Phased Array Ultrasonic Weld Tracking Robot
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Solution Overview
Problem
Current robotic systems for non-destructive evaluation of welds face challenges in maintaining position accuracy, especially when the weld cap is removed, and lack general-purpose design, requiring manual intervention and relying on surface features for automated tracking.
Innovation Solution
A robot equipped with a phased array ultrasonic probe and a controller that generates morphological images to compare with a weld mask, using cross-correlation to adjust the probe's position and maintain a predetermined distance from the weld, enabling precise localization and tracking without surface features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a laser is used to automatically move the robot based on detecting the weld position, then automation is improved, but the system only works with simple welds and requires a visible weld cap protruding from the surface
Solution Approach 1:
The patent replaces the laser-based optical detection system with a phased array ultrasonic probe that uses acoustic waves to detect weld positions. This substitution allows the system to work with complex weld geometries and hidden welds without requiring visible surface features, while maintaining automated robot control through image processing of ultrasonic data
Solution Approach 2:
The patent introduces morphological image processing as an intermediary between the raw ultrasonic signals and the robot control system. This intermediary process extracts weld position information from ultrasonic images through thresholding and morphological operations, enabling automated robot movement control without relying on visible weld caps
2Ease of operation
If manual positioning of the robot is used, then initial position setup is simple, but the robot cannot maintain its position once released without user intervention
Solution Approach 1:
The patent implements a feedback loop where the phased array ultrasonic probe continuously monitors the weld position, the controller processes the ultrasonic images to determine actual position, and the actuator automatically adjusts the probe position to maintain the predetermined distance. This closed-loop feedback system enables autonomous position maintenance without manual intervention
Solution Approach 2:
The system performs self-positioning and self-correction by automatically detecting its own position relative to the weld using ultrasonic imaging and autonomously adjusting its position through the actuator, eliminating the need for continuous manual management
3Measurement precision
If the robot maintains a predetermined distance from the weld using ultrasonic feedback, then positional accuracy is improved, but the system complexity increases with additional sensors and control mechanisms
Solution Approach 1:
The patent merges the detection function and the control function into a single integrated system. The phased array ultrasonic probe serves both as the detection sensor and the control actuator, eliminating the need for separate sensors and control mechanisms. The morphological image processing further integrates multiple functions including thresholding, noise filtering, and position extraction into one computational framework
Solution Approach 2:
The phased array ultrasonic probe performs multiple functions: it generates ultrasonic waves for imaging, detects weld position through reflected waves, provides feedback for control, and enables automated robot positioning. This multi-functionality reduces overall system complexity by eliminating the need for separate dedicated components for each function
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
Achieves a mean positional error of 0.8 mm in weld localization, enhancing the accuracy and autonomy of robotic systems for complex weld geometries and reducing manual intervention.
Implementation Method 1
The ultrasonic probe typically includes an ultrasonic transmitter and receiver to transmit ultrasonic signals and receive their reflections
Data Source
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AI summary
The present disclosure relates to a robot for performing non-destructive evaluation of a weld of a component. The robot comprises: a phased array ultrasonic probe for sending and receiving phased array ultrasonic signals; a processor configured to generate phased array ultrasonic images using the received phased array ultrasonic signals; an actuator for moving the phased array ultrasonic probe during the non-destructive evaluation; and a controller configured to control the actuator to move the phased array ultrasonic probe based on a position of the weld in the generated phased array ultrasonic images to maintain a predetermined distance from the weld during the non-destructive evaluation