SAMPE Journal - January/February 2020 - 36
FEATURE / LARGE FINISHED AEROSTRUCTURES
which is of key importance for NCU. In this area of
the transducer, we are able to affect the efficiency
of acoustic propagation into the desired medium.
These advancements have opened the door to new
QC methods for aerospace inspection.
In addition to transducer technology, there have
been significant strides in advancing ultrasound
system technology, specifically in the development
of microprocessors which can provide comparable performance to large electronic systems. These
microchips can excite multi-channel transducers
at ultrasonic frequencies with high voltage and
are available at low cost. Miniaturized systems are
currently under development with the intention of
creating small robotic "crawlers," which can be employed as small wireless systems for inspection of
large complex shaped aerospace structures.
Robotic Systems
Genesis Systems Group supplies robotic NDI systems that include various inspection processes
to Aerospace manufacturers. These systems have
taken various forms, from single robot solutions to
dual-robot systems that work in coordination. For
projects that involve very large Aerospace structures, the use of large yoke end of arm tools (EOAT's) on KUKA robots has been deployed. With the
advancement of tool changer technology, robotic
systems can operate with different inspection processes and end of arm tools on the same system.
This approach reduces the overall system cost and
complexity, while achieving the process targets.
The air-coupled ultrasound inspection of large
aerostructures relies upon a consistent manipulation of the instrumentation along the part surface.
As the size of the work piece increases, so does the
challenge of delivering the process equipment. In
order to achieve an acceptable signal quality, the
Figure 1. Ultrasonic Transducer Composition.
two transducers operating in Through Transmission Ultrasound (TTU) must maintain a coaxial
relationship within +/- 1.25 mm with a working
distance of 100 mm between the faces of the transducers. This level of accuracy can be met with both
single and dual-robot approaches to automation.
In both instances, significant attention must be
given to the accuracy of the system and/or the yoke
structure.
Robots offer greater flexibility when compared
to gantry systems since the modular approach to
robotic system designs provides more options for
future system configurations. Multiple load stations, turn tables, elevators, and floor rails can be
added to the system. This allows a wide range of
part designs to be processed in a single machine.
Figure 2. Schematic and A-scan (time domain) signal of through transmission non-contact ultrasound.
36
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SAMPE Journal - January/February 2020
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