paths and maintaining alignment within ±1 mm tolerance, effectively overcoming limitations of traditional multi-axis robots and ensuring precise defect measurement in large parts.
Implementation Method 1
The emitter and the receiver are positioned on opposite sides of the calibration assembly to exchange a calibration signal between the first robotic device and the second robotic device
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.