System and method for inspecting metal parts

A method of inspecting internal and/or external surfaces of metal parts performed by an inspection system, wherein the method comprises:

• performing a relative displacement between a frame of the inspection system and a metal part to be inspected, wherein the inspection system further comprises:
• a plurality of geometric profile sensors attached to the frame at spaced intervals through at least one geometric profile sensor support;
• a plurality of eddy current sensors attached to the frame at spaced intervals through at least one eddy current sensor support and facing an internal and/or external surface of the metal part to be inspected, wherein during operation of the inspection system, there is a relative displacement between the frame and the inspected metal part;
• an electronic circuit for multiplexing electromagnetic signals that receives and processes in real time signals obtained by the plurality of geometric profile sensors and the plurality of eddy current sensors;
• and
• an interpretation and evaluation unit that receives processed signals from the electronic circuit and identifies flaws on the internal and/or external surface of the inspected metal part;
• and
• during the relative displacement:
• identifying geometric profile flaws on the internal and/or external surface of the inspected metal part based on data obtained by the plurality of geometric profile sensors;
• and
• identifying surface flaws based on data obtained by the plurality of eddy current sensors,
• wherein during the relative displacement between the frame of the inspection system and the inspected metal part:
• a.1) the plurality of geometric profile sensors obtain measurements related to the geometry of a segment of the inspected metal part;
• a.2) an eddy current is induced in the segment of the inspected metal part;
• a.3) the plurality of eddy current sensors measure interference between magnetic fields generated by coils of the eddy current sensors and the magnetic field generated by the induced eddy current in the segment of the inspected metal part;
• a.4) the plurality of geometric profile sensors and the plurality of eddy current sensors send the respective analog measurements to the electronic circuit;
• b) the electronic circuit converts analog data captured in a.4) into digital data and sends the digital data to the interpretation and evaluation unit;
• and
• c) the interpretation and evaluation unit identifies flaws on the internal and/or external surface of the inspected metal part based on the signals obtained by the plurality of geometric profile sensors and the plurality of eddy current sensors.

An inspection system for internal and/or external surfaces of metal parts, comprising:

• a frame;
• a plurality of geometric profile sensors attached to the frame at spaced intervals through at least one geometric profile sensor support;
• a plurality of eddy current sensors attached to the frame at spaced intervals through at least one eddy current sensor support and facing the internal and/or external surface of a metal part to be inspected of the metal parts, wherein during operation of the inspection system, there is a relative displacement between the frame and the inspected metal part;
• an electronic circuit for multiplexing electromagnetic signals that receives and processes in real time signals obtained by the plurality of geometric profile sensors and the plurality of eddy current sensors;
• and
• an interpretation and evaluation unit that receives processed signals from the electronic circuit and identifies flaws on the internal and/or external surface of the inspected metal part,
• wherein a positioning and quantity of the plurality of eddy current sensors and the plurality of geometric profile sensors used are defined based on predetermined resolution and redundancy, and each one of the plurality of the eddy current sensors and each one of the plurality of geometric profile sensors is mounted independently on an articulated arm, and
• wherein the plurality of eddy current sensors and the plurality of geometric profile sensors are regularly distributed in at least two dimensions, defining at least two rows, and there is a displacement between adjacent sensors of two sequential rows, and wherein the displacement between adjacent sensors of two sequential rows is smaller than a width of a single eddy current sensor.