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Efficient data acquisition and reconstruction for air-coupled ultrasonic robotic NDE
Ciaron Hamilton1, Oleksii Karpenko1, Lalita Udpa1
1Nondestructive Evaluation Laboratory (NDEL), Composite Vehicle Research Center (CVRC), Michigan State University College of Electrical and Computer Engineering, East Lansing, MI, 48824-1226, USA.
Scientific Reports
|June 18, 2024
Summary
This study introduces a structured light reconstruction method for precise robotic non-destructive evaluation (NDE). It enables accurate path planning for ultrasonic probes, improving defect detection in composite materials.
Area of Science:
- Materials Science and Engineering
- Robotics and Automation
- Non-Destructive Evaluation (NDE)
Background:
- Non-destructive evaluation (NDE) of complex geometries requires precise sensor manipulation.
- Robotic arms offer potential for controlled probe positioning in NDE.
- Accurate specimen geometry is crucial for quantitative NDE results.
Purpose of the Study:
- To develop and validate a methodology for accurate physical-to-virtual reconstruction of complex part geometries using structured light.
- To enable precise path planning for robotic NDE probes, ensuring constant probe-to-surface distance (lift-off).
- To demonstrate the application in air-coupled ultrasonic inspection of composite materials with simulated flaws.
Main Methods:
- Structured light scanning (CR-Scan 01) for submillimeter accurate surface reconstruction.
- A novel ray-triangle intersection array algorithm for robotic path planning.
- Air-coupled ultrasonic testing (SonoAir system, 200 kHz) with a pitch-catch configuration on a Fanuc 100ib robot arm.
- Guided wave propagation for single-side access inspection.
Main Results:
- Achieved submillimeter accurate geometric reconstruction of specimens.
- Successfully planned and executed robotic probe movements for constant lift-off.
- Demonstrated effective detection of simulated flaws (interlaminar delamination) in CFRP composites.
- Synchronized defect detection with probe orientation and position.
Conclusions:
- Structured light-based reconstruction provides accurate geometric data for robotic NDE path planning.
- The proposed methodology enhances the precision and reliability of ultrasonic inspection for complex parts.
- The approach offers a framework for the automation of NDE processes.
