U.S. patent application number 16/708084 was filed with the patent office on 2021-06-10 for apparatus and method for non-destructive inspection of variable angle manufacturing components.
The applicant listed for this patent is The Boeing Company. Invention is credited to Barry A. Fetzer, Kareem Shehab.
Application Number | 20210172910 16/708084 |
Document ID | / |
Family ID | 1000004552317 |
Filed Date | 2021-06-10 |
United States Patent
Application |
20210172910 |
Kind Code |
A1 |
Fetzer; Barry A. ; et
al. |
June 10, 2021 |
APPARATUS AND METHOD FOR NON-DESTRUCTIVE INSPECTION OF VARIABLE
ANGLE MANUFACTURING COMPONENTS
Abstract
Disclosed herein is a non-destructive inspection apparatus that
utilizes a biased probe housing to maintain ultrasonic coupling
with a part. The apparatus includes an attachment body attached to
a robotic arm that has a tool center point (TCP). The apparatus
also includes a probe assembly coupled to the attachment body such
that movement of the TCP results in a corresponding movement of the
probe assembly, and a probe housing disposed around the probe
assembly and moveably coupled to the attachment body. The apparatus
also includes a biasing member disposed between the attachment body
and the probe housing that urges the probe housing away from the
attachment body. Also disclosed is a method that includes
positioning a probe housing and a probe assembly adjacent a part,
ultrasonically scanning the part for defects, and biasing the probe
housing relative to the attachment body to maintain engagement of
the part.
Inventors: |
Fetzer; Barry A.; (Renton,
WA) ; Shehab; Kareem; (Seattle, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Boeing Company |
Chicago |
IL |
US |
|
|
Family ID: |
1000004552317 |
Appl. No.: |
16/708084 |
Filed: |
December 9, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B25J 9/0009 20130101;
G01N 2291/0289 20130101; G01N 29/265 20130101 |
International
Class: |
G01N 29/265 20060101
G01N029/265; B25J 9/00 20060101 B25J009/00 |
Claims
1. A non-destructive inspection (NDI) apparatus comprising: an
attachment body configured to attach to a robotic arm, where the
robotic arm defines a tool center point (TCP); an ultrasonic probe
assembly fixedly coupled to the attachment body such that the
ultrasonic probe assembly is non-moveably fixed relative to the TCP
of the robotic arm and movement of the TCP by the robotic arm
results in a corresponding movement of the ultrasonic probe
assembly; a probe housing disposed around the ultrasonic probe
assembly and moveably coupled to the attachment body such that the
ultrasonic probe housing is moveable relative to the ultrasonic
probe assembly; and a biasing member disposed between the
attachment body and the probe housing, where the biasing member
urges the probe housing away from the attachment body.
2. The NDI apparatus of claim 1, further comprising a first housing
rod slidably coupled with an opening in the probe housing, wherein
the biasing member is disposed between the opening of the probe
housing and the attachment body and the first housing rod
comprises: a first end coupled to the attachment body; and a second
end having a diameter greater than a diameter of the opening of the
probe housing.
3. The NDI apparatus of claim 2, where the biasing member comprises
a compression spring positioned around the first housing rod.
4. The NDI apparatus of claim 3, further comprising a second
housing rod slidably coupled with a second opening in the probe
housing, wherein a second biasing member is disposed between the
second opening of the probe housing and the attachment body and the
second housing rod comprises: a first end coupled to the attachment
body; and a second end having a diameter greater than a diameter of
the second opening of the probe housing.
5. The NDI apparatus of claim 4 where the second biasing member
comprises a second compression spring positioned around the second
housing rod.
6. The NDI apparatus of claim 1, where the attachment body
comprises: an attachment plate; and an overload protection device
disposed between the attachment plate and the robotic arm.
7. The NDI apparatus of claim 1, where the probe housing comprises:
a body having: a part engagement surface configured to engage a
surface of a part and facing away from the attachment body; an end
surface facing the attachment body; and a sensor cavity formed in
the body and configured to receive the ultrasonic probe assembly
and to allow the ultrasonic probe assembly to translationally move
within the sensor cavity, where the sensor cavity extends entirely
through the body from the end surface to the part engagement
surface.
8. The NDI apparatus of claim 7, wherein an entire length of the
sensor cavity, between the part engagement surface and the end
surface is between about 1 inch and about 5 inches.
9. The NDI apparatus of claim 7, further comprising a water channel
formed in the body and extending from a first opening in the end
surface of the body to a second opening formed in a wall of the
sensor cavity, the second opening positioned adjacent an opening in
the part engagement surface of the body.
10. The NDI apparatus of claim 7, where the part comprises a wing
spar having a varying radius and a varying web to flange angle, and
where a size and a shape of the probe housing is selected according
to a maximum radius of the wing spar and a minimum web to flange
angle of the wing spar.
11. The NDI apparatus of claim 1, where the ultrasonic probe
assembly comprises: an ultrasonic sensor array; and at least one
sensor rod having a first end rigidly coupled to the attachment
body and a second end rigidly coupled to the ultrasonic sensor
array, the at least one sensor rod configured to maintain a fixed
position of the ultrasonic sensor array with reference to the
attachment body.
12. A system for a non-destructively inspecting a part, the system
comprising: a robotic arm; a controller configured to control
movement of a tool center point (TCP) of the robotic arm; and a
non-destructive inspection (NDI) apparatus coupled to the TCP, the
NDI apparatus comprising: an attachment body configured to attach
to a robotic arm, where the robotic arm defines the TCP; an
ultrasonic probe assembly fixedly coupled to the attachment body
such that the ultrasonic probe assembly is non-moveably fixed
relative to the TCP of the robotic arm and movement of the TCP by
the robotic arm results in a corresponding movement of the
ultrasonic probe assembly; a probe housing disposed around the
ultrasonic probe assembly and moveably coupled to the attachment
body such that the ultrasonic probe housing is moveable relative to
the ultrasonic probe assembly; and a biasing member disposed
between the attachment body and the probe housing, where the
biasing member urges the probe housing away from the attachment
body.
13. The system of claim 12, further comprising a first housing rod
slidably coupled with an opening in the probe housing, wherein the
biasing member is disposed between the opening of the probe housing
and the attachment body and the first housing rod comprises: a
first end coupled to the attachment body; and a second end having a
diameter greater than a diameter of the opening of the probe
housing.
14. The system of claim 13, where the biasing member comprises a
compression spring positioned around the first housing rod.
15. The system of claim 12, where the ultrasonic probe assembly
comprises: an ultrasonic sensor array; and at least one sensor rod
having a first end rigidly coupled to the attachment body and a
second end rigidly coupled to the ultrasonic sensor array, the at
least one sensor rod configured to maintain a fixed position of the
ultrasonic sensor array with reference to the attachment body.
16. The system of claim 12, where the probe housing comprises: a
body having: a part engagement surface configured to engage a
surface of a part and facing away from the attachment body; an end
surface facing the attachment body; and a sensor cavity formed in
the body and configured to receive the ultrasonic probe assembly
and to allow the ultrasonic probe assembly to translationally move
within the sensor cavity, where the sensor cavity extends entirely
through the body from the end surface to the part engagement
surface.
17. The system of claim 16, further comprising a water channel
formed in the body and extending from a first opening in the end
surface of the body to a second opening formed in a wall of the
sensor cavity, the second opening positioned adjacent an opening in
the part engagement surface of the body.
18. The system of claim 12, where the controller comprises a laser
profiler configured to measure a distance between the TCP and an
inspection radius, and where the controller is further configured
to move the TCP in response to the measured distance.
19. A method of non-destructively inspecting a part, the method
comprising: positioning a probe housing and an ultrasonic probe
assembly such that a moveable part engagement surface of the probe
housing engages the part, wherein the ultrasonic probe assembly is
fixedly coupled to an attachment body and the probe housing is
moveably coupled to the attachment body; ultrasonically scanning
the part for defects while traversing the part engagement surface
across a surface of the part; moving the biasing probe relative to
the probe housing; adjusting a distance between the ultrasonic
probe assembly and the surface of the part while traversing and
scanning the part; and biasing the probe housing relative to the
attachment body to maintain engagement of the part engagement
surface with the surface of the part.
20. The method of claim 19, where engaging the surface of the part
comprises pressing the part engagement surface against the surface
of the part.
Description
FIELD
[0001] This disclosure relates generally to non-destructive
inspection, and more particularly to non-destructive inspection of
components of those vehicles and machinery.
BACKGROUND
[0002] Various manufacturing components, such as vehicle parts, may
be utilized during a manufacturing process. Such manufacturing
components may be composite structures formed from composite
materials. The formation of these composite structures may
inadvertently include defects. Accordingly, the manufacturing
components are scanned to assess a quality of the component to
identify defects. One scanning technique that is useful for
identifying defects uses ultrasonic energy to generate a
representation or image of the interior of the component. The
generated representation is used to identify defects such as cracks
and voids. Generally, a robot arm moves a scanning probe along a
surface of the component. If the surface of the component has a
variable curvature, the robot arm moves to accommodate the changing
curvature while motors and sensors adjust a sensor array. However,
often it is difficult or time consuming to accommodate the changing
curvature. Further, often it is difficult for the robot to maintain
a water couple of the scanning probe with the surface of the
component.
SUMMARY
[0003] The subject matter of the present application provides
example non-destructive inspection devices that overcome the
above-discussed shortcomings of prior art techniques. The subject
matter of the present application has been developed in response to
the present state of the art, and in particular, in response to
shortcomings of current non-destructive inspection devices.
[0004] Disclosed herein is a non-destructive inspection (NDI)
apparatus that includes an attachment body configured to attach to
a robotic arm, where the robotic arm defines a tool center point
(TCP). The apparatus also includes an ultrasonic probe assembly
fixedly coupled to the attachment body such that movement of the
TCP by the robotic arm results in a corresponding movement of the
ultrasonic probe assembly. The apparatus also includes a probe
housing disposed around the ultrasonic probe assembly and moveably
coupled to the attachment body, and a biasing member disposed
between the attachment body and the probe housing, where the
biasing member urges the probe housing away from the attachment
body. The preceding subject matter of this paragraph characterizes
example 1 of the present disclosure.
[0005] The NDI apparatus, in certain examples, includes a first
housing rod slidably coupled with an opening in the probe housing,
wherein the biasing member is disposed between the opening of the
probe housing and the attachment body. In certain examples, the
first housing rod includes a first end coupled to the attachment
body, and a second end having a diameter greater than a diameter of
the opening of the probe housing. The preceding subject matter of
this paragraph characterizes example 2 of the present disclosure,
wherein example 2 also includes the subject matter according to
example 1, above.
[0006] The biasing member, in certain examples, is a compression
spring positioned around the first housing rod. The preceding
subject matter of this paragraph characterizes example 3 of the
present disclosure, wherein example 3 also includes the subject
matter according to example 2, above.
[0007] The NDI apparatus, in certain examples, includes a second
housing rod slidably coupled with a second opening in the probe
housing, wherein a second biasing member is disposed between the
second opening of the probe housing and the attachment body. In
certain examples, the second housing rod includes a first end
coupled to the attachment body, and a second end having a diameter
greater than a diameter of the second opening of the probe housing.
The preceding subject matter of this paragraph characterizes
example 4 of the present disclosure, wherein example 4 also
includes the subject matter according to example 3, above.
[0008] The second biasing member, in certain examples, is a
compression spring positioned around the second housing rod. The
preceding subject matter of this paragraph characterizes example 5
of the present disclosure, wherein example 5 also includes the
subject matter according to example 4, above.
[0009] The attachment body, in certain examples, includes an
attachment plate, and an overload protection device disposed
between the attachment plate and the robotic arm. The preceding
subject matter of this paragraph characterizes example 6 of the
present disclosure, wherein example 6 also includes the subject
matter according to any one of examples 1-5, above.
[0010] The probe housing, in certain examples, includes a part
engagement surface configured to engage a surface of a part and
facing away from the attachment body, and an end surface facing the
attachment body. The probe housing also includes a sensor cavity
formed in the body and configured to receive the ultrasonic probe
assembly and to allow the ultrasonic probe assembly to
translationally move within the sensor cavity. The sensor cavity,
in certain examples, extends entirely through the body from the end
surface to the part engagement surface. The preceding subject
matter of this paragraph characterizes example 7 of the present
disclosure, wherein example 7 also includes the subject matter
according to any one of example 1-6, above.
[0011] The sensor cavity, in certain embodiments has an entire
length between the part engagement surface and the end surface of
between about 1 inch and about 5 inches. The preceding subject
matter of this paragraph characterizes example 8 of the present
disclosure, wherein example 8 also includes the subject matter
according to example 7, above.
[0012] The NDI apparatus, in certain examples, also includes a
water channel formed in the body and extending from a first opening
in the end surface of the body to a second opening formed in a wall
of the sensor cavity, the second opening positioned adjacent an
opening in the part engagement surface of the body. The preceding
subject matter of this paragraph characterizes example 9 of the
present disclosure, wherein example 9 also includes the subject
matter according to any one of examples 7 and 8, above.
[0013] The part, in certain examples, is a wing spar having a
varying radius and a varying web to flange angle. A size and a
shape of the probe housing is selected according to a maximum
radius of the wing spar and a minimum web to flange angle of the
wing spar. The preceding subject matter of this paragraph
characterizes example 10 of the present disclosure, wherein example
10 also includes the subject matter according to any one of
examples 7-9, above.
[0014] The ultrasonic probe assembly, in certain examples includes
an ultrasonic sensor array, and at least one sensor rod having a
first end rigidly coupled to the attachment body and a second end
rigidly coupled to the ultrasonic sensor array. The at least one
sensor rod is configured to maintain a fixed position of the
ultrasonic sensor array with reference to the attachment body. The
preceding subject matter of this paragraph characterizes example 11
of the present disclosure, wherein example 11 also includes the
subject matter according to any one of examples 1-10 above.
[0015] Additionally disclosed herein is a system for NDI. The
system includes, in certain examples: a robotic arm; a controller
configured to control movement of a tool center point (TCP) of the
robotic arm; and an NDI apparatus coupled to the TCP. In certain
examples, the NDI apparatus includes an attachment body configured
to attach to a robotic arm, where the robotic arm defines the TCP,
and an ultrasonic probe assembly fixedly coupled to the attachment
body such that movement of the TCP by the robotic arm results in a
corresponding movement of the ultrasonic probe assembly. The NDI
apparatus also includes a probe housing disposed around the
ultrasonic probe assembly and moveably coupled to the attachment
body, and a biasing member disposed between the attachment body and
the probe housing, where the biasing member urges the probe housing
away from the attachment body. The preceding subject matter of this
paragraph characterizes example 12 of the present disclosure.
[0016] The system, in certain examples, includes a first housing
rod slidably coupled with an opening in the probe housing, wherein
the biasing member is disposed between the opening of the probe
housing and the attachment body. In certain examples, the first
housing rod includes a first end coupled to the attachment body,
and a second end having a diameter greater than a diameter of the
opening of the probe housing. The preceding subject matter of this
paragraph characterizes example 13 of the present disclosure,
wherein example 13 also includes the subject matter according to
example 12, above.
[0017] The biasing member, in certain examples, is a compression
spring positioned around the first housing rod. The preceding
subject matter of this paragraph characterizes example 14 of the
present disclosure, wherein example 14 also includes the subject
matter according to example 13, above.
[0018] The ultrasonic probe assembly, in certain examples includes
an ultrasonic sensor array, and at least one sensor rod having a
first end rigidly coupled to the attachment body and a second end
rigidly coupled to the ultrasonic sensor array. The at least one
sensor rod is configured to maintain a fixed position of the
ultrasonic sensor array with reference to the attachment body. The
preceding subject matter of this paragraph characterizes example 15
of the present disclosure, wherein example 15 also includes the
subject matter according to any one of examples 12-14 above.
[0019] The probe housing, in certain examples, includes a part
engagement surface configured to engage a surface of a part and
facing away from the attachment body, and an end surface facing the
attachment body. The probe housing also includes a sensor cavity
formed in the body and configured to receive the ultrasonic probe
assembly and to allow the ultrasonic probe assembly to
translationally move within the sensor cavity. The sensor cavity,
in certain examples, extends entirely through the body from the end
surface to the part engagement surface. The preceding subject
matter of this paragraph characterizes example 16 of the present
disclosure, wherein example 16 also includes the subject matter
according to any one of example 12-15, above.
[0020] The system, in certain examples, also includes a water
channel formed in the body and extending from a first opening in
the end surface of the body to a second opening formed in a wall of
the sensor cavity, the second opening positioned adjacent an
opening in the part engagement surface of the body. The preceding
subject matter of this paragraph characterizes example 17 of the
present disclosure, wherein example 17 also includes the subject
matter according to example 16, above.
[0021] The controller, in certain examples, includes a laser
profiler configured to measure a distance between the TCP and an
inspection radius, and where the controller is further configured
to move the TCP in response to the measured distance. The preceding
subject matter of this paragraph characterizes example 18 of the
present disclosure, wherein example 18 also includes the subject
matter according to any one of examples 12-17, above.
[0022] Additionally, disclosed herein is a method of
non-destructively inspecting a part. The method, in certain
examples, includes positioning a probe housing and an ultrasonic
probe assembly such that a part engagement surface of the probe
housing engages the part, wherein the ultrasonic probe assembly is
fixedly coupled to an attachment body and the probe housing is
moveably coupled to the attachment body. The method also includes
ultrasonically scanning the part for defects while traversing the
part engagement surface across a surface of the part, adjusting a
distance between the ultrasonic probe assembly and the surface of
the part while traversing and scanning the part, and biasing the
probe housing relative to the attachment body to maintain
engagement of the part engagement surface with the surface of the
part. The preceding subject matter of this paragraph characterizes
example 19 of the subject disclosure.
[0023] Engaging the surface of the part, in certain examples,
includes pressing the part engagement surface against the surface
of the part. The preceding subject matter of this paragraph
characterizes example 20 of the present disclosure, wherein example
20 also includes the subject matter according to example 19,
above.
[0024] The described features, structures, advantages, and/or
characteristics of the subject matter of the present disclosure may
be combined in any suitable manner in one or more examples,
including embodiments and/or implementations. In the following
description, numerous specific details are provided to impart a
thorough understanding of examples of the subject matter of the
present disclosure. One skilled in the relevant art will recognize
that the subject matter of the present disclosure may be practiced
without one or more of the specific features, details, components,
materials, and/or methods of a particular example, embodiment, or
implementation. In other instances, additional features and
advantages may be recognized in certain examples, embodiments,
and/or implementations that may not be present in all examples,
embodiments, or implementations. Further, in some instances,
well-known structures, materials, or operations are not shown or
described in detail to avoid obscuring aspects of the subject
matter of the present disclosure. The features and advantages of
the subject matter of the present disclosure will become more fully
apparent from the following description and appended claims, or may
be learned by the practice of the subject matter as set forth
hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] In order that the advantages of the subject matter may be
more readily understood, a more particular description of the
subject matter briefly described above will be rendered by
reference to specific examples that are illustrated in the appended
drawings. Understanding that these drawings depict only typical
examples of the subject matter, they are not therefore to be
considered to be limiting of its scope. The subject matter will be
described and explained with additional specificity and detail
through the use of the drawings, in which:
[0026] FIG. 1 is a schematic block diagram illustrating one
embodiment of a system for non-destructive inspection (NDI) of a
manufacturing component, according to examples of the subject
disclosure;
[0027] FIG. 2 is a perspective view diagram of an NDI apparatus,
according to examples of the subject disclosure;
[0028] FIG. 3 is a perspective view diagram of the ultrasonic probe
assembly, according to examples of the subject disclosure;
[0029] FIGS. 4a and 4b are schematic diagrams of probe housing
positions with respect to the attachment plate, according to
examples of the subject disclosure;
[0030] FIG. 5 is a perspective view diagram of the NDI apparatus,
according to examples of the subject disclosure;
[0031] FIG. 6 is a perspective view diagram illustrating a part
engagement surface of the probe housing, according to examples of
the subject disclosure.
[0032] FIGS. 7a-7c are illustrations of the body, according to
examples of the subject disclosure;
[0033] FIGS. 8a and 8b are section view diagrams of the body,
according to examples of the subject disclosure;
[0034] FIG. 9 is a schematic block diagram illustrating a
controller, according to examples of the subject disclosure;
and
[0035] FIG. 10 is a flowchart diagram illustrating a method of
non-destructively inspecting a part, according to examples of the
subject disclosure.
DETAILED DESCRIPTION
[0036] Reference throughout this specification to "one example,"
"an example," or similar language means that a particular feature,
structure, or characteristic described in connection with the
example is included in at least one example of the present
disclosure. Appearances of the phrases "in one example," "in an
example," and similar language throughout this specification may,
but do not necessarily, all refer to the same example. Similarly,
the use of the term "implementation" means an implementation having
a particular feature, structure, or characteristic described in
connection with one or more examples of the present disclosure,
however, absent an express correlation to indicate otherwise, an
implementation may be associated with one or more examples.
[0037] FIG. 1 is a schematic block diagram illustrating one
embodiment of a system 100 for non-destructive inspection (NDI) of
a manufacturing component 112 (also referred to herein as a part),
according to examples of the subject disclosure. In certain
embodiments, the system 100 is used to inspect a variety of
structures including composite structures of a wide range of sizes
and shapes, such as composite aircraft wings, spars, and fuselage
barrels.
[0038] The system 100, in certain examples, includes a robotic arm
102. The robotic arm 102 is a jointed-arm robot that is configured
to provide movement and positioning of a tool center point (TCP)
104. The TCP 104, in certain examples, is a mathematical point
(positioned on an end of the robotic arm 102) that the robotic arm
102 moves through space with reference to the robotic base 106. The
TCP 104, in certain examples, is located at an end of the robotic
arm 102, and is configured to couple to a tool, such as a
non-destructive inspection apparatus 108. For example, the end of
the robotic arm 102 is a plate to which the tool, or the end
effector, is attached. The TCP 104, in certain examples, is a point
positioned a predetermined distance from the end of the robotic arm
that corresponds with a location of an ultrasonic sensor array
attached to the robotic arm. For example, the TCP 104 may identify
a location of a focal point of a curved ultrasonic sensor array
(see FIG. 3) that is offset from the end of the robotic arm 102. A
controller 110 controls the movement and positioning of the TCP
104.
[0039] The controller 110, in certain examples, is implemented
using software, hardware, firmware, or a combination thereof. When
software is used, the operations performed by the controller 110
are implemented using, for example, program code configured to run
on a processor unit. When firmware is used, the operations are
implemented using, for example, program code and data stored in
persistent memory to run on a processor unit. When hardware is
used, the hardware includes one or more circuits that operate to
perform the operation of moving the TCP 104. The hardware, in
certain embodiments, takes the form of a circuit system, an
integrated circuit, an application specific integrated circuit
(ASIC), a programmable logic device, etc.
[0040] The controller 110, in certain embodiments, is configured to
control the movement of the robotic arm 102 which is capable of
movement with up to six degrees of freedom or more. The robotic arm
102 is, in certain examples, is configured to couple with the end
effector (e.g., the NDI apparatus 108). The end effector, in one
example, is integrated as part of the robotic arm 102 or
alternatively, is removably coupled to the TCP 104. Inspection of
the manufacturing component 112, in certain examples, uses an
ultrasonic probe assembly 114 (see FIG. 3) having ultrasonic
sensors. The structure of the manufacturing component 112 is
scanned by the NDI apparatus 108 to measure structural and
mechanical properties to ensure the manufacturing component 112 is
free of defects.
[0041] The manufacturing component 112, in certain examples, has
portions with curvatures of varying radii and varying angles. For
effective scanning, a probe housing 116 (see FIG. 2), that is
disposed around the ultrasonic probe assembly 114, is positioned
adjacent the manufacturing component 112. In certain examples, the
probe housing 116 maintains contact with a surface of the
manufacturing component 112. The ultrasonic probe assembly 114 is
maintained at a particular distance and angle or orientation
relative to a particular position of the manufacturing component
112. However, certain configurations of the manufacturing component
112, such as a sharp transition from a flange to a web of a wing
spar, may not provide the clearance necessary for a traditional
inspection head attached to a robotic arm 102 to traverse the
transition while maintaining the proper distance between the
ultrasonic probe assembly and the manufacturing component 112.
[0042] Beneficially, and as will be discussed in greater detail
below, the NDI apparatus 108 is configured with the probe housing
116, which is moveable with reference to an attachment body 118 of
the NDI apparatus 108. The NDI apparatus 108 provides the ability
to inspect a manufacturing component 112 that has a variable radius
and a variable angle. The system 100 (e.g., the NDI apparatus 108)
includes position sensors that monitor changes in a radius and
angle of the manufacturing component 112 and facilitate adjustment
of the position of the TCP 104 relative to the manufacturing
component 112. The ultrasonic probe assembly 114 is fixedly coupled
to the TCP 104 (see FIG. 1) and moves together with the TCP 104.
The probe housing 116, beneficially, is moveably coupled to the TCP
104 and biased away from the TCP 104 by a biasing member 120 (see
FIG. 2) to maintain contact with the manufacturing component 112
even when the configuration of the manufacturing component 112
causes the robotic arm 102 to increase a distance between the
ultrasonic probe assembly 114 and the manufacturing component (see
FIG. 4). In certain examples, the probe housing 116 always
maintains contact with the manufacturing component regardless of
the position of the ultrasonic probe assembly 114 so that
ultrasonic coupling is maintained (e.g., water coupling is
maintained).
[0043] FIG. 2 is a perspective view diagram of the NDI apparatus
108, according to examples of the subject disclosure. The NDI
apparatus 108, in certain examples, comprises the attachment body
118, which is configured to connect the NDI apparatus 108 to the
robotic arm 102. The attachment body 118 includes an attachment
plate 122 and an overload protection device 124. The attachment
plate 122, in certain examples, is a generally rectangular member
provided with one or more openings for mounting the ultrasonic
probe assembly 114, the probe housing 116, various positioning
sensors, and the overload protection device 124. The overload
protection device 124 is a sensor-enabled coupling that detects a
collision between the probe housing 116 and any object that was not
expected by the controller 110. The overload protection device 124,
in certain examples, is disposed between the attachment plate 122
and the TCP 104, or end, of the robotic arm 102.
[0044] In certain examples, the ultrasonic probe assembly 114 is
fixedly coupled to, and extends outward from the attachment plate
122. One or more sensor rods 126 position the ultrasonic sensor
array (see FIG. 3) a fixed distance from the attachment plate 122.
The sensor rod(s) 126 maintain this distance as the robotic arm 102
moves the NDI apparatus 108 across the surface of the manufacturing
component 112. In the depicted example, the NDI apparatus 108 is
scanning a surface of a wing spar, and in particular, a transition
between a flange 128 and a web 130 or sidewall of the wing spar.
The wing spar, in certain examples, has a varying radius and a
varying web to flange angle, and accordingly, the size and shape of
the probe housing 116 is selected based on a maximum radius of the
wing spar and a minimum web to flange angle of the wing spar.
However, the NDI apparatus 108 is adaptable to scan any component
of any vehicle or structure.
[0045] The probe housing 116, in certain examples, is moveably
coupled with the attachment plate 122. One or more housing rods 132
are rigidly coupled to the attachment plate 122 and extend outward
in a direction opposite that of the overload protection device 124.
Within examples, the one or more housing rods 132 include a first
housing rod and a second housing rod (see FIG. 5). The probe
housing 116 has openings (see FIG. 7b) that slideably engage the
housing rods 132. A biasing member 120, in certain examples, is
disposed around each housing rod 132 between the probe housing 116
and the attachment plate 122. The biasing member 120 is configured
to urge the probe housing 116 away from the attachment plate 122.
Accordingly, the robotic arm 102 can adjust the position of the
ultrasonic probe assembly 114 with respect to the manufacturing
component 112 while the probe housing 116 maintains contact with
the surface of the manufacturing component 112. In other words, if
the curvature of the manufacturing component 112 is such that the
robotic arm 102 must increase a distance between the ultrasonic
probe assembly 114 and the manufacturing component 112, the biasing
member 120 urges the probe housing 116 away from the attachment
plate 122 to maintain contact with the manufacturing component
112.
[0046] The probe housing 116, in certain examples, is configured
with one or more hose couplings 134 that are fluidly connected to
water passageways in the probe housing 116. The hose couplings 134
receive a fluid, such as water, that is useful as an ultrasonic
coupling medium to maintain ultrasonic coupling (i.e., "water
coupling") between the sensors of the ultrasonic probe assembly 114
and the manufacturing component 112. For clarity, the various inlet
tubes that supply water to the hose couplings 134 have been omitted
from these figures.
[0047] FIG. 3 is a perspective view diagram of the ultrasonic probe
assembly 114, according to examples of the subject disclosure. The
ultrasonic probe assembly 114, in certain examples, includes an
ultrasonic sensor array 136 or transducer. The ultrasonic sensor
array 136 is configured to deliver energy to and/or analyze energy
received from the manufacturing component 112 that is being
scanned. The ultrasonic sensor array 136, in certain examples, is
configured to operate in a pulse echo mode that uses sound energy
to detect and identify defects or flaws that may be present within
the manufacturing component 112. The ultrasonic probe assembly 114
communicates with the controller 110 to relay sensor values
determined as the ultrasonic probe assembly 114 is moved along a
scanning path 113 (see FIG. 1) associated with the manufacturing
component 112.
[0048] One or more sensor rods 126, in certain examples, are
configured to position the ultrasonic sensor array 136 a distance
137 from the attachment plate 122. Each elongated sensor rod 126
includes a first end 138 and a second end 140. The first end 138 of
the sensor rod is fixedly coupled, in certain examples, to the
attachment plate 122. The second end 140, in certain examples, is
fixedly coupled to the ultrasonic sensor array 136. In other
examples, the second end 140 includes a flexible connection to the
ultrasonic sensor array 136 to allow for small movements in
translation and rotation. For example, the flexible connection is
configured to allow a +/-3-degree rotation to accommodate movement
of the probe housing 116 during traversal of the scanning path
113.
[0049] FIGS. 4a and 4b are schematic block diagrams of probe
housing 116 positions with respect to the attachment plate 122,
according to examples of the subject disclosure. In certain
examples, the probe housing 116 includes one or more housing rod
couplers 142. Each of the housing rod couplers 142 includes an
opening (see FIGS. 7a-8b) that is configured to slidably engage the
housing rod 132. The housing rod 132, in certain examples, is an
elongated rod having a first end 144 fixedly coupled with the
attachment plate 122, and a second end 146. The second end 146, as
depicted, has a diameter greater than a diameter of the first end
144 or a region of the housing rod 132 between the first end 144
and the second end 146. As such, the second end 146 acts as a stop
to prevent the probe housing 116 from translational movement along
the housing rod 132, away from the attachment plate 122, past the
second end 146.
[0050] FIG. 4a depicts a first position of the probe housing 116 at
a maximum distance 148 away from the attachment plate 122. As
discussed above, the biasing member 120 (omitted from FIGS. 4a and
4b for clarity) is disposed between the probe housing 116 and the
attachment plate around the housing rod 132. The biasing member
120, in certain examples, is a compression spring, has a length
that is greater than a maximum distance between the housing rod
coupler 142 and the attachment plate 122. Accordingly, even at the
maximum distance, the compression spring is applying a biasing
force on the probe housing away from the attachment plate.
[0051] In the depicted example of FIG. 4a, the ultrasonic sensor
array 136 is disposed within the probe housing 116 and is
configured to move within a cavity of the probe housing 116. When
the configuration of the manufacturing component 112 is such that
the NDI apparatus 108 does not have sufficient clearance, the
controller 110 instructs the robotic arm 102 to increase a distance
between the TCP 104 and the manufacturing component 112. The
robotic arm 102, in certain examples, positions the TCP 104 at a
distance from the manufacturing component 112 such that the robotic
arm "pushes" the probe housing 116 against the surface of the
manufacturing component 112. This pushing force overcomes a spring
force of the biasing member 120 and compresses the distance between
the probe housing 116 and the attachment plate 122. FIG. 4b is a
depiction of a minimum distance 150 between the probe housing 116
and the attachment plate. As the robotic arm 102 moves the TCP 104
towards and away from the manufacturing component 112 (to account
for changes in the contour of the surface), the biasing member 120
pushes the probe housing 116 away from the attachment plate 122 and
maintains contact between the probe housing 116 and the
manufacturing component 112. The relative distance 152 between the
ultrasonic sensor array 136, in certain examples, and the
attachment plate 122 remains constant despite the movement of the
probe housing 116 between the maximum distance 148 and the minimum
distance 150.
[0052] FIG. 5 is a perspective view diagram of the NDI apparatus
108, according to examples of the subject disclosure. FIG. 5 omits
the probe housing 116 and the ultrasonic probe assembly 114. As
discussed above, the housing rod 132 is a rigid member having first
end 144 and second end 146. The second end 146, in certain
examples, includes a head (or collar) that has a greater diameter
than a diameter of the housing rod 132.
[0053] The housing rod 132 is configured to slideably engage the
probe housing 116 and allow the probe housing 116 to move between a
fully extended position (see FIG. 4a) to a collapsed position (see
FIG. 4b). The biasing member 120, in certain examples, is a
compression spring disposed around the housing rod 132. In certain
examples, a single component is used to function as the housing rod
132 and the biasing member 120. For example, a gas spring, gas
strut, or mechanical strut is capable of applying a biasing force
to the probe housing 116 away from the attachment plate 122.
[0054] FIG. 6 is a perspective view diagram illustrating a part
engagement surface 154 of the probe housing 116, according to
examples of the subject disclosure. The probe housing 116, in
certain examples, is formed of a body 153 that includes the part
engagement surface 154 that is configured to contact the surface of
the manufacturing component 112. The part engagement surface 154,
in certain examples, is generally V-shaped to allow the probe
housing 116 to traverse a wide variety of surface contours
including, but not limited to, concave and convex surface
contours.
[0055] The part engagement surface 154 also includes an opening 156
through which the ultrasonic sensor array 136 transmits and
receives ultrasonic energy. Water, received by the hose couplings
134 and passed through internal passageways, exits through the
opening 164. The part engagement surface 154, in certain examples,
is substantially smooth and continuous to enable the probe housing
116 to traverse the surface of the manufacturing component 112
without damaging the manufacturing component 112.
[0056] FIGS. 7a-7c are illustrations of the body 153, according to
examples of the subject disclosure. In particular, FIG. 7a is a
side view illustration of the body 153 that depicts the part
engagement surface 154 and an opposing end surface 155. The end
surface 155, in certain examples, faces the attachment plate 122 of
the attachment body 118 while the part engagement surface 154 faces
away from the attachment plate 122. The body 153, in certain
examples, includes a pair of openings 156 formed in the body 153
for receiving the housing rods 132. In certain examples, the
openings 156 are formed in housing rod couplers 142 that extend
outward from a side surface 158 of the body 153. The diameter of
the opening 156 is less than the second end 146 of the housing rod
132 so that the second end 146 of the housing rod 132 acts as a
bump stop to movement of the body 153 away from the attachment
plate 122. In certain examples, a distance 157 between the part
engagement surface 154 and the end surface 155 is between about 1
and 5 inches.
[0057] In certain examples, a sensor cavity 160 is formed in the
body 153. An opening in the end surface 155 is configured to
receive the ultrasonic probe assembly 114 and allow movement of the
body 153 with respect to the ultrasonic probe assembly 114. As the
NDI apparatus 108 traverses the surface of the manufacturing
component 112, and the probe housing 116 moves to different
positions between the fully extended position and a collapsed
position, the ultrasonic probe assembly 114 will move
translationally within the sensor cavity 160. In certain
embodiments, the sensor cavity 160 extends from an opening in the
end surface 155 to an opening 164 in the part engagement surface
154.
[0058] Water channels, in certain examples, extend through the body
153 from the end surface 155 to the part engagement surface 154.
Water openings 162, in certain examples, are threaded for
connecting to the hose couplings 134. The water openings 162 are
fluidly coupled with water channels that extend through the body
153 to direct water out the opening 164 of the part engagement
surface 154.
[0059] FIGS. 8a and 8b are section view diagrams of the body 153,
according to examples of the subject disclosure. As discussed
above, the body 153 is formed with at least one water channel 166
that extends through the body 153 from the end surface 155 to the
part engagement surface 154. In certain examples, the water channel
166 extends to a second opening 168 in the sensor cavity 160 that
is adjacent the opening 164 in the part engagement surface 154.
Beneficially, this allows water to flow into the area between the
ultrasonic sensor array 136 and the manufacturing component 112 and
provide a coupling medium for the ultrasonic energy.
[0060] FIG. 9 is a schematic block diagram illustrating a
controller 110, according to examples of the subject disclosure.
The controller 110 is an example of a computing device, which, in
some examples, is used to implement one or more components of
examples of the disclosure, and in which computer usable program
code or instructions implementing the processes can be located for
the illustrative examples. In this illustrative example, the
controller includes a communications fabric 214, which provides
communications between a processor unit 216, memory 218, a laser
profiler 125, persistent storage 220, a communications unit 235,
and a display 237. The laser profiler 125, in certain examples, is
disposed on the attachment plate 122 and is configured to scan the
surface of the manufacturing component 112 to determine an
inspection radius of the wing spar for example, and also to
determine a minimum web to flange angle of the web 130 and flange
128. The laser profiler 125 is also configured to measure a
distance between the TCP 104 and the manufacturing component 112
and communicate that distance with the controller 110. In turn, the
controller 110 is configured to move the TCP 104 in response to the
determined distance.
[0061] The processor unit 216 serves to execute instructions for
software that are loaded into memory 218 in some examples. In one
example, the processor unit 216 is a set of one or more processors
or can be a multi-processor core, depending on the particular
implementation. Further, the processor unit 216 is implemented
using one or more heterogeneous processor systems, in which a main
processor is present with secondary processors on a single chip,
according to some examples. As another illustrative example, the
processor unit 216 is a symmetric multi-processor system containing
multiple processors of the same type.
[0062] Memory 218 and persistent storage 220 are examples of
storage devices 228. A storage device is any piece of hardware that
is capable of storing information, such as, for example, without
limitation, data, program code in functional form, and/or other
suitable information either on a temporary basis and/or a permanent
basis. Memory 218, in these examples, is a random-access memory, or
any other suitable volatile or non-volatile storage device.
Persistent storage 220 takes various forms, depending on the
particular implementation. In one example, persistent storage 220
contains one or more components or devices. In an example,
persistent storage 220 is a hard drive, a flash memory, a
rewritable optical disk, a rewritable magnetic tape, or some
combination of the above. The media used by persistent storage 220
is removable in some examples. For example, a removable hard drive
is used for persistent storage 220 in various implementations.
[0063] The communications unit 235, in these examples, provides for
communication with other data processing systems or devices. In
these examples, the communications unit 235 is a network interface
card. The communications unit 235 provides communications through
the use of either, or both, physical and wireless communications
links. In some examples, the communication unit 235 also provides a
connection for user input through a keyboard, a mouse, and/or some
other suitable input device. Further, the input/output unit sends
output to a printer or receive input from any other peripheral
device in various examples. The display 237 provides a mechanism to
display information to a user.
[0064] In some examples, instructions for the operating system,
applications, and/or programs are located in the storage devices
228, which are in communication with the processor unit 216 through
the communications fabric 214. In these illustrative examples, the
instructions are in a functional form on persistent storage 220.
These instructions are loaded into memory 218 for execution by the
processor unit 216 in some examples. In certain examples, the
processes of the different examples are performed by the processor
unit 216 using computer implemented instructions, which is located
in a memory, such as the memory 218.
[0065] These instructions are referred to as program code, computer
usable program code, or computer readable program code that can be
read and executed by a processor in the processor unit 216. The
program code, in the different examples, is embodied on different
physical or computer readable storage media, such as the memory 218
or the persistent storage 220.
[0066] Program code 230 is located in a functional form on computer
readable media 232 that is selectively removable and can be loaded
onto or transferred to the controller 110 for execution by the
processor unit 216. In some examples, the program code also
contains the scanning plan discussed above with reference to FIG.
1. The program code 230 and computer readable media 236 form
computer program product 234. In one example, the computer readable
media 232 is a computer readable storage media 236 or a computer
readable signal media 238. The computer readable storage media 236
includes, in one example, an optical or magnetic disc that is
inserted or placed into a drive or other device that is part of the
persistent storage 220 for transfer onto a storage device, such as
a hard drive, that is part of the persistent storage 220. In other
examples, the computer readable storage media 236 also takes the
form of a persistent storage, such as a hard drive, a thumb drive,
or a flash memory that is connected to the controller 110. In some
instances, the computer readable storage media 236 is not removable
from the controller 110.
[0067] Alternatively, the program code 230 is transferred to the
controller 110 using computer readable signal media 238. Computer
readable signal media 238 is, as one example, a propagated data
signal containing program code 230. For example, the computer
readable signal media 238 is an electromagnetic signal, an optical
signal, and/or any other suitable type of signal in one example.
These signals are transmitted over communications links, such as
wireless communication links, an optical fiber cable, a coaxial
cable, a wire, and/or any other suitable type of communications
link. In other words, the communications link and/or the connection
is physical or wireless in the illustrative examples. The computer
readable media also takes the form of non-tangible media, such as
communications links or wireless transmissions containing the
program code, in some examples.
[0068] In some illustrative examples, the program code 230 is
downloaded over a network to the persistent storage 220 from
another device or data processing system through the computer
readable signal media 238 for use within the controller 110. In one
instance, program code stored in a computer readable storage media
in a server data processing system is downloaded over a network
from a server to the controller 110. According to various examples,
the system providing the program code 230 is a server computer, a
client computer, or some other device capable of storing and
transmitting program code 230.
[0069] The different components illustrated for the controller 110
are not meant to provide physical or architectural limitations to
the manner in which different examples can be implemented. The
different illustrative examples can be implemented in a controller
including components in addition to and/or in place of those
illustrated for the controller 110. Other components shown in FIG.
9 can be varied from the illustrative examples shown. The different
examples can be implemented using any hardware device or system
capable of executing program code. For example, a storage device in
the controller 110 is any hardware apparatus that can store data.
The memory 218, persistent storage 220, and the computer readable
media 232 are examples of storage devices in a tangible form.
[0070] In another example, a bus system is used to implement
communications fabric 214 and can be comprised of one or more
buses, such as a system bus or an input/output bus. Of course, in
some examples, the bus system is implemented using any suitable
type of architecture that provides for a transfer of data between
different components or devices attached to the bus system. In
addition examples, a communications unit includes one or more
devices used to transmit and receive data, such as a modem or a
network adapter. Further, a memory is, for example, the memory 218
or a cache such as found in an interface and memory controller hub
that can be present in the communications fabric 214.
[0071] Computer program code for carrying out operations for
aspects of the subject disclosure can be written in any combination
of one or more programming languages, including an object-oriented
programming language such as Java, Smalltalk, C++ or the like and
conventional procedural programming languages, such as the "C"
programming language or similar programming languages. The program
code can execute entirely on the user's computer, partly on the
user's computer, as a stand-alone software package, partly on the
user's computer and partly on a remote computer or entirely on the
remote computer or server. In the latter scenario, the remote
computer can be connected to the user's computer through any type
of network, including a local area network (LAN) or a wide area
network (WAN), or the connection can be made to an external
computer (for example, through the Internet using an Internet
Service Provider).
[0072] These computer program instructions can also be stored in a
computer readable medium that can direct a computer, other
programmable data processing apparatus, or other devices to
function in a particular manner, such that the instructions stored
in the computer readable medium produce an article of manufacture
including instructions which implement the function/act specified
in the flowchart and/or block diagram block or blocks. The computer
program instructions can also be loaded onto a computer, other
programmable data processing apparatus, or other devices to cause a
series of operational steps to be performed on the computer, other
programmable apparatus or other devices to produce a computer
implemented process such that the instructions which execute on the
computer or other programmable apparatus provide processes for
implementing the functions/acts specified in the flowchart and/or
block diagram block or blocks.
[0073] FIG. 10 is a flowchart diagram illustrating a method 300 of
non-destructively inspecting a part, according to examples of the
subject disclosure. The method includes, at step 302, positioning
the probe housing 116 and ultrasonic probe assembly 114 so that the
part engagement surface 154 engages the part (e.g., the
manufacturing component 112). Engaging the surface of the part 112
may include pressing the part engagement surface 154 against the
surface of the part 112. In certain examples, the method 300
includes, at step 304, ultrasonically scanning the part for defects
while traversing the part engagement surface across a surface of
the part. The method also includes, at step 306, adjusting a
distance between the ultrasonic probe assembly and the surface of
the part while traversing and scanning the part. The method also
includes, at step 308, biasing the probe housing 116 relative to
the attachment body 118 to maintain engagement of the part
engagement surface 154 with the surface of the part.
[0074] In the above description, certain terms may be used such as
"up," "down," "upper," "lower," "horizontal," "vertical," "left,"
"right," "over," "under" and the like. These terms are used, where
applicable, to provide some clarity of description when dealing
with relative relationships. But, these terms are not intended to
imply absolute relationships, positions, and/or orientations. For
example, with respect to an object, an "upper" surface can become a
"lower" surface simply by turning the object over. Nevertheless, it
is still the same object. Further, the terms "including,"
"comprising," "having," and variations thereof mean "including but
not limited to" unless expressly specified otherwise. An enumerated
listing of items does not imply that any or all of the items are
mutually exclusive and/or mutually inclusive, unless expressly
specified otherwise. The terms "a," "an," and "the" also refer to
"one or more" unless expressly specified otherwise. Further, the
term "plurality" can be defined as "at least two."
[0075] Additionally, instances in this specification where one
element is "coupled" to another element can include direct and
indirect coupling. Direct coupling can be defined as one element
coupled to and in some contact with another element. Indirect
coupling can be defined as coupling between two elements not in
direct contact with each other, but having one or more additional
elements between the coupled elements. Further, as used herein,
securing one element to another element can include direct securing
and indirect securing. Additionally, as used herein, "adjacent"
does not necessarily denote contact. For example, one element can
be adjacent another element without being in contact with that
element.
[0076] As used herein, the phrase "at least one of", when used with
a list of items, means different combinations of one or more of the
listed items may be used and only one of the items in the list may
be needed. The item may be a particular object, thing, or category.
In other words, "at least one of" means any combination of items or
number of items may be used from the list, but not all of the items
in the list may be required. For example, "at least one of item A,
item B, and item C" may mean item A; item A and item B; item B;
item A, item B, and item C; or item B and item C. In some cases,
"at least one of item A, item B, and item C" may mean, for example,
without limitation, two of item A, one of item B, and ten of item
C; four of item B and seven of item C; or some other suitable
combination.
[0077] Unless otherwise indicated, the terms "first," "second,"
etc. are used herein merely as labels, and are not intended to
impose ordinal, positional, or hierarchical requirements on the
items to which these terms refer. Moreover, reference to, e.g., a
"second" item does not require or preclude the existence of, e.g.,
a "first" or lower-numbered item, and/or, e.g., a "third" or
higher-numbered item.
[0078] As used herein, a system, apparatus, structure, article,
element, component, or hardware "configured to" perform a specified
function is indeed capable of performing the specified function
without any alteration, rather than merely having potential to
perform the specified function after further modification. In other
words, the system, apparatus, structure, article, element,
component, or hardware "configured to" perform a specified function
is specifically selected, created, implemented, utilized,
programmed, and/or designed for the purpose of performing the
specified function. As used herein, "configured to" denotes
existing characteristics of a system, apparatus, structure,
article, element, component, or hardware which enable the system,
apparatus, structure, article, element, component, or hardware to
perform the specified function without further modification. For
purposes of this disclosure, a system, apparatus, structure,
article, element, component, or hardware described as being
"configured to" perform a particular function may additionally or
alternatively be described as being "adapted to" and/or as being
"operative to" perform that function.
[0079] The schematic flow chart diagrams included herein are
generally set forth as logical flow chart diagrams. As such, the
depicted order and labeled steps are indicative of one example of
the presented method. Other steps and methods may be conceived that
are equivalent in function, logic, or effect to one or more steps,
or portions thereof, of the illustrated method. Additionally, the
format and symbols employed are provided to explain the logical
steps of the method and are understood not to limit the scope of
the method. Although various arrow types and line types may be
employed in the flow chart diagrams, they are understood not to
limit the scope of the corresponding method. Indeed, some arrows or
other connectors may be used to indicate only the logical flow of
the method. For instance, an arrow may indicate a waiting or
monitoring period of unspecified duration between enumerated steps
of the depicted method. Additionally, the order in which a
particular method occurs may or may not strictly adhere to the
order of the corresponding steps shown.
[0080] The present subject matter may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described examples are to be considered in all
respects only as illustrative and not restrictive. All changes
which come within the meaning and range of equivalency of the
claims are to be embraced within their scope.
* * * * *