# US 2020/0393418 A1 · Automated Ultrasonic Inspection of Elongated Composite Members Using Single-Pass Robotic System

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- Number: US 2020/0393418 A1
- Document ID: US20200393418A1
- Status: Published application
- Kind: A1
- Application number: 16/437,239
- Filed: 2019-06-11
- Published: 2020-12-17
- Earliest claimed: 2019-06-11
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: Barry A. Fetzer; Justin D. Serrill; Kareem Gamal Shehab
- Web page: https://patentgrep.com/patent/US20200393418A1

## CPC

- G01N 29/265: by moving the sensor relative to a stationary material
- B64C 1/064: {Stringers; Longerons}
- B64C 3/182: {Stringers, longerons}
- B64F 5/60: Testing or inspecting aircraft components or systems
- G01N 29/04: Analysing solids (using acoustic emission techniques G01N29/14)
- G01N 29/043: {in the interior, e.g. by shear waves}
- G01N 29/225: {Supports, positioning or alignment in moving situation}
- G01N 29/262: {by electronic orientation or focusing, e.g. with phased arrays (phased arrays per se G10K11/34)}
- G01N 2291/0231: Composite or layered materials
- G01N 2291/0289: Internal structure, e.g. defects, grain size, texture
- G01N 2291/105: two or more emitters, two or more receivers
- G01N 2291/106: one or more transducer arrays
- G01N 2291/262: Linear objects
- G01N 2291/2638: Complex surfaces
- G01N 2291/2694: Wings or other aircraft parts
- 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)
- B64C: AEROPLANES; HELICOPTERS
- B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR

## Abstract

Apparatus and methods for ultrasonic inspection of elongated composite members in a single scan pass using pulse echo phased arrays operating in a bubbler method. The system concept is fully automated by integrating an inspection NDI probe assembly to a robot and using the robot to move the inspection NDI probe assembly along the part (i.e., outside of an inspection tank); and by integrating tooling fixtures that move out of the way as the inspection NDI probe assembly travels along the length of the part during the inspection. In addition, the system allows for generally elongated composite members having lengthwise variation in shape, curvature and dimensions.

## Claims

### Claim 1

An 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
a first frame assembly comprising 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.

### Claim 2 (depends on 1)

The apparatus as recited in claim 1, wherein the first pivot comprises first and second pivot pins which are coaxial and the first bearing block assembly further comprises:
a linear ball bearing disposed between the first rotatable shaft and the first pivot;
first and second bearings that support the first and second pivot pins respectively of the first pin; and
first and second linear bearings which are slidably coupled to the first guide shaft.

### Claim 3 (depends on 1)

The apparatus as recited in claim 1, wherein the first frame assembly comprises a lower frame bracket and first and second linear slide tables which are translatable relative to the lower frame bracket along first and second linear paths which are mutually parallel.

### Claim 4 (depends on 3)

The apparatus as recited in claim 3, wherein the first frame assembly further comprises third and fourth linear slide tables which are respectively translatable relative to the first and second linear slide tables along a third linear path which is perpendicular to the first and second linear paths.

### Claim 5 (depends on 4)

The apparatus as recited in claim 4, further comprising an upper assembly attached to the third and fourth linear slide tables and a lower assembly attached to the lower frame bracket, wherein the upper assembly comprises first and second NDI probes which are translatable relative to each other and rotatable in tandem.

### Claim 6 (depends on 4)

The apparatus as recited in claim 4, further comprising a first upper subassembly attached to the third linear slide table, a second upper subassembly attached to the fourth linear slide table, and a lower assembly attached to the lower frame bracket, wherein the first upper subassembly comprises a first NDI probe and the second upper subassembly comprises a second NDI probe, the first and second NDI probes being translatable relative to each other and rotatable in tandem.

### Claim 7 (depends on 4)

The apparatus as recited in claim 4, further comprising a first upper subassembly attached to the third linear slide table, a second upper subassembly attached to the fourth linear slide table, and a lower assembly attached to the lower frame bracket, wherein the lower assembly comprises first and second NDI probes.

### Claim 8 (depends on 1)

The apparatus as recited in claim 1, wherein the tool frame assembly further comprises third and fourth guide shafts oriented parallel to the Z axis of the tool frame assembly, a first lower guide shaft spacer which maintains a spacing between the first and third guide shafts, and a second lower guide shaft spacer which maintains a spacing between the second and fourth guide shafts, and wherein the apparatus further comprises:
third and fourth bearing block assemblies slidably coupled to the third and fourth guide shafts respectively and comprising third and fourth pivots respectively, the third and fourth pivots being rotatable about fourth and fifth axes of rotation which are parallel to the X axis; and
a second frame assembly comprising third and fourth rotatable shafts which are coaxial with a sixth axis of rotation perpendicular to the X axis, the third and fourth rotatable shafts being rotatably and translatably coupled to the third and fourth pivots respectively for rotation about and translation along the sixth axis of rotation.

### Claim 9 (depends on 8)

The apparatus as recited in claim 8, wherein the tool frame assembly further comprises fifth and sixth guide shafts oriented parallel to the Z axis of the tool frame assembly, the first lower guide shaft spacer maintains a spacing between the third and fifth guide shafts, and the second lower guide shaft spacer maintains a spacing between the fourth and sixth guide shafts, and wherein the apparatus further comprises:
fifth and sixth bearing block assemblies slidably coupled to the fifth and sixth guide shafts respectively and comprising fifth and sixth pivots respectively, the fifth and sixth pivots being rotatable about seventh and eighth axes of rotation which are parallel to the X axis; and
a third frame assembly comprising fifth and sixth rotatable shafts which are coaxial with a ninth axis of rotation perpendicular to the X axis, the fifth and sixth rotatable shafts being rotatably and translatably coupled to the fifth and sixth pivots respectively for rotation about and translation along the ninth axis of rotation.

### Claim 10 (depends on 1)

The apparatus as recited in claim 1, further comprising first and second NDI probes supported by the first frame assembly.

### Claim 11 (depends on 10)

The apparatus as recited in claim 10, wherein the first and second NDI probes are respective ultrasonic transducer arrays.

### Claim 12 (depends on 10)

The apparatus as recited in claim 10, wherein the first frame assembly comprises:
a lower frame bracket;
first and second linear slide tables which are translatable relative to the lower frame bracket along first and second linear paths which are mutually parallel; and
third and fourth linear slide tables which are respectively translatable relative to the first and second linear slide tables along a third linear path which is perpendicular to the first and second linear paths, and
wherein the first NDI probe is coupled to the third linear slide table and the second NDI probe is coupled to the fourth linear slide table.

### Claim 13

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.

### Claim 14 (depends on 13)

The apparatus as recited in claim 13, wherein each of the first through third probe frame assemblies comprises a lower frame bracket and first and second linear slide tables which are respectively translatable relative to the lower frame bracket along first and second linear paths which are mutually parallel.

### Claim 15 (depends on 14)

The apparatus as recited in claim 14, wherein each of the first through third probe frame assemblies further comprises third and fourth linear slide tables which are respectively translatable relative to the first and second linear slide tables along a third linear path which is perpendicular to the first and second linear paths.

### Claim 16 (depends on 15)

The apparatus as recited in claim 15, wherein:
the first and second NDI probes are respectively coupled to the third and fourth linear slide tables of the first probe frame assembly;
the third and fourth NDI probes are respectively coupled to the third and fourth linear slide tables of the second probe frame assembly; and
the fifth and sixth NDI probes are respectively coupled to the third and fourth linear slide tables of the third probe frame assembly;

### Claim 17 (depends on 13)

The apparatus as recited in claim 13, wherein each pivot of the first through sixth bearing block assemblies comprises first and second pivot pins which are coaxial, and wherein each of the first through sixth bearing block assemblies further comprises:
a linear ball bearing disposed between a respective one of the first through sixth rotatable shafts and the respective pivot;
first and second bearings that support the first and second pivot pins respectively of the respective pivot; and
first and second linear bearings which are slidably coupled to a respective guide shaft of the first through sixth guide shafts.

### Claim 18 (depends on 13)

The apparatus as recited in claim 13, wherein the first through sixth NDI probes are respective ultrasonic transducer arrays.

### Claim 19

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.

### Claim 20 (depends on 19)

The apparatus as recited in claim 19, wherein the probe frame assembly comprises:
a lower frame bracket;
first and second linear slide tables which are translatable relative to the lower frame bracket along first and second linear paths which are mutually parallel; and
third and fourth linear slide tables which are respectively translatable relative to the first and second linear slide tables along a third linear path which is perpendicular to the first and second linear paths, and
wherein the first NDI probe is coupled to the third linear slide table and the second NDI probe is coupled to the fourth linear slide table.