Automated Ultrasonic Inspection of Elongated Composite Members Using Single-Pass Robotic System

An apparatus for non-destructive inspection (NDI) of a blade stiffener, the apparatus comprising:

• a tool frame assembly comprising first through sixth guide shafts oriented parallel to a Z axis of the tool frame assembly;
• first through sixth bearing block assemblies slidably coupled to the first through sixth guide shafts respectively, wherein the first through sixth bearing block assemblies comprise respective pivots which are rotatable about respective axes of rotation which are parallel to an X axis, which X axis is perpendicular to the Z axis;
• a first NDI probe assembly comprising a first probe frame assembly and first and second NDI probes arranged for inspecting respective portions of a flange disposed on opposite sides of a web of a blade stiffener, wherein the first probe frame assembly comprises first and second rotatable shafts which are coaxial with a first axis of rotation perpendicular to the X axis, the first and second rotatable shafts being rotatably and translatably coupled to the respective pivots of the first and second bearing block assemblies for rotation about and translation along the first axis of rotation;
• a second NDI probe assembly comprising a second probe frame assembly and third and fourth NDI probes arranged for inspecting respective radiused portions of the blade stiffener which connect the web to the flange, wherein the second probe frame assembly comprises third and fourth rotatable shafts which are coaxial with a second axis of rotation perpendicular to the X axis, the third and fourth rotatable shafts being rotatably and translatably coupled to the respective pivots of the third and fourth bearing block assemblies for rotation about and translation along the second axis of rotation;
• and
• a third NDI probe assembly comprising a third probe frame assembly and fifth and sixth NDI probes arranged for inspecting the web of the blade stiffener, wherein the third probe frame assembly comprises fifth and sixth rotatable shafts which are coaxial with a third axis of rotation perpendicular to the X axis, the fifth and sixth rotatable shafts being rotatably and translatably coupled to the respective pivots of the fifth and sixth bearing block assemblies for rotation about and translation along the third axis of rotation.

An apparatus for non-destructive inspection (NDI) of an elongated composite member, the apparatus comprising:

• a tool frame assembly comprising first and second guide shafts oriented parallel to a Z axis of the tool frame assembly;
• first and second bearing block assemblies slidably coupled to the first and second guide shafts respectively and comprising first and second pivots respectively, the first and second pivots being rotatable about first and second axes of rotation which are parallel to an X axis perpendicular to the Z axis;
• and
• an NDI probe assembly comprising a probe frame assembly and first and second NDI probes, wherein the probe frame assembly comprises first and second rotatable shafts which are coaxial with a third axis of rotation perpendicular to the X axis, the first and second rotatable shafts being rotatably and translatably coupled to the first and second pivots respectively for rotation about and translation along the third axis of rotation.