Robot-Guided Ultrasonic Weld Testing With Optical Alignment
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Solution Overview
Problem
Current methods for testing and correcting welds, such as spot welds, face challenges in achieving precise and efficient testing while ensuring reliable coupling and avoiding probe damage, particularly in aligning the ultrasonic probe with the actual weld position without collisions.
Innovation Solution
A method utilizing CAD data to align a phased-array ultrasonic probe with a multi-axis robot, combined with an optical sensor for precise positioning and force-torque sensors for controlled force application, ensures accurate alignment and testing of welds, while a swivelable probe design prevents collisions and facilitates problem-free wetting with a coupling medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the ultrasonic probe is aligned on the target position based on CAD data, then the testing speed is improved, but the alignment precision with the actual weld position deteriorates
Solution Approach 1:
The system performs preliminary alignment based on CAD data to quickly position the probe near the weld, then uses optical sensors to detect the actual weld position and corrects the alignment. This two-stage approach combines the speed of pre-positioning with the precision of actual position detection.
Solution Approach 2:
The optical sensor detects the actual weld position and provides feedback to the control system, which then adjusts the probe position accordingly. This closed-loop feedback mechanism ensures high precision alignment while maintaining efficient testing throughput.
2Reliability
If the ultrasonic probe is placed on the weld with high force, then the coupling reliability is improved, but the risk of probe damage increases
Solution Approach 1:
The system dynamically adjusts the contact force between the probe and weld based on real-time feedback from force sensors and coupling quality measurements. The force is increased when good coupling is achieved and reduced when coupling problems are detected, optimizing both reliability and probe protection.
Solution Approach 2:
The contact force parameter is continuously adjusted during the testing process based on coupling quality feedback. The system transitions between different force levels to maintain optimal coupling while preventing excessive force that could damage the probe.
3Device complexity
If the ultrasonic probe is fixed in position, then the device complexity is reduced, but the ability to test multiple weld positions without collision deteriorates
Solution Approach 1:
The probe is mounted on a robotic manipulator that provides dynamic positioning capabilities. The robot can move the probe to different weld positions and adjust its orientation to avoid collisions, enabling comprehensive testing coverage while maintaining relatively simple probe hardware.
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
This approach enables quick and precise testing of welds, allowing for reliable coupling and accurate measurement, reducing the risk of probe damage and ensuring high precision across multiple welds without collisions, with self-regulation for precise alignment and efficient testing of adjacent welds.
Implementation Method 1
determination of the actual position of the weld by means of an optical sensor
Implementation Method 2
measurement of the weld using an ultrasonic probe
Implementation Method 3
ultrasonic probe arrangement comprising an ultrasonic probe with a cover, such as a diaphragm, to be provided with a coupling medium
Data Source
AI summary
A method and arrangement for testing and/or correction of a weld (34, 36, 38) of a test object (26, 102), including alignment of an ultrasonic probe (16, 128) guided by a robot (100) on a target position of the weld (28, 30, 32), determination of the actual position (34, 36, 38) of the weld by means of an optical sensor (22, 130) and alignment of the ultrasonic probe (16) on the actual position, and measurement of the weld, where CAD data of the target position of the weld (28, 30, 32) is made available, on the basis of the CAD data of the weld the ultrasonic probe (16, 128) is aligned on the target position of the weld, and the ultrasonic probe is placed on the weld with controlled force after determination of the actual position (34, 36, 38) of the weld by means of the optical sensor (22, 130).