# US 11,906,470 B2 · Probe, system, and method for non-destructive ultrasonic inspection > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,906,470 B2 - Document ID: US11906470B2 - Status: Granted - Kind: B2 - Application number: 17/546,795 - Filed: 2021-12-09 - Published: 2022-07-07 - Granted: 2024-02-20 - Earliest claimed: 2021-01-04 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Justin D. Serrill; Hien T. Bui; Shereef G. Shehab - Web page: https://patentgrep.com/patent/US11906470B2 ## CPC - G01N 29/262: {by electronic orientation or focusing, e.g. with phased arrays (phased arrays per se G10K11/34)} - G01N 29/265: by moving the sensor relative to a stationary material - G01N 29/043: {in the interior, e.g. by shear waves} - G01N 29/24: Probes {(transducers for acoustic waves B06B, G10K; for measuring G01H)} - G01N 29/28: providing acoustic coupling {, e.g. water (impedance matching G10K11/02)} - G01N 29/225: {Supports, positioning or alignment in moving situation} - G01N 2291/0231: Composite or layered materials - G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q) ## Abstract Disclosed herein is a probe for non-destructively inspecting a hat stiffener. The probe comprises a body, which comprises an inspection surface and a slot formed in the inspection surface. The probe also comprises an ultrasonic-sensor assembly that is fixed to the body and open to the inspection surface via the slot. The probe further comprises a surface-engagement assembly, which comprises a first foot and a second foot. The surface-engagement assembly is movably coupled to the body such that the first foot and the second foot are on opposite ends of the slot of the body and the first foot and the second foot are movable relative to the body and the ultrasonic-sensor assembly. ## Claims ### Claim 1 A probe for non-destructively inspecting a hat stiffener, the probe comprising: a body, comprising a stiffener-engagement surface and a slot formed in the stiffener-engagement surface; an ultrasonic-sensor assembly, fixed to the body over the slot such that access to the ultrasonic-sensor assembly, through the slot, is unobstructed by the body; and a surface-engagement assembly, comprising a first foot and a second foot, wherein the surface-engagement assembly is movably coupled to the body such that the first foot and the second foot are on opposite ends of the slot of the body and the first foot and the second foot are movable relative to the body and the ultrasonic-sensor assembly. ### Claim 2 (depends on 1) The probe according to claim 1, wherein: the first foot is movable between a first retracted position and a first extended position; the first foot is further from the stiffener-engagement surface in the first extended position than in the first retracted position; the second foot is movable between a second retracted position and a second extended position; and the second foot is further from the stiffener-engagement surface in the second extended position than in the second retracted position. ### Claim 3 (depends on 2) The probe according to claim 2, further comprising: a first biasing mechanism, coupled to the body and the surface-engagement assembly and configured to bias the first foot into the first extended position; and a second biasing mechanism, coupled to the body and the surface-engagement assembly and configured to bias the second foot into the second extended position. ### Claim 4 (depends on 2) The probe according to claim 2, wherein the first foot and the second foot are co-movable relative to each other. ### Claim 5 (depends on 4) The probe according to claim 4, wherein the surface-engagement assembly further comprises a crossbar, movable relative to the body and the ultrasonic-sensor assembly and intercoupling the first foot and the second foot such that translational movement of the crossbar: in a first direction away from the stiffener-engagement surface corresponds with movement of the first foot toward the first retracted position and movement of the second foot toward the second retracted position; and in a second direction toward the stiffener-engagement surface and opposite the first direction corresponds with movement of the first foot toward the first extended position and movement of the second foot toward the second extended position. ### Claim 6 (depends on 5) The probe according to claim 5, wherein: the body further comprises a guiderail; and the crossbar comprises a guiderail slot slidably engaged with the guiderail such that the guiderail limits movement of the crossbar to the first direction and the second direction. ### Claim 7 (depends on 1) The probe according to claim 1, wherein the first foot and the second foot are slidable relative to the body along linear paths. ### Claim 8 (depends on 1) The probe according to claim 1, wherein: the first foot is movable along a first path relative to the body; the second foot is movable along a second path relative to the body; and an angle defined between the first path and the second path is perpendicular or oblique. ### Claim 9 (depends on 8) The probe according to claim 8, wherein: the first foot comprises a first engagement surface configured to engage the hat stiffener; the first engagement surface is substantially perpendicular to the first path; the second foot comprises a second engagement surface configured to engage the hat stiffener; and the second engagement surface is substantially perpendicular to the second path. ### Claim 10 (depends on 1) The probe according to claim 1, wherein: the first foot comprises a first engagement surface configured to engage the hat stiffener; the first foot further comprises a first groove formed in the first engagement surface; the second foot comprises a second engagement surface configured to engage the hat stiffener; the second foot further comprises a second groove formed in the second engagement surface; the probe further comprises a fluid chamber open to the ultrasonic-sensor assembly and defined at least partially between the stiffener-engagement surface of the body, the first groove, and the second groove; the fluid chamber is configured to receive a fluid during non-destructive inspection of the hat stiffener; and a volume of the fluid chamber changes as the first foot and the second foot move relative to the body and the ultrasonic-sensor assembly. ### Claim 11 (depends on 1) The probe according to claim 1, wherein: the first foot comprises a first engagement surface configured to engage the hat stiffener; the first foot further comprises opposing first beveled leading and trailing edges and the first engagement surface is interposed between the opposing first beveled leading and trailing edges of the first foot; the second foot comprises a second engagement surface configured to engage the hat stiffener; and the second foot further comprises opposing second beveled leading and trailing edges and the second engagement surface is interposed between the opposing second beveled leading and trailing edges of the second foot. ### Claim 12 (depends on 1) The probe according to claim 1, wherein: the first foot comprises a first engagement surface configured to engage the hat stiffener; the second foot comprises a second engagement surface configured to engage the hat stiffener; and the first engagement surface and the second engagement surface are planar. ### Claim 13 A system for non-destructively inspecting a hat stiffener, the system comprising: a robotic arm; and a probe, fixed to the robotic arm and comprising: a body, comprising stiffener-engagement surface and a slot formed in the stiffener-engagement surface; an ultrasonic-sensor assembly, fixed to the body over the slot such that access to the ultrasonic-sensor assembly, through the slot, is unobstructed by the body; and a surface-engagement assembly, comprising a first foot and a second foot, wherein the surface-engagement assembly is movably coupled to the body such that the first foot and the second foot are on opposite ends of the slot of the body and the first foot and the second foot are movable relative to the body and the ultrasonic-sensor assembly; wherein the robotic arm is configured to autonomously move the probe along the hat stiffener such that at least a portion of the stiffener-engagement surface of the body contacts the hat stiffener and the first foot and the second foot contact the hat stiffener. ### Claim 14 (depends on 13) The system according to claim 13, wherein: the hat stiffener comprises a cap portion having a first radius; the first foot and the second foot are in first positions relative to the body and the ultrasonic-sensor assembly when in contact with the hat stiffener; the robotic arm is configured to autonomously remove the probe from the hat stiffener and autonomously move the probe along a second hat stiffener, having a second radius that is different than the first radius, such that at least a portion of the stiffener-engagement surface of the body contacts the second hat stiffener and the first foot and the second foot contact the second hat stiffener; the first foot and the second foot are in second positions relative to the body and the ultrasonic-sensor assembly when in contact with the second hat stiffener; and the first positions are different than the second positions. ### Claim 15 A method of non-destructively inspecting a hat stiffener, the method comprising steps of: contacting a cap portion of the hat stiffener with a stiffener-engagement surface of a body of a probe; moving a first foot of the probe, relative to the body, to contact a first web portion of the hat stiffener when the stiffener-engagement surface is contacting the cap portion of the hat stiffener; moving a second foot of the probe, relative to the body, to contact a second web portion of the hat stiffener when the stiffener-engagement surface is contacting the cap portion of the hat stiffener; and ultrasonically inspecting the cap portion of the hat stiffener with an ultrasonic-sensor assembly, fixed to the body over a slot formed in the stiffener-engagement surface of the body such that access to the ultrasonic-sensor assembly, through the slot, is unobstructed by the body. ### Claim 16 (depends on 15) The method according to claim 15, further comprising steps of: filling a fluid chamber of the probe with a fluid, the fluid chamber being open to the ultrasonic-sensor assembly and defined at least partially between the stiffener-engagement surface of the body, a first groove formed in the first foot, and a second groove formed in the second foot; and changing a volume of the fluid chamber by moving the first foot relative to the body and moving the second foot relative to the body. ### Claim 17 (depends on 15) The method according to claim 15, further comprising steps of: biasing the first foot away from the stiffener-engagement surface and toward the second foot; and biasing the second foot away from the stiffener-engagement surface and toward the first foot. ### Claim 18 (depends on 15) The method according to claim 15, wherein: the first foot and the second foot are in first positions, relative to the body when in contact with the first web portion and the second web portion, respectively, of the hat stiffener and when the stiffener-engagement surface of the body is in contact with the cap portion of the hat stiffener; the method further comprises steps of: removing the probe from the hat stiffener; contacting a cap portion of a second hat stiffener with the stiffener-engagement surface of the body of the probe, wherein an amount of the stiffener-engagement surface in contact with the cap portion of the second hat stiffener is different than the amount of the stiffener-engagement surface in contact with the cap portion of the first hat stiffener; moving the first foot of the probe, relative to the body, into a second position to contact a first web portion of the second hat stiffener when the stiffener-engagement surface is contacting the cap portion of the second hat stiffener; moving the second foot of the probe, relative to the body, into a second position to contact a second web portion of the second hat stiffener when the stiffener-engagement surface is contacting the cap portion of the second hat stiffener; and ultrasonically inspecting the cap portion of the second hat stiffener with the ultrasonic-sensor assembly; and the first positions are different than the second positions of the first foot and the second foot. ### Claim 19 (depends on 18) The method according to claim 18, wherein moving the first foot of the probe into the second position and moving the second foot of the probe into the second position comprises co-moving the first foot and the second foot into the second positions. ### Claim 20 (depends on 15) The method according to claim 15, wherein: the first foot of the probe is moved, relative to the body, along a first path; the second foot of the probe is moved, relative to the body, along a second path; and an angle defined between the first path and the second path is perpendicular or oblique.