Abstract:
A method of inspecting a radius area of composite parts with an ultrasonic inspection system, the system includes at least one ultrasonic probe, an upper sliding surface, a lower sliding surface, an adjustable guide rail, and an adjustable encoder wheel rotatably coupled to a rotary encoder, is provided. The method includes generating a high frequency sound wave using the probe including a radius of curvature extending from a center point, the sound wave travels partially through the part, adjusting the guide rail to align the center point of the probe with a center axis of a part corner portion, sliding the part through the inspection system to inspect the corner portion using the sound wave by rotating the wheel and rotary encoder such that the arcuate distance of the part is recorded, adjusting the wheel to avoid any apertures defined within the part, and processing the sound wave information.

Description:
BACKGROUND OF THE INVENTION 
   This disclosure relates generally to test equipment for nondestructive evaluation systems, and more specifically, to ultrasonic inspection devices for the inspection of parts. 
   As newer materials, such as composite materials, are used in more applications throughout the aircraft industry and other industries, the use of nondestructive test equipment, such as ultrasonic test equipment, to inspect fabricated parts prior to use has become widespread. Ultrasonic test equipment allows an operator to nondestructively inspect the interior of parts, such as fuselage or wing components, for areas of discontinuity such as structural inconsistencies, imperfections, delaminations, and foreign objects introduced during fabrication to name a few. 
   Ultrasonic test equipment utilizes a high frequency sound wave generated by an ultrasonic transducer, sometimes referred to as a probe, which is located near the surface of the part being tested. The ultrasonic transducer is oriented such that the high frequency sound wave travels through the part, usually in the height or thickness direction. When the sound wave encounters a discontinuity, such as a delamination, or a change in the stiffness of the material, part of the sound energy is reflected. The reflected sound energy travels back through the part and is received by the same ultrasonic transducer, which acts as both a transmitter and receiver in what is commonly referred to as a “pulse echo” ultrasonic test system. Alternatively, the high frequency sound wave generated by the ultrasonic transmitter passes through the entire thickness of the part and is received on the opposite side of the part by a separate receiver in what is commonly known as “through transmission” ultrasonic testing. 
   The waveform of the received signal from an ultrasonic test is recorded by the test equipment and/or displayed on a monitor or other display device. The data contained in the signal can be displayed in a number of different formats for review by technicians. 
   In some known ultrasonic inspection devices, a customized part holder is designed for the unique angles and dimensions of each part. The customized part holder is used to hold the part during the inspection process. The fabrication and/or use of multiple part holders may increase the inspection time of the variety of parts. As a result, the efficiency of the inspection process is reduced which may increase the overall cost of inspecting a variety of differently shaped parts. 
   BRIEF DESCRIPTION OF THE INVENTION 
   In one aspect, a method of inspecting a radius area of composite parts with an ultrasonic inspection system, where the inspection system includes an inspection device that includes at least one ultrasonic probe, an upper sliding surface, a lower sliding surface, an adjustable guide rail, and an adjustable encoder wheel rotatably coupled to a rotary encoder, is provided. The method includes generating a high frequency sound wave using the at least one ultrasonic probe, the probe including a radius of curvature extending from a center point, wherein the high frequency sound wave travels at least partially through the part, adjusting the guide rail to align the center point of the at least one probe with a center axis of a corner portion of the part, sliding the part through the inspection device to inspect the corner portion of the part using the high frequency sound wave by rotating the encoder wheel and rotary encoder such that the arcuate distance of the part is recorded, adjusting the encoder wheel to avoid any apertures defined within the part, and processing the high frequency sound wave information. 
   In another aspect, an inspection device for ultrasonic inspection of a variety of differently shaped parts, is provided. The inspection device includes a frame, a support assembly coupled to the frame, the support assembly comprising at least one upper sliding surface and at least one lower sliding surface, an adjustable guide rail rotatably coupled to the frame and positioned adjacent the lower sliding surface such that an angle is defined between the guide rail and the lower sliding surface, and an adjustable encoder assembly slidably coupled to the frame, the adjustable encoder assembly comprising a wheel configured to contact at least one of the inner surface and the outer surface of the part, and a rotary encoder rotatably coupled to the wheel. 
   In yet another aspect, an ultrasonic inspection system for the inspection of a variety of differently shaped parts, is provided. The ultrasonic inspection system includes a tank at least partially filled with an immersion fluid, an inspection device at least partially submerged within the tank, the inspection device comprising a frame, a support assembly coupled to the frame, the support assembly comprising at least one upper sliding surface and at least one lower sliding surface, an adjustable guide rail rotatably coupled to the frame and positioned adjacent the lower sliding surface such that an angle is defined between the guide rail and the lower sliding surface, and an adjustable encoder assembly slidably coupled to the frame, the adjustable encoder assembly comprising a wheel configured to contact at least one of an inner surface and an outer surface of the part, and a rotary encoder rotatably coupled to the wheel, at least one ultrasonic probe coupled within the inspection device, wherein the at least one ultrasonic probe generates a high frequency sound wave that passes at least partially through a corner portion of the part, and a computer coupled in communication with the rotary encoder and the at least one ultrasonic probe to identify and locate discontinuities within the part. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of an exemplary workpiece. 
       FIG. 2  is a cross-sectional view of the workpiece shown in  FIG. 1 . 
       FIG. 3  is a side view of an inspection device for inspecting the workpiece shown in  FIG. 1 . 
       FIG. 4  is a top-front perspective view of the inspection device shown in  FIG. 3 . 
       FIG. 5  is a top-rear perspective view of the inspection device shown in  FIG. 3 . 
       FIG. 6  is a top-front perspective view of the inspection device shown in  FIG. 3 . 
       FIG. 7  is a perspective view of another inspection device for inspecting the workpiece shown in  FIG. 1 . 
       FIG. 8  is a side view of the inspection device shown in  FIG. 3 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The embodiments herein described generally provide an exemplary apparatus and methods for nondestructive ultrasonic inspection of a variety of parts. The embodiments described herein are not limiting, but rather are examples only. It should be understood that the present invention may apply to the ultrasonic inspection of any type of part or workpiece. 
     FIG. 1  is a perspective view of an arcuate fuselage workpiece  10 .  FIG. 2  is a cross-sectional view of workpiece  10 . In one embodiment, workpiece  10  may be a fuselage shear-tie. In the illustrated embodiment, workpiece  10  is substantially L-shaped and includes a short side, or flange  12  and a long side, or web  14 . Moreover, workpiece  10  has an arcuate length, or distance  16 , a web width  18 , and a flange height  20 . In one embodiment, arcuate distance  16  may extend between about 1 inch to about 96 inches. In another embodiment, web width  18  is between about 1 inch to about 6 inches. Web  14  also has a thickness  26  defined between an inner surface  28  and an outer surface  30  of workpiece  10 . Alternatively, thickness  26  may vary along arcuate distance  16  of workpiece  10 . In the illustrated embodiment, workpiece  10  includes at least one cutout  24  partially defined within web  14  and partially defined within flange  12 . Each cutout  24  facilitates reducing web width  18  of web  14  compared to areas of web  14  that do not include cutouts  24 . Alternatively, workpiece  10  may not include any cutouts  24 . 
   Flange  12  extends away from web  14  at a corner portion  32 , such that flange  12  is oriented at a web-to-flange angle  34 , with respect to web  14 . In one embodiment, web-to-flange angle  34  is between about 79° to about 110°. In the illustrated embodiment, web-to-flange angle  34  is about 98°. Moreover, workpiece  10  has an inner corner radius of curvature  38  and an outer corner radius of curvature  40  defined at corner portion  32 . Inner corner radius  38  is defined by the substantially arcuate inner surface  28  at corner portion  32  of workpiece  10 . Specifically, inner corner radius  38  extends from an axis  42  to inner surface  28  at corner portion  32 . Moreover, outer corner radius  40  is defined by the substantially arcuate outer surface  30  at corner portion  32  of workpiece  10 . Specifically, outer corner radius  40  extends from axis  42  to outer surface  30  at corner portion  32 . In one embodiment, the outer corner radius  40  is about 0.375 inches. In another embodiment, the outer corner radius  40  is about 0.520 inches. The inner corner radius  38  varies, depending on a thickness of corner portion  32 . With respect to the above described embodiments, one range of part thicknesses is from about 0.14 inches to about 0.22 inches. 
     FIG. 3  is a side view of an inspection device  100 .  FIG. 4  is a top-front perspective view of inspection device  100 .  FIG. 5  is a top-rear perspective view of inspection device  100 .  FIG. 6  is a perspective view of inspection device  100  positioned within a tank  101 . In the illustrated embodiment, inspection device  100  is a pulse echo (“PE”) ultrasonic inspection device that inspects radii  38  and  40  of workpiece  10 . Moreover, PE inspection device  100  includes an ultrasonic sensor, or transducer  102  that is coupled within a cavity  103  that is defined within a frame  104 . In the illustrated embodiment, transducer  102  is generally arcuate and is operable about an adjustable radius of curvature  105  that extends from a center point  106  towards transducer  102 . Transducer  102  is configured to locate areas of discontinuity within workpiece  10 , such as but not limited to, voids, areas of high resin porosity, delaminations, foreign matter, or a change in stiffness caused by a composite ply formed of a different material. 
   In the illustrated embodiment, PE inspection device  100  also includes a pair of stabilizer plates  108  and an adjustable guide rail assembly  110 . Stabilizer plates  108  include an upper plate  112  and a lower plate  114 . Lower plate  114  is coupled to frame  104  and is positioned adjacent upper plate  112 , such that a gap  113  is defined therebetween, wherein gap  113  is configured to receive web  14 , as described in more detail below. Upper plate  112  is coupled to a pair of support columns  116  which are coupled to a pair of corresponding support arms  118 . Support columns  116  are slidably coupled to arms  118  to facilitate sliding upper plate  112  towards or away from arms  118  in the event thickness  26  of web  14  varies. Specifically, stabilizer plates  108  are configured to slidably couple to web  14  of workpiece  10  to facilitate stabilizing workpiece  10  during inspection, as described in more detail below. In one embodiment, upper plate  112  includes at least one aperture  120  defined therein. Alternatively, an upper plate  112  may include two individual plates, wherein each plate is coupled to a support member such that a gap is defined between each plate. 
   Adjustable guide rail assembly  110  includes a guide rail  122  coupled to a mounting bracket  124 . In one embodiment, guide rail  122  is positioned adjacent stabilizer plates  108  such that an angle  126  is formed between guide rail  122  and lower plate  114 . In the illustrated embodiment, guide rail assembly  110  is rotatably coupled to frame  104  using mounting bracket  124 . Specifically, mounting bracket  124  includes an arcuate slot  128  defined therein. Moreover, frame  104  includes an arcuate aperture  130  defined therein that is sized and oriented substantially identical to arcuate slot  128 . A locking screw  132  extends through arcuate slot  128  and aperture  130  to facilitate locking guide rail assembly  110  in a specific position. Guide rail  122  is adjustable such that guide rail  122  may be oriented at angle  126  that is substantially identical to web-to-flange angle  34  of workpiece  10 . Specifically, guide rail  122  may be oriented between about 79° to about 110° with respect to lower plate  114 . Moreover, guide rail assembly  110  rotates about an axis of rotation  134  that is substantially coincident with center point  106  of transducer  102 . 
   PE inspection device  100  also includes an adjustable encoder assembly  140  that includes an encoder support member  142  that is coupled to a slide block  144  using a pair of extension arms  146 . Support member  142  includes a bottom, or first end  148 , an opposite top, or second end  150 , and a body  151  extending therebetween. First end  148  includes an encoder wheel  152  coupled thereto, wherein encoder wheel  152  is rotatably coupled to a first gear  154  using a first shaft  156 . Moreover, second end  150  includes a rotary encoder  158  coupled thereto, wherein rotary encoder  158  is rotatably coupled to a second gear  160  using a second shaft (not shown). In one embodiment, first gear  154  is rotatably coupled to second gear  160  using a belt  164 , such that rotation of first gear  154  facilitates rotation of second gear  160 . In an alternative embodiment, first and/or second gear may be a sprocket or any other type of wheel that enables PE inspection device  100  to function as described herein. First end  148  of encoder assembly  140  is positioned adjacent upper plate  112  such that encoder wheel  152  extends at least partially through aperture  120  defined in upper plate  112 , as described in more detail below. In the illustrated embodiment, slide block  144  is slidably coupled to frame  104  and includes an elongated aperture  166  defined therein. A locking screw  168  is coupled to frame  104  and extends through elongated aperture  166  to facilitate locking slide block  144 , and more specifically, encoder assembly  140  in a specific location. 
   In one embodiment, PE inspection device  100  may be at least partially submerged within tank  101 , and more specifically an immersion fluid  172 . PE inspection device  100  is submerged such that an amount of fluid  172  is positioned between workpiece  10  and transducer  102  to facilitate coupling the ultrasonic sound waves to workpiece  10 . In an alternative embodiment, the flow of fluid  172  may be channeled between the inspected part and transducer  102  to facilitate coupling the ultrasonic sounds waves to the inspected part. In one embodiment, water is used to couple the ultrasonic sound waves to the inspected part. In another embodiment, any type of fluid may be used that enables PE inspection device  100  to function as described herein. Second end  150  facilitates positioning rotary encoder  158  above the surface of fluid  172  to facilitate preventing fluid  172  from contacting rotary encoder  158 . 
   PE inspection device  100  is electrically coupled to a computer  176  such that information recorded by transducer  102  and/or rotary encoder  158  can be transmitted to computer  176 , which facilitates processing the information. Computer  176 , in the illustrated embodiment, includes a processor  178 , a memory  180 , a plurality of inputs  182 , and a plurality of outputs  184 . As used herein, the term computer is not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a processor, a microcontroller, a microcomputer, a programmable logic controller, an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. In one embodiment, memory  180  may include, but is not limited to a random access memory. Alternatively, a computer-readable medium, such as a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. Also, in one embodiment, the plurality of inputs  182  may include, but not limited to, computer peripherals associated with an operator interface such as a mouse (not shown) and/or a keyboard (not shown). Furthermore, in the illustrated embodiment, a plurality of output channels may include, but not be limited to, an operator interface monitor  186 . 
   During operation, workpiece  10  is inserted within PE inspection device  100  such that web  14  is positioned between upper and lower plates  112  and  114 , and flange  12  is positioned against guide rail  122 . Moreover, angle  126  of guide rail  122  is adjusted using locking screw  132 , such that angle  126  is substantially equal to web-to-flange angle  34  of workpiece  10  to facilitate reducing the time required to perform the inspection of multiple workpieces  10  compared to inspection devices that use a unique part holder to inspect each workpiece. As a result, corner portion  32  is positioned adjacent transducer  102  such that axis  42  of workpiece  10  is substantially coincident with center point  106  of transducer  102  and axis of rotation  134  of guide rail  122 , to facilitate inspecting corner portion  32 , and more specifically, radii  38  and  40 . 
   During inspection of corner portion  32 , an operator pushes and/or pulls workpiece  10  through PE inspection device  100 . More specifically, web  14  slides between plates  108  such that workpiece  10  is stabilized during inspection. In the event thickness  26  varies, upper plate  112 , and more specifically support columns  116 , slide towards or away from arms  118 . In the illustrated embodiment, PE inspection device  100  is stationary with respect to the inspected part. Alternatively, PE inspection device  100  may be configured to move with respect to a stationary part. In one embodiment, encoder wheel  152  contacts inner surface  28  of web  14 , such that movement of workpiece  10  rotates encoder wheel  152 , which facilitates rotating first gear  154 . The rotation of first gear  154  causes belt  164  to rotate second gear  160 , which facilitates rotating rotary encoder  158 . Rotary encoder  158  records the arcuate distance  16  of workpiece  10  that passes through PE inspection device  100 . Moreover, rotary encoder  158  transmits the recorded information to computer  176 , wherein the information is processed. 
   In the event cutout  24  is positioned within a path of encoder wheel  152 , the operator moves encoder assembly substantially away from flange  12 , and more specifically cutout  24  such that encoder wheel remains in contact with web  14 . Specifically, the operator slides slide block  144 , and more specifically encoder wheel  152 , away from cutout  24  such that encoder wheel  152  remains in contact with web  14  and continues to record the arcuate distance  16  of workpiece  10  that passes through PE inspection device  100 . The operator may secure slide block  144  in a specific position using locking screw  168 . 
   As workpiece  10  is pushed and/or pulled through PE inspection device  100 , a high frequency sound wave (not shown) generated by transducer  102  passes through fluid  172  and enters workpiece  10  and more specifically corner portion  32 . As the high frequency sound wave passes through workpiece  10  at corner portion  32 , the sound wave comes into contact with any areas of discontinuity located in the path of the sound wave. Contact by the sound wave with areas of discontinuity causes at least a portion of the sound wave to be reflected back through workpiece  10  towards transducer  102 . 
   Transducer  102  is configured to transmit and receive ultrasonic sound waves. The received sound waves are recorded and/or transmitted to computer  176 . Specifically, the time the sound wave is transmitted and received, and the amplitude of the received sound wave are recorded. Generally, the time between transmission and reception of the sound wave is related to a depth of the discontinuity. Moreover, the amplitude of the received sound wave is generally related to the magnitude of the discontinuity. In one embodiment, computer  176  processes the ultrasonic information to determine whether any discontinuities are present within corner portion  32 . Moreover, computer  176  processes the recorded information of arcuate distance  16  transmitted from rotary encoder  158  to determine the location of the discontinuity within corner portion  32 . Computer  176  displays the discontinuity information and the location of the discontinuity on monitor  186 . 
   The reduced time afforded by the use of adjustable guide rail assembly  110  and adjustable encoder assembly  140  during the inspection of multiple workpieces  10  that include cutouts  24  and a variety of web-to-flange angles  34  facilitates increasing the efficiency of the inspection process. Moreover, an increase in the inspection process facilitates decreasing the cost of inspecting multiple workpieces  10 . 
     FIG. 7  is a perspective view of another embodiment of inspection device  200 .  FIG. 8  is a side view of inspection device  200  partially submerged within a tank  201 . In the illustrated embodiment, inspection device  200  is a through transmission ultrasonic (“TTU”) device  200  that inspects corner portion  32 , and more specifically radii  38  and  40  of workpiece  10 . As described herein, the device  200  is operable to inspect parts with varying radii, over a range, without an adjustment of the below described sensors. Moreover, TTU inspection device  200  includes a first arcuate sensor housing  202  coupled to a second arcuate sensor housing  204  that is coupled to a base  206 . First arcuate sensor housing  202  is positioned opposite second arcuate sensor housing  204 . First arcuate sensor housing  202  includes five first sensors, or transducers  208 , and second arcuate sensor housing  204  includes five second transducers  210 . In one embodiment, first and second arcuate sensor housings  202  and  204  may include any number of transducers that enable TTU inspection device  200  to function as described herein. In the illustrated embodiment, first arcuate sensor housing  202  is coupled to second arcuate sensor housing  204  such that each first transducer  208  is positioned opposite each corresponding second transducer  210 . As a result, each first and each opposite second transducer  208  and  210  form a transducer pair (not shown). More specifically, an ultrasonic beam  212  extends between each transducer pair, wherein each ultrasonic beam  212  intersects at an intersection point  214 . Each transducer pair is configured to locate areas of discontinuity within workpiece  10  such as, but not limited to, voids, areas of high resin porosity, delaminations, foreign matter, or a change in stiffness caused by a composite ply formed of a different material. 
   In one embodiment, TTU inspection device  200  also includes a wheel housing  216  that is coupled to second arcuate sensor housing  204 . Wheel housing  216  includes a pair of side members  218  that define a cavity  220  therebetween. Each side member  218  includes a sliding surface  222  that is configured to contact workpiece  10  during inspection. In the illustrated embodiment, TTU inspection device  200  includes a stabilizer plate assembly  224  that includes an upper stabilizer plate  226  coupled to a pair of support arms  228  using a pair of corresponding columns  230 . Upper stabilizer plate  226  is positioned above sliding surface  222  such that a gap (not shown) is defined between sliding surface  222  and upper stabilizer plate  226 . The gap is configured to receive web  14  of workpiece  10 , as described below in more detail. Support columns  230  are slidably coupled to arms  228  such that upper plate  226  may slide towards or away from arms  228  in the event thickness  26  of web  14  varies. Specifically, upper plate  226  and sliding surface  222  of wheel housing  216  are configured to slidably couple to web  14  to facilitate stabilizing workpiece  10  during inspection, as described in more detail below. 
   TTU inspection device  200  also includes an adjustable guide rail assembly  232  and an adjustable encoder assembly  234 . Adjustable guide rail assembly  232  includes a guide rail  236  coupled to a mounting bracket  238 . In the illustrated embodiment, guide rail  236  is positioned adjacent sliding surface  222  such that an angle  240  is formed between guide rail  236  and sliding surface  222 . Guide rail assembly  232  is rotatably coupled to second arcuate sensor housing  204  using mounting bracket  238 . Specifically, mounting bracket  238  includes an arcuate slot  242  defined therein. Moreover, second arcuate sensor housing  204  includes an arcuate aperture  244  that is sized and oriented substantially identical to arcuate slot  242 . A locking clamp  248  at least partially extends through arcuate slot  242  and arcuate aperture  244  to facilitate locking guide rail assembly  232  in a specific position. In one embodiment, guide rail  236  is adjustable such that guide rail  236  may be oriented at an angle  250  that is substantially identical to web-to-flange angle  34  of workpiece  10 . Specifically, guide rail  236  may be oriented at an angle between about 79° to about 110° with respect to sliding surface  222 . Moreover, guide rail assembly  232  rotates about an axis  246  that is substantially coincident with intersection point  214 . 
   In the illustrated embodiment, adjustable encoder assembly  234  includes an encoder support member  252  that is coupled to a slide plate  254 . Support member  252  includes a bottom, or first end  256 , an opposite top, or second end  258 , and a body  260  extending therebetween. A first gear  262  is coupled to a first shaft  264 , wherein the first gear  262  and first shaft are coupled to first end  256 . First shaft  264  is also coupled to an encoder wheel  266  that is positioned within cavity  220 . At least a portion of encoder wheel  266  extends away from wheel housing  216  and more specifically, sliding surface  222  such that encoder wheel  266  contacts workpiece  10  in the event workpiece  10  is inserted within TTU inspection device  200 . Moreover, second end  258  includes a rotary encoder  268  coupled thereto, wherein rotary encoder  268  is rotatably coupled to a second gear  270  using a second shaft (not shown). Alternatively, first and/or second gear may be a sprocket or any other type of wheel that enables TTU inspection device  200  to function as described herein. In one embodiment, first gear  262  is rotatably coupled to second gear  270  using a belt  272 , such that rotation of first gear  262  facilitates rotation of second gear  270 . 
   Moreover, stabilizer plate assembly  224  and adjustable encoder assembly  234  are couple to slide plate  254 , wherein slide plate  254  is slidably coupled to base  206 . Specifically, base  206  includes a pair of elongated slots  274  defined therein, and slide plate  254  includes a pair of apertures  276  that are substantially aligned with elongated slots  274 . A locking screw  278  extends through each aperture and into each corresponding elongated slot  274  to facilitate locking slide plate  254  in a specific location with respect to base  206 . 
   TTU inspection device  200  may be at least partially submerged within tank  201 , and more specifically an immersion fluid  280 . TTU inspection device  200  is submerged such that an amount of fluid  280  is positioned between workpiece  10  and first and second transducers  208  and  210  to facilitate coupling ultrasonic sound beams  212  to workpiece  10 . Alternatively, the flow of fluid  280  may be channeled between the inspected part and first and second transducers  208  and  210  to facilitate coupling ultrasonic sounds beams  212  to the inspected part. In one embodiment, water is used to couple ultrasonic sound beams  212  to the inspected part. In another embodiment, any type of fluid may be used that enables TTU inspection device  200  to function as described herein. In the illustrated embodiment, second end  258  facilitates positioning rotary encoder  268  above a surface  282  of fluid  280  to facilitate preventing fluid  280  from contacting rotary encoder  268 . 
   TTU inspection device  200  is electrically coupled to computer  284  such that information recorded by transducer  202  and/or rotary encoder  268  can be transmitted to computer  284 , which facilitates processing the information. Computer  284 , in the illustrated embodiment, includes a processor  286 , a memory  288 , a plurality of inputs  290 , and a plurality of outputs  292 . As used herein, the term computer is not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a processor, a microcontroller, a microcomputer, a programmable logic controller, an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. In one embodiment, memory  288  may include, but is not limited to a random access memory. Alternatively, a computer-readable medium, such as a floppy disk, a compact disc—read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. Also, in one embodiment, the plurality of inputs  290  may include, but not limited to, computer peripherals associated with an operator interface such as a mouse (not shown) and/or a keyboard (not shown). Furthermore, in the illustrated embodiment, a plurality of output channels may include, but not be limited to, an operator interface monitor  294 . 
   During operation, workpiece  10  is inserted within TTU inspection device  200  such that web  14  is positioned between upper plate  226  and sliding surface  222 , and flange  12  is positioned against guide rail  236 . Moreover, angle  250  of guide rail  236  is adjusted using locking clamp  248 , such that angle  250  is substantially equal to web-to-flange angle  34  of workpiece  10  to facilitate reducing the time required to perform the inspection of multiple workpieces  10  compared to inspection devices that use a unique part holder to inspect each workpiece. As a result, corner portion  32  is positioned within TTU inspection device  200  such that axis  246  of workpiece  10  is substantially coincident with intersection point  214  of ultrasonic beams  212 , to facilitate inspecting corner portion  32 , and more specifically, radii  38  and  40 . 
   During inspection of corner portion  32 , an operator pushes and/or pulls workpiece  10  through TTU inspection device  200 . More specifically, web  14  slides between upper plate  226  and sliding surface  222  such that workpiece  10  is stabilized during inspection. In the event thickness  26  varies, upper plate  226 , and more specifically support columns  230 , slide towards or away from arms  228 . In the illustrated embodiment, TTU inspection device  200  is stationary with respect to the inspected part. Alternatively, TTU inspection device  200  may be configured to move with respect to a stationary part. In one embodiment, encoder wheel  266  contacts outer surface  30  of web  14 , such that movement of workpiece  10  rotates encoder wheel  266 , which facilitates rotating first gear  262 . The rotation of first gear  262  causes belt  272  to rotate second gear  270  which facilitates rotating rotary encoder  268 . Rotary encoder  268  records the arcuate distance  16  of workpiece  10  that passes through TTU inspection device  200 . Moreover, rotary encoder  268  transmits the recorded information to computer  284 , wherein the information is processed. 
   In the event cutout  24  is positioned within a path of encoder wheel  266 , the operator moves encoder assembly substantially away from flange  12 , and more specifically cutout  24  such that encoder wheel remains in contact with web  14 . Specifically, the operator slides slide plate  254 , and more specifically encoder wheel  266 , away from cutout  24  such that encoder wheel  266  remains in contact with web  14  and continues to record the arcuate distance  16  of workpiece  10  that passes through TTU inspection device  200 . The operator may secure slide plate  254  in a specific position using locking clamp  248 . 
   As workpiece  10  is pushed and/or pulled through TTU inspection device  200 , a high frequency beams  212  are generated by first transducers  208  and pass through fluid  280  and enter workpiece  10  and more specifically corner portion  32 . The high frequency beams are received by second transducers  210  that are positioned opposite first transducers  208 . Alternatively, second transducers  210  may generate high frequency beams  212  and first transducers may receive high frequency beams  212 . As high frequency beams  212  pass through workpiece  10  at corner portion  32 , each beam  212  comes into contact with any areas of discontinuity located in the path of the sound wave. Contact by each beam  212  with areas of discontinuity causes at least a change in amplitude and/or frequency of each beam  212  received by second transducers  210 . 
   First and second transducers  208  and  210  are configured to record the received beam  212  information and transmit the information to computer  284 . Specifically, the time each beam  212  is transmitted and received, and the amplitude of the received beam  212  are recorded. Generally, the time between transmission and reception of each beam  212  is related to a depth of the discontinuity. Moreover, the amplitude of each received beam  212  is generally related to the magnitude of the discontinuity. In one embodiment, computer  284  processes the ultrasonic information to determine whether any discontinuities are present within corner portion  32 . Moreover, computer  284  processes the recorded information of arcuate distance  16  transmitted from rotary encoder  268  to determine the location of the discontinuity within corner portion  32 . Computer  284  displays the discontinuity information and the location of the discontinuity on monitor  294 . 
   The reduced time afforded by the use of adjustable guide rail assembly  232  and adjustable encoder assembly  234  during the inspection of multiple workpieces  10  that include cutouts  24  and a variety of web-to-flange angles  34  facilitates increasing the efficiency of the inspection process. Moreover, an increase in the inspection process facilitates decreasing the cost of inspecting multiple workpieces  10 . 
   Exemplary embodiments of ultrasonic inspection devices are described in detail above. The inspection devices are not limited to use with the workpieces described herein, but rather, the inspection devices can be utilized independently and separately from the workpiece components described herein. Moreover, the invention is not limited to the embodiments of the inspection devices described above in detail. Rather, other variations of the inspection devices may be utilized within the spirit and scope of the claims. 
   While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.