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

Patent metadata

Field	Value
Publication number	US-9933396-B2
Application number	US-201514836154-A
Country	US
Kind code	B2
Filing date	Aug 26, 2015
Priority date	Aug 26, 2015
Publication date	Apr 3, 2018
Grant date	Apr 3, 2018

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 probe assembly to a robot and using the robot to move the inspection 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 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 frame;
first and second rotatable shafts which are mutually coaxial and rotatable relative to said frame; and
a probe housing assembly clamped to said first and second rotatable shafts, wherein said probe housing assembly comprises:
a first probe platform clamped to said first and second rotatable shafts;
a second probe platform;
first and second linear slides configured to translatably couple said second probe platform to said first probe platform;
a third probe platform; and
third and fourth linear slides configured to translatably couple said third probe platform to said first probe platform.

2. The apparatus as recited in claim 1 , wherein said frame comprises first through fourth guide shafts, the apparatus further comprising a first bearing block assembly translatably coupled to said first and second guide shafts, and a second bearing block assembly translatably coupled to said third and fourth guide shafts, wherein said first rotatable shaft is rotatably coupled to said first bearing block assembly, and said second rotatable shaft is rotatably coupled to said second bearing block assembly.

3. The apparatus as recited in claim 1 , further comprising a gimbal assembly disposed between said frame and a tool-side connector configured to be attached to a connector of a robot, said gimbal assembly comprising a revolute joint supported by said tool-side connector, a thrust bearing, and fifth and sixth linear slides configured to translatably couple said thrust bearing to said revolute joint.

4. The apparatus as recited in claim 1 , further comprising:
a first web probe translatably coupled to one of said first through third probe platforms for translation along first and second axes which are mutually perpendicular, said first web probe comprising a first linear ultrasonic transducer array;
a second web probe translatably coupled to said one of said first through third probe platforms for translation along third and fourth axes which are mutually perpendicular, said second web probe comprising a second linear ultrasonic transducer array which is parallel to said first linear ultrasonic transducer array.

5. The apparatus as recited in claim 4 , wherein said first web probe is rotatably coupled to said one of said first through third probe platforms for rotation about a fifth axis which is perpendicular to said first and second axes, and said second web probe is rotatably coupled to said one of said first through third probe platforms for rotation about a sixth axis which is perpendicular to said third and fourth axes, the apparatus further comprising:
an L-shaped member comprising first and second legs that form a right angle;
a fifth linear slide configured to translatably couple said first leg of said L-shaped member to said first web probe to enable translation along a length of said first leg; and
a sixth linear slide configured to translatably couple said second leg of said L-shaped member to said first web probe to enable translation along a length of said second leg,
wherein said first and second linear ultrasonic transducer arrays stay mutually parallel and displace relative to each other during rotation in tandem about said first and second axes respectively.

6. The apparatus as recited in claim 1 , further comprising:
a first radius probe translatably coupled to one of said first through third probe platforms for translation along first and second axes which are mutually perpendicular, said first radius probe comprising a first curved ultrasonic transducer array; and
a second radius probe translatably coupled to said one of said first through third probe platforms for translation along third and fourth axes which are mutually perpendicular, said second radius probe comprising a second curved ultrasonic transducer array.

7. The apparatus as recited in claim 1 , further comprising:
a linear ultrasonic transducer array housed in one of said first through third probe platforms; and
a dry acoustic couplant material separated from said linear ultrasonic transducer array by a gap,
wherein said probe housing assembly further comprises:
a dry acoustic couplant housing translatably coupled to said one of said first through third probe platforms for translation along first and second axes which are mutually perpendicular, said dry acoustic couplant housing supporting said dry acoustic couplant material.

8. The apparatus as recited in claim 1 , further comprising:
a first web probe translatably coupled to one of said first through third probe platforms for translation along first and second axes which are mutually perpendicular, said first web probe comprising a first linear ultrasonic transducer array;
a second web probe translatably coupled to said one of said first through third probe platforms for translation along third and fourth axes which are mutually perpendicular, said second web probe comprising a second linear ultrasonic transducer array which is parallel to said first linear ultrasonic transducer array;
a first radius probe translatably coupled to another of said first through third probe platforms for translation along fifth and sixth axes which are mutually perpendicular, said first radius probe comprising a first curved ultrasonic transducer array; and
a second radius probe translatably coupled to said another of said first through third probe platforms for translation along seventh and eighth axes which are mutually perpendicular, said second radius probe comprising a second curved ultrasonic transducer array.

9. The apparatus as recited in claim 8 , further comprising:
a third linear ultrasonic transducer array housed in a further one of said first through third probe platforms; and
a dry acoustic couplant material separated from said third linear ultrasonic transducer array by a gap,
wherein said probe housing assembly further comprises:
a dry acoustic couplant housing translatably coupled to said further one of said first through third probe platforms for translation along ninth and tenth axes which are mutually perpendicular, said dry acoustic couplant housing supporting said dry acoustic couplant material.

10. The apparatus as recited in claim 9 , wherein said first, second and third linear ultrasonic transducer arrays and said first and second curved ultrasonic transducer arrays are arranged so that said first and second linear ultrasonic transducer arrays can interrogate a web portion of an elongated composite member having a generally T-shaped profile, while said first and second curved ultrasonic transducer arrays can interrogate respective radiused portions of the elongated composite member, and said third linear ultrasonic transducer array can interrogate a flange portion of the elongated composite member in a single pass.

11. An apparatus comprising:
a probe housing assembly;
a first web probe rotatably coupled to said probe housing assembly for rotation about a first axis, said first web probe comprising a first linear ultrasonic transducer array;
a second web probe rotatably coupled to said probe housing assembly for rotation about a second axis which is parallel to said first axis, said second web probe comprising a second linear ultrasonic transducer array which is parallel to said first linear ultrasonic transducer array;
an L-shaped member comprising first and second legs that form a right angle;
a first linear slide configured to translatably couple said first leg of said L-shaped member to said first web probe to enable translation along a length of said first leg; and
a second linear slide configured to translatably couple said second leg of said L-shaped member to sa

Assignees

• Boeing Co

Inventors

• Fetzer Barry A
• Serrill Justin D

Classifications

• G01N2291/2638

  Complex surfaces · CPC title

• G01N2291/0231

  Composite or layered materials · CPC title

• G01N29/225

  Supports, positioning or alignment in moving situation · CPC title

• G01N29/043

  in the interior, e.g. by shear waves · CPC title

• G01N2291/2694

  Wings or other aircraft parts · CPC title