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A Novel Complete-Surface-Finding Algorithm for Online Surface Scanning with Limited View Sensors.

Alastair Poole1,2, Mark Sutcliffe2, Gareth Pierce1

  • 1Centre of Ultrasonic Engineering (CUE), University of Strathclyde, Glasgow G1 1XW, UK.

Sensors (Basel, Switzerland)
|November 27, 2021
PubMed
Summary

This study introduces a novel algorithm for robot-assisted ultrasonic testing, enabling autonomous scanning of unknown surfaces in a single pass. This innovation enhances inspections in challenging environments and for complex geometries without prior digital models.

Keywords:
NDTautonomous robotic systemsfree-form surface profiling

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Area of Science:

  • Robotics and Automation
  • Non-Destructive Testing (NDT)
  • Materials Science

Background:

  • Robot-assisted Non-Destructive Testing (NDT) offers speed and access to hazardous areas.
  • Current methods struggle with unknown or deforming surfaces, lacking accurate digital models for robotic path planning.
  • Existing solutions require pre-scans with camera systems to generate CAD models, limiting flexibility.

Purpose of the Study:

  • To develop a novel algorithm for robot-assisted ultrasonic testing of unknown surfaces in a single pass.
  • To enable autonomous surface profiling using small-aperture sensors on surfaces of any scale.
  • To overcome limitations of digital model availability and accuracy in robotic path planning for NDT.

Main Methods:

  • Development of a novel algorithm for autonomous robotic path planning and surface scanning.
  • Utilizing local sensor information to map surfaces of unknown geometry.
  • Implementing single-pass scanning for robot-assisted ultrasonic testing.

Main Results:

  • The algorithm successfully mapped complex and curved surfaces in simulation using only local data.
  • Practical demonstrations confirmed full mapping of curved and non-simple surfaces with no operator intervention.
  • The method generated traditional raster patterns for surfaces with single-direction curvature.

Conclusions:

  • The developed algorithm enables autonomous, single-pass robotic ultrasonic testing of unknown surfaces, regardless of scale.
  • This approach is applicable to diverse scenarios, including drone/crawler inspections and confined spaces.
  • Future work will integrate low-accuracy environmental sensing to address collision prevention and expand practical applications.