Automated ultrasonic inspection of elongated composite members using single-pass robotic system

Patent metadata

Field	Value
Publication number	US-10969367-B2
Application number	US-201916437239-A
Country	US
Kind code	B2
Filing date	Jun 11, 2019
Priority date	Jun 11, 2019
Publication date	Apr 6, 2021
Grant date	Apr 6, 2021

Abstract

Apparatus and methods for ultrasonic inspection of elongated composite members in a single scan pass using pulse echo phased arrays operating in a bubbler method. The system concept is fully automated by integrating an inspection NDI probe assembly to a robot and using the robot to move the inspection NDI probe assembly along the part (i.e., outside of an inspection tank); and by integrating tooling fixtures that move out of the way as the inspection NDI probe assembly travels along the length of the part during the inspection. In addition, the system allows for generally elongated composite members having lengthwise variation in shape, curvature and dimensions.

First claim

The invention claimed is:

1. An apparatus comprising:
a tool frame assembly comprising first and second guide shafts oriented parallel to a Z axis of the tool frame assembly;
first and second bearing block assemblies slidably coupled to the first and second guide shafts respectively and comprising first and second pivots respectively, the first and second pivots being rotatable about first and second axes of rotation which are parallel to an X axis perpendicular to the Z axis; and
a first frame assembly comprising first and second rotatable shafts which are coaxial with a third axis of rotation perpendicular to the X axis, the first and second rotatable shafts being rotatably and translatably coupled to the first and second pivots respectively for rotation about and translation along the third axis of rotation.

2. The apparatus as recited in claim 1 , wherein the first pivot comprises first and second pivot pins which are coaxial and the first bearing block assembly further comprises:
a linear ball bearing disposed between the first rotatable shaft and the first pivot;
first and second bearings that support the first and second pivot pins respectively of the first pivot; and
first and second linear bearings which are slidably coupled to the first guide shaft.

3. The apparatus as recited in claim 1 , wherein the first frame assembly comprises a lower frame bracket and first and second linear slide tables which are translatable relative to the lower frame bracket along first and second linear paths which are mutually parallel.

4. The apparatus as recited in claim 3 , wherein the first frame assembly further comprises third and fourth linear slide tables which are respectively translatable relative to the first and second linear slide tables along a third linear path which is perpendicular to the first and second linear paths.

5. The apparatus as recited in claim 4 , further comprising an upper assembly attached to the third and fourth linear slide tables and a lower assembly attached to the lower frame bracket, wherein the upper assembly comprises first and second non-destructive inspection probes which are translatable relative to each other and rotatable in tandem.

6. The apparatus as recited in claim 4 , further comprising a first upper subassembly attached to the third linear slide table, a second upper subassembly attached to the fourth linear slide table, and a lower assembly attached to the lower frame bracket, wherein the first upper subassembly comprises a first non-destructive inspection (NDI) probe and the second upper subassembly comprises a second NDI probe, the first and second NDI probes being translatable relative to each other and rotatable in tandem.

7. The apparatus as recited in claim 4 , further comprising a first upper subassembly attached to the third linear slide table, a second upper subassembly attached to the fourth linear slide table, and a lower assembly attached to the lower frame bracket, wherein the lower assembly comprises first and second non-destructive inspection probes.

8. The apparatus as recited in claim 1 , wherein the tool frame assembly further comprises third and fourth guide shafts oriented parallel to the Z axis of the tool frame assembly, a first lower guide shaft spacer which maintains a spacing between the first and third guide shafts, and a second lower guide shaft spacer which maintains a spacing between the second and fourth guide shafts, and wherein the apparatus further comprises:
third and fourth bearing block assemblies slidably coupled to the third and fourth guide shafts respectively and comprising third and fourth pivots respectively, the third and fourth pivots being rotatable about fourth and fifth axes of rotation which are parallel to the X axis; and
a second frame assembly comprising third and fourth rotatable shafts which are coaxial with a sixth axis of rotation perpendicular to the X axis, the third and fourth rotatable shafts being rotatably and translatably coupled to the third and fourth pivots respectively for rotation about and translation along the sixth axis of rotation.

9. The apparatus as recited in claim 8 , wherein the tool frame assembly further comprises fifth and sixth guide shafts oriented parallel to the Z axis of the tool frame assembly, the first lower guide shaft spacer maintains a spacing between the third and fifth guide shafts, and the second lower guide shaft spacer maintains a spacing between the fourth and sixth guide shafts, and wherein the apparatus further comprises:
fifth and sixth bearing block assemblies slidably coupled to the fifth and sixth guide shafts respectively and comprising fifth and sixth pivots respectively, the fifth and sixth pivots being rotatable about seventh and eighth axes of rotation which are parallel to the X axis; and
a third frame assembly comprising fifth and sixth rotatable shafts which are coaxial with a ninth axis of rotation perpendicular to the X axis, the fifth and sixth rotatable shafts being rotatably and translatably coupled to the fifth and sixth pivots respectively for rotation about and translation along the ninth axis of rotation.

10. The apparatus as recited in claim 1 , further comprising first and second non-destructive inspection (NDI) probes supported by the first frame assembly.

11. The apparatus as recited in claim 10 , wherein the first and second NDI probes are respective ultrasonic transducer arrays.

12. The apparatus as recited in claim 10 , wherein the first frame assembly comprises:
a lower frame bracket;
first and second linear slide tables which are translatable relative to the lower frame bracket along first and second linear paths which are mutually parallel; and
third and fourth linear slide tables which are respectively translatable relative to the first and second linear slide tables along a third linear path which is perpendicular to the first and second linear paths, and
wherein the first NDI probe is coupled to the third linear slide table and the second NDI probe is coupled to the fourth linear slide table.

13. An apparatus for non-destructive inspection (NDI) of a blade stiffener, the apparatus comprising:
a tool frame assembly comprising first through sixth guide shafts oriented parallel to a Z axis of the tool frame assembly;
first through sixth bearing block assemblies slidably coupled to the first through sixth guide shafts respectively, wherein the first through sixth bearing block assemblies comprise respective pivots which are rotatable about respective axes of rotation which are parallel to an X axis, wherein the X axis is perpendicular to the Z axis;
a first NDI probe assembly comprising a first probe frame assembly and first and second NDI probes arranged for inspecting respective portions of a flange disposed on opposite sides of a web of a blade stiffener, wherein the first probe frame assembly comprises first and second rotatable shafts which are coaxial with a first axis of rotation perpendicular to the X axis, the first and second rotatable shafts being rotatably and translatably coupled to the respective pivots of the first and second bearing block assemblies for rotation about and translation along the first axis of rotation;
a second NDI probe assembly comprising a second probe frame assembly and third and fourth NDI probes arranged for inspecting respective radiused portions of the blade stiffener which connect the web to the flange, wherein the second probe frame assembly comprises third and fourth rotatable shafts which are coaxial with a second axis of rotation perpendicular to the X axis, the third and fourth rotatable shafts being rotatably and translatably coupled to th

Assignees

• Boeing Co

Inventors

• Fetzer Barry A
• Serrill Justin D
• Shehab Kareem Gamal

Classifications

• B64C1/064

  Stringers; Longerons · CPC title

• G01N29/225

  Supports, positioning or alignment in moving situation · CPC title

• G01N2291/2694

  Wings or other aircraft parts · CPC title

• B64F5/60

  Testing or inspecting aircraft components or systems · CPC title

• G01N29/04

  Analysing solids (using acoustic emission techniques G01N29/14) · CPC title