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US 7,698,947 B2Granted
Rapid prototype integrated matrix ultrasonic transducer array inspection apparatus, systems, and methods
AssigneeThe Boeing Company
InventorDennis P. Sarr
Life of this patent
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Abstract
Apparatus, systems, and methods for inspecting a structure are provided which use a sensor holder constructed from rapid prototyping, such as stereolithography, and which is configured to support a plurality of inspection sensors typically arranged in an ordered matrix array and possibly with one or more additional inspection sensors aligned for inspection of difficult to inspect features of a structure such as radius corner or edge features. Rapid prototype integrated matrix array inspection apparatus, systems, and methods provide fast and efficient methods of constructing custom inspection devices.
Claims35
A method of non-destructive inspection, comprising:
- supporting a sensor holder on a first portion of a structure, wherein the sensor holder is configured for traveling over at least the first portion of the structure, wherein the sensor holder defines a plurality of holes configured to support and orient a plurality of non-destructive inspection sensors arranged in a matrix array having at least two rows and at least two columns, wherein an offset hole in a first row of the matrix array of holes is defined at an offset position from the holes in other columns in the matrix array of holes and to permit a first non-destructive inspection sensor of the matrix array and supported by the offset hole to inspect a different portion of the structure than the non-destructive inspection sensors of the holes in any other columns in the matrix array of holes, and wherein the sensor holder comprises the plurality of non-destructive inspection sensors supported and oriented by the plurality of holes, each of the non-destructive inspection sensors disposed within one of the holes of the matrix array and the first non-destructive inspection sensor being supported and oriented by the offset hole;
- passing the sensor holder over at least the first portion of the structure;
- and
- transmitting ultrasonic signals from the plurality of non-destructive inspection sensors to at least the first portion of the structure in an offset matrix array corresponding to the matrix array of the plurality of holes, including the offset hole.
1 more element
A method of non-destructive inspection, comprising:
- supporting a sensor holder on a first portion of a structure, wherein the sensor holder is configured for traveling over at least the first portion of the structure, wherein the sensor holder defines a plurality of holes configured to support and orient a plurality of non-destructive inspection sensors arranged in a matrix array, and wherein the sensor holder comprises the plurality of non-destructive inspection sensors supported and oriented by the plurality of holes, each of the non-destructive inspection sensors disposed within one of the holes of the matrix array;
- passing the sensor holder over at least the first portion of the structure;
- transmitting ultrasonic signals from the plurality of non-destructive inspection sensors to at least the first portion of the structure in a matrix array corresponding to the matrix array of the plurality of holes;
- and
- coupling the ultrasonic signals transmitted from the plurality of non-destructive inspection sensors to at least the first portion of the structure, wherein coupling comprises:
- injecting a fluid into a fluid manifold;
- and disbursing the fluid from the fluid manifold through at least one of the holes of the matrix array.
4 more elements
A method of non-destructive inspection, comprising:
- supporting a sensor holder on a first portion of a structure, wherein the sensor holder is configured for traveling over at least the first portion of the structure, wherein the sensor holder defines a plurality of holes configured to support and orient a plurality of non-destructive inspection sensors arranged in a matrix array, wherein the sensor holder further defines a first hole of the plurality of holes aligned at a first angle to the structure to permit a first non-destructive inspection sensor supported by the first hole and oriented at the first angle to inspect the structure at the first angle while the sensor holder travels over the structure, and wherein the sensor holder comprises the plurality of non-destructive inspection sensors supported and oriented by the plurality of holes, each of the non-destructive inspection sensors disposed within one of the holes of the matrix array and the first non-destructive inspection sensor being supported and oriented by the first hole at the first angle;
- passing the sensor holder over at least the first portion of the structure;
- and
- transmitting ultrasonic signals from the plurality of non-destructive inspection sensors to the first portion of the structure and from the first non-destructive inspection sensor supported and oriented by the first hole at the first angle to the structure.
1 more element
A method of non-destructive inspection, comprising:
- supporting a sensor holder on a first portion of a structure, wherein the sensor holder is configured for traveling over at least the first portion of the structure, wherein the sensor holder defines a plurality of holes configured to support and orient a plurality of non-destructive inspection sensors arranged in a matrix array, wherein the sensor holder further defines a radius hole defined at a first angle to the structure to permit a first non-destructive inspection sensor supported by the radius hole and oriented at the first angle to inspect a radius feature of the structure while the sensor holder travels over at least the first portion of the structure and the radius feature, and wherein the sensor holder comprises the plurality of non-destructive inspection sensors supported and oriented by the plurality of holes, each of the non-destructive inspection sensors disposed within one of the holes of the matrix array and the first non-destructive inspection sensor being supported and oriented by the at least one radius hole at the first angle;
- passing the sensor holder over at least the first portion of the structure;
- and
- transmitting ultrasonic signals from the plurality of non-destructive inspection sensors to the first portion of the structure and from the first non-destructive inspection sensor supported and oriented by the radius hole at the first angle to the radius feature of the structure.
1 more element
Dependencies are inferred from the claim text.