Ultrasonic inspection apparatus, system, and method

• US 20070006658A1
• Filed: 07/11/2005
• Published: 01/11/2007
• Est. Priority Date: 07/11/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Little, Mark, Kennedy, James, Uyehara, Clyde
• Granted Patent: US 7,640,810 B2
• Time in Patent Office: Days
• US Class Current: 73/622
• CPC Class Codes: G01N 2291/044 Internal reflections (echoes), e.g. on walls or defects
• CPC Class Codes: G01N 2291/106 one or more transducer arrays
• CPC Class Codes: G01N 29/265 by moving the sensor relative to a stationary material
• CPC Class Codes: G01N 29/343 pulse waves, e.g. particular sequence of pulses, bursts

Abstract

Improved apparatus, systems, and methods for inspecting a structure are provided that use a pedestal robot mounted on a rail system, a probe extension coupler, and an inspection probe capable of performing pulse echo ultrasonic inspection. A probe may also include sled appendages and an axial braking system to inspect over holes and off edges. A probe may also include an ultrasonic pulse echo transducer array for high rate inspection; the transducer array may be mounted in a bubbler shoe for individually coupling each of the transducers in the array. A rail system may also include an optical encoder for providing location information for the robot and axial braking system. A probe extension coupler presses the inspection probe against the structure for adjusting to changes in surface contours.

Claims

1. A system for non-destructive inspection of a structure, comprising:

a motion control system comprising a robot control system, wherein the robot control system comprises a robotic arm;

an extension coupler attached to the robotic arm, the extension coupler having an extendable and retractable distal end; and

an inspection probe attached to the distal end of the extension coupler, configured for traveling over holes and off edges of the structure, and comprising at least one pulse echo ultrasonic transducer configured for inspecting the structure as the inspection probe and transducer are moved over the structure by at least one of the motion control system and extension coupler,

wherein the extension coupler is configured to extend and retract the first end to which the probe is attached for applying pressure to the probe to press the probe against the structure.

2. The system of claim 1, wherein the robot control system is configured for being attached to and moved along a rail system, and wherein the motion control system further comprises a rail system to which the robot control system is attached, the rail system being capable of moving the attached robot control system.

3. The system of claim 2, wherein the motion control system comprises a controller for controlling the movement of at least one of the rail system and the robot control system.

4. The system of claim 2, wherein the rail system is configured for controlling linear motion to the attached motion control system.

5. The system of claim 2, wherein the rail system comprises:

a rail support structure; and

a robot carriage to which the robot control system is mounted and for traveling along the rail support structure, thereby moving the robot control system along the rail system.

6. The system of claim 1, wherein the motion control system comprises an optical encoder capable of measuring and transmitting the position of the motion control system with respect to the structure.

7. The system of claim 1, wherein the robot control system comprises a pedestal robot configured for controlling the motion of the extension coupler in at least two directions of motion.

8. The system of claim 1, wherein the extension coupler comprises:

a dual action cylinder having an extendable and retractable cylinder piston rod having a first end protruding from the dual action cylinder;

a transition rod connected to the protruding first end of the cylinder piston rod for translating the motion of the cylinder piston rod, the transition rod having a first end connected to the protruding distal end of the cylinder piston rod and a second end; and

a transducer extension rod connected to the second end of the transition rod for translating the motion of the transition rod and the cylinder piston rod, the transducer extension rod having a first end connected to the second end of the transition rod and a second end forming the distal end of the extension coupler.

9. The system of claim 1, wherein the extension coupler further comprises a pillow block bearing surrounding a portion of the transducer extension rod between the first and second ends of the transducer extension rod and configured for stabilizing the transducer extension rod.

10. The system of claim 1, wherein the inspection probe comprises:

a frame configured for attaching to the second end of the extension coupler and for supporting the transducer;

at least one sled appendage configured for supporting the frame while traveling over a surface of the structure and rotatably connected to the frame; and

a braking system capable of affixing the respective positions of the frame and sled appendage in at least a first direction of motion about a first axis defined by the rotatable connection of the frame and the sled appendage.

11. The system of claim 9, wherein the motion control system is capable of providing a braking signal to the braking system of the probe based upon a determination of the location of the probe with respect to a predetermined location of at least one of a hole and an edge of the structure known to the motion control system.

12. The system of claim 1, wherein the inspection probe comprises:

a bubbler shoe configured for supporting a plurality of transducers and dispersing a couplant between the transducers supported thereby and the surface over which the inspection probe travels; and

a plurality of transducers supported by the bubbler shoe.

13. The system of claim 1, wherein the motion control system is configured for interpreting electronic data representing the configuration of the structure for controlling movement of the probe over the structure for inspection and for providing the ability to communicate the location of holes and edges to at least one of the extension coupler and the inspection probe.

14. An apparatus for connecting an inspection probe to a motion control system for non-destructive inspection of a structure, comprising:

a dual action cylinder having an extendable and retractable cylinder piston rod having a first end protruding from the dual action cylinder;

a transition rod connected to the protruding first end of the cylinder piston rod for transfer the motion of the cylinder piston rod, the transition rod having a first end connected to the protruding distal end of the cylinder piston rod and a second end; and

a transducer extension rod connected to the second end of the transition rod for transfer the motion of the transition rod and the cylinder piston rod, the transducer extension rod having a first end connected to the second end of the transition rod and a second end forming the second end of the extension coupler,

wherein the connections of the transducer extension rod to the transition rod and the transition rod to the cylinder piston rod form an s-shaped configuration such that the transducer extension rod is positioned parallel with and adjacent to eh cylinder piston rod.

15. The apparatus of claim 14, further comprising a z-axis brake proximate the cylinder piston rod, configured for applying pressure to the cylinder piston rod, and capable of holding the cylinder rod in a fixed position.

16. The apparatus of claim 14, further comprising a pillow block bearing surrounding at least a portion of the transducer extension rod between the first and second ends of the transducer extension rod and configured for providing longitudinal stability of the transducer extension rod.

17. A method for inspecting a structure, comprising the steps of:

providing an ultrasonic inspection system for inspecting a structure, the ultrasonic inspection system having a motion control system, an extension coupler, and an inspection probe, the inspection probe having at least one pulse echo ultrasonic transducer for transmitting and receiving pulse echo ultrasonic signals;

applying pressure to the probe to press the probe against a surface of a structure using the extension coupler;

moving the probe over the structure using the motion control system;

transmitting pulse echo ultrasonic signals from the transducer into the structure; and

receiving pulse echo ultrasonic signals at the transducer reflected from the structure.

18. The method of claim 17, wherein the motion control system comprises a rail system and a robotic arm, the rail system having a first end and a second end defined by a length of the rail system between the first end and the second end, and wherein the step of moving the probe over the structure comprises translating the robotic arm along at least a portion of the length of the rail system.

19. The method of claim 17, further comprising the step of fixing the position of the probe with respect to the surface.

20. The method of claim 18, wherein the step of fixing the position of the probe comprises activating an axial braking system.

21. The method of claim 17, further comprising the step of coupling the pulse echo ultrasonic signals transmitted to and received from the structure using a couplant.