Ultrasonic inspection probe, system, and method

An ultrasonic inspection system for inspecting parts, the ultrasonic inspection system comprising:

• a robot;
• and
• an end effector, coupled to and movable by the robot, wherein the end effector comprises:
• a compliance interface assembly, directly coupled to the robot;
• and
• an ultrasonic inspection probe, coupled to the compliance interface assembly such that the compliance interface assembly couples the ultrasonic inspection probe to the robot, wherein the ultrasonic inspection probe comprises:
• a probe body, comprising an ultrasonic array and a plate attachment surface, wherein the ultrasonic array comprises a plurality of ultrasound elements, each selectively operable to generate an ultrasonic beam and each fixed relative to the plate attachment surface, wherein the plurality of ultrasound elements of the ultrasonic array is arranged in a first circular arc having a first radius, and wherein the ultrasonic array is fixed relative to the probe body such that the ultrasonic array does not move relative to the probe body;
• and
• an interface plate, comprising a body attachment surface, removably attachable to the plate attachment surface of the probe body, a part inspection surface, shaped to complement a shape of one of the parts, and an opening extending entirely through the interface plate from the body attachment surface to the part inspection surface,
• wherein the ultrasonic beams are directed through the opening in the interface plate without being redirected by the interface plate.

A method of inspecting parts, the method comprising:

• removably attaching a first interface plate to a probe body, wherein:
• the probe body comprises an ultrasonic array and a plate attachment surface, wherein the ultrasonic array comprises a plurality of ultrasound elements, each selectively operable to generate an ultrasonic beam and each fixed relative to the plate attachment surface, wherein the plurality of ultrasound elements of the ultrasonic array is arranged in a first circular arc having a first radius, and wherein the ultrasonic array is fixed relative to the probe body such that the ultrasonic array does not move relative to the probe body;
• and
• the first interface plate comprises a body attachment surface, removably attachable to the plate attachment surface of the probe body, a first part inspection surface, shaped to complement a shape of one of the parts, and an opening extending entirely through the first interface plate from the body attachment surface to the part inspection surface;
• riding the first part inspection surface of the first interface plate along a first one of the parts;
• and
• while riding the part inspection surface of the first interface plate along the first one of the parts, directing ultrasonic beams, generated from the ultrasonic array of the probe body, toward the first one of the parts and through the opening in the first interface plate without being redirected by the first interface plate.