Systems, methods, and apparatus for inspection of a surface using sensor holder with dual linear phased array of ultra-sonic elements

Patent metadata

Field	Value
Publication number	US-12442797-B2
Application number	US-202418935035-A
Country	US
Kind code	B2
Filing date	Nov 1, 2024
Priority date	Dec 23, 2022
Publication date	Oct 14, 2025
Grant date	Oct 14, 2025

Abstract

An example payload for an inspection robot having a mounting rail to inspect an inspection surface, the payload including a wedge element; and a probe holder, including: a mounting rail connection member structured to connect to the mounting rail; a wedge element holder structured to hold the wedge element; a spring-loaded member structured to connect to the mounting rail connection member and to provide a selected vertical force on the wedge element holder; and an extended member structured to connect to the spring-loaded member between a first end and a second end, and to connect to the wedge element holder at the second end.

First claim

What is claimed is:

1. A payload for an inspection robot having a mounting rail to inspect an inspection surface, the payload comprising:
a wedge element; and
a probe holder, including:
a mounting rail connection member structured to connect to the mounting rail;
a wedge element holder structured to hold the wedge element;
a spring-loaded member structured to connect to the mounting rail connection member and to provide a selected vertical force on the wedge element holder;
an extended member structured to connect to the spring-loaded member between a first end and a second end, and to connect to the wedge element holder at the second end; and
a joint member structured to connect between the extended member and the wedge element holder, wherein the joint member includes:
a Hirth joint structured to set a yaw axis relative to the inspection surface; and
a rotational joint structured to set a roll axis relative to the inspection surface.

2. The payload of claim 1 , wherein the wedge element holder connects to the joint member via at least one clamp on a frame of the joint member.

3. The payload of claim 1 , further comprising:
the extended member including a linear rail, wherein the extended member is structured to connect to the spring-loaded member via the linear rail, and the spring-loaded member travels along the linear rail between the first end and the second end.

4. The payload of claim 1 , further comprising:
the spring-loaded member including a constant force spring to provide the selected vertical force, wherein the constant force spring is connected to the first end of the extended member and is structured to be replaced to adjust the selected vertical force.

5. The payload of claim 4 , wherein the selected vertical force is a selected downward force.

6. The payload of claim 1 , further comprising:
the spring-loaded member including a Hirth joint structured to set a skew axis relative to the inspection surface.

7. The payload of claim 1 , further comprising:
a wedge element with at least one ultrasonic (UT) transducer mounted thereon, the wedge element connected to the wedge element holder.

8. The payload of claim 1 , wherein the mounting rail connection member includes a dovetail joint.

9. The payload of claim 1 , wherein the wedge element has a travel length corresponding to a length of the extended member between the first and second ends.

10. A payload for an inspection robot having a mounting rail to inspect an inspection surface, the payload comprising:
a wedge element; and
a probe holder, including:
a mounting rail connection member structured to connect to the mounting rail;
a wedge element holder structured to hold the wedge element;
a spring-loaded member structured to connect to the mounting rail connection member and to provide a selected vertical force on the wedge element holder; and
an extended member structured to connect to the spring-loaded member between a first end and a second end, and to connect to the wedge element holder at the second end,
the extended member including a linear rail, wherein the extended member is structured to connect to the spring-loaded member via the linear rail, and the spring-loaded member travels along the linear rail between the first end and the second end.

11. The payload of claim 10 , further comprising:
a joint member structured to connect between the extended member and the wedge element holder, wherein the joint member includes:
a Hirth joint structured to set a yaw axis relative to the inspection surface; and
a rotational joint structured to set a roll axis relative to the inspection surface,
wherein the wedge element holder connects to the joint member via at least one clamp on a frame of the joint member.

12. The payload of claim 10 , further comprising:
the spring-loaded member including a constant force spring to provide the selected vertical force, wherein the constant force spring is connected to the first end of the extended member and is structured to be replaced to adjust the selected vertical force.

13. The payload of claim 12 , wherein the selected vertical force is a selected downward force.

14. The payload of claim 10 , further comprising:
the spring-loaded member including a Hirth joint structured to set a skew axis relative to the inspection surface.

15. The payload of claim 10 , further comprising:
a wedge element with at least one ultrasonic (UT) transducer mounted thereon, the wedge element connected to the wedge element holder.

16. The payload of claim 10 , wherein the mounting rail connection member includes a dovetail joint.

17. The payload of claim 10 , wherein the wedge element has a travel length corresponding to a length of the extended member between the first and second ends.

18. A payload for an inspection robot having a mounting rail to inspect an inspection surface, the payload comprising:
a wedge element; and
a probe holder, including:
a mounting rail connection member structured to connect to the mounting rail;
a wedge element holder structured to hold the wedge element;
a spring-loaded member structured to connect to the mounting rail connection member and to provide a selected vertical force on the wedge element holder,
the spring-loaded member including a Hirth joint structured to set a skew axis relative to the inspection surface; and
an extended member structured to connect to the spring-loaded member between a first end and a second end, and to connect to the wedge element holder at the second end.

19. The payload of claim 18 , further comprising:
a joint member structured to connect between the extended member and the wedge element holder, wherein the joint member includes:
a Hirth joint structured to set a yaw axis relative to the inspection surface; and
a rotational joint structured to set a roll axis relative to the inspection surface,
wherein the wedge element holder connects to the joint member via at least one clamp on a frame of the joint member.

20. The payload of claim 18 , further comprising:
the spring-loaded member including a constant force spring to provide the selected vertical force, wherein the constant force spring is connected to the first end of the extended member and is structured to be replaced to adjust the selected vertical force.

21. The payload of claim 20 , wherein the selected vertical force is a selected downward force.

22. The payload of claim 18 , further comprising:
a wedge element with at least one ultrasonic (UT) transducer mounted thereon, the wedge element connected to the wedge element holder.

23. The payload of claim 18 , wherein the mounting rail connection member includes a dovetail joint.

24. The payload of claim 18 , wherein the wedge element has a travel length corresponding to a length of the extended member between the first and second ends.

25. A payload for an inspection robot having a mounting rail to inspect an inspection surface, the payload comprising:
a wedge element; and
a probe holder, including:
a mounting rail connection member structured to connect to the mounting rail,
wherein the mounting rail connection member includes a dovetail joint;
a wedge element holder structured to hold the wedge element;
a spring-loaded member structured to connect to the mounting rail connection member and to provide a selected vertical force on the wedge element holder; and
an extended member struct

Assignees

• Gecko Robotics Inc

Inventors

• David Chase
• Binger Michael A
• Low Kevin Y
• Desoto Ryan
• Reitz Brandon J
• Bowman Spencer
• Bryner Edward A
• Biglan Albert J

Classifications

• G01N2291/106

  one or more transducer arrays · CPC title

• G01N29/2487

  Directing probes, e.g. angle probes (directing arrangements G01N29/221) · CPC title

• G01N29/225

  Supports, positioning or alignment in moving situation · CPC title

• G01N29/265

  by moving the sensor relative to a stationary material · CPC title

• G01N29/262

  by electronic orientation or focusing, e.g. with phased arrays (phased arrays per se G10K11/34) · CPC title