Ultrasonic inspection probe, system, and method

Disclosed herein is an ultrasonic inspection probe for inspecting parts. The ultrasonic inspection probe comprises a probe body that comprises an ultrasonic array and a plate attachment surface. The ultrasonic array comprises a plurality of ultrasound elements, each selectively operable to generate an ultrasonic beam and each fixed relative to the plate attachment surface. The ultrasonic inspection probe also comprises an interface plate, comprising a body attachment surface, removably attachable to the plate attachment surface of the probe body, and a part inspection surface, shaped to complement a shape of one of the parts.

FIELD

This disclosure relates generally to the non-destructive testing of parts, and more particularly to an ultrasonic inspection probe for the non-destructive testing of parts.

BACKGROUND

Non-destructive testing of parts using ultrasonic testing techniques includes penetrating the parts with ultrasonic beams and detecting the behavior of the ultrasonic beams upon existing the parts. Under certain circumstances, to properly penetrate the parts with ultrasonic beams, the tool for generating the ultrasonic beams rides along the surface of part being tested. Accordingly, the tool is calibrated and re-calibrated based on the shapes of the parts being tested. Accurately calibrating conventional tools to conform to different shapes of parts being tested is difficult and time consuming.

SUMMARY

The subject matter of the present application provides examples of an ultrasonic inspection system, ultrasonic inspection probe, and method of inspecting parts that overcome the above-discussed shortcomings of prior art techniques. The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to shortcomings of conventional ultrasonic testing systems and methods.

Disclosed herein is an ultrasonic inspection probe for inspecting parts. The ultrasonic inspection probe comprises a probe body, comprising an ultrasonic array and a plate attachment surface. The ultrasonic array comprises a plurality of ultrasound elements, each selectively operable to generate an ultrasonic beam and each fixed relative to the plate attachment surface. The ultrasonic inspection probe also comprises an interface plate, comprising a body attachment surface, removably attachable to the plate attachment surface of the probe body, and a part inspection surface, shaped to complement a shape of one of the parts. The preceding subject matter of this paragraph characterizes example 1 of the present disclosure.

When the body attachment surface of the interface plate is removably attached to the plate attachment surface of the probe body, each ultrasonic beam generated by the plurality of ultrasound elements is substantially normal to the part inspection surface at an intersection of each ultrasonic beam and the part inspection surface. The preceding subject matter of this paragraph characterizes example 2 of the present disclosure, wherein example 2 also includes the subject matter according to example 1, above.

The plurality of ultrasound elements of the ultrasonic array is arranged in a first circular arc having a first radius. The preceding subject matter of this paragraph characterizes example 3 of the present disclosure, wherein example 3 also includes the subject matter according to any one of examples 1-2, above.

The part inspection surface defines a second circular arc having a second radius. The second radius is smaller than the first radius. The first circular arc and the second circular arc are substantially concentric when the body attachment surface of the interface plate is removably attached to the plate attachment surface of the probe body. The preceding subject matter of this paragraph characterizes example 4 of the present disclosure, wherein example 4 also includes the subject matter according to example 3, above.

The interface plate is removably attached to the probe body by at least one fastener. The preceding subject matter of this paragraph characterizes example 5 of the present disclosure, wherein example 5 also includes the subject matter according to any one of examples 1-4, above.

The probe body further comprises a first fluid supply line. The interface plate further comprises a second fluid supply line. The second fluid supply line is fluidly coupleable with the first fluid supply line when the body attachment surface of the interface plate is removably attached to the plate attachment surface of the probe body. The interface plate further comprises a fluid reservoir pocket formed in the body attachment surface. The second fluid supply line is fluidly coupleable with the fluid reservoir pocket. The preceding subject matter of this paragraph characterizes example 6 of the present disclosure, wherein example 6 also includes the subject matter according to any one of examples 1-5, above.

The interface plate further comprises a plurality of second fluid supply lines. Each one of the plurality of second fluid supply lines is fluidly coupleable with the first fluid supply line when the body attachment surface of the interface plate is removably attached to the plate attachment surface of the probe body. Each one of the plurality of second fluid supply lines is fluidly coupleable with the fluid reservoir pocket. The preceding subject matter of this paragraph characterizes example 7 of the present disclosure, wherein example 7 also includes the subject matter according to example 6, above.

The interface plate comprises at least two part inspection surfaces, spaced apart from each other, and the ultrasonic array is interposed between the at least two part inspection surfaces. The preceding subject matter of this paragraph characterizes example 8 of the present disclosure, wherein example 8 also includes the subject matter according to example 1, above.

The plurality of ultrasound elements of the ultrasonic array is arranged in a circular arc. The shape of one of the parts comprises an inside radius. The at least two part inspection surfaces are configured such that, when the at least two part inspection surfaces engage the one of the parts, the inside radius is substantially concentric with the circular arc of the plurality of ultrasound elements. The preceding subject matter of this paragraph characterizes example 9 of the present disclosure, wherein example 9 also includes the subject matter according to example 8, above.

The probe body further comprises at least two plate attachment surfaces, spaced apart from each other. The interface plate further comprises at least two body attachment surfaces, spaced apart from each other. Each one of the at least two body attachment surfaces of the interface plate is removably attachable to a corresponding one of the at least two plate attachment surfaces of the probe body. The preceding subject matter of this paragraph characterizes example 10 of the present disclosure, wherein example 10 also includes the subject matter according to any one of examples 8 or 9, above.

The interface plate is removably attached to the probe body by only one fastener. The preceding subject matter of this paragraph characterizes example 11 of the present disclosure, wherein example 11 also includes the subject matter according to example 10, above.

The part inspection surface of the interface plate is non-adjustable. The preceding subject matter of this paragraph characterizes example 12 of the present disclosure, wherein example 12 also includes the subject matter according to any one of examples 1-11, above.

The ultrasonic inspection probe further comprises a plurality of interface plates. Each one of the parts is shaped differently than any other one of the parts. The plurality of interface plates is interchangeably removably attachable to the probe body. The part inspection surface of each one of the plurality of interface plates is shaped differently than the part inspection surface of any other one of the plurality of interface plates to complement the shape of a corresponding one of the parts. The preceding subject matter of this paragraph characterizes example 13 of the present disclosure, wherein example 13 also includes the subject matter according to any one of examples 1-12, above.

The plurality of ultrasound elements of the ultrasonic array is arranged in a first circular arc having a first radius. The part inspection surface of each one of the plurality of interface plates defines a second circular arc. A second radius of the second circular arc of the part inspection surface of each one of the plurality of interface plates is smaller than the first radius and is different than the second radius of the second circular arc of the part inspection surface of any other one of the plurality of interface plates. The first circular arc and the second circular arc of the part inspection surface of any one of the plurality of interface plates when the body attachment surface of the corresponding one of the plurality of interface plates is removably attached to the plate attachment surface of the probe body. The preceding subject matter of this paragraph characterizes example 14 of the present disclosure, wherein example 14 also includes the subject matter according to example 13, above.

When the body attachment surface of any one of the plurality of interface plates is removably attached to the plate attachment surface of the probe body, each ultrasonic beam generated by the plurality of ultrasound elements is substantially normal to the part inspection surface of the corresponding one of the plurality of interface plates at an intersection of each ultrasonic beam and the part inspection surface. The preceding subject matter of this paragraph characterizes example 15 of the present disclosure, wherein example 15 also includes the subject matter according to example 14, above.

Each one of the plurality of interface plates comprises at least two part inspection surfaces, spaced apart from each other. The plurality of ultrasound elements of the ultrasonic array is arranged in a circular arc. Each one of the parts comprises an inside radius and is shaped differently than any other of the parts. When the at least two part inspection surfaces of any one of the plurality of interface plates, when removably attached to the probe body, engage a corresponding one of the parts, the inside radius of the corresponding one of the parts is substantially concentric with the circular arc of the plurality of ultrasound elements. The at least two part inspection surfaces of any one of the plurality of interface plates is configured differently than the at least two inspection surfaces of any other one of the plurality of interface plates. The preceding subject matter of this paragraph characterizes example 16 of the present disclosure, wherein example 16 also includes the subject matter according to example 13, above.

Further disclosed herein is an ultrasonic inspection system for inspecting parts. The ultrasonic inspection system comprises a robot and an end effector, coupled to and movable by the robot. The end effector comprises a compliance interface assembly, directly coupled to the robot and an ultrasonic inspection probe, coupled to the compliance interface assembly such that the compliance interface assembly couples the ultrasonic inspection probe to the robot. The ultrasonic inspection probe comprises a probe body, comprising an ultrasonic array and a plate attachment surface. The ultrasonic array comprises a plurality of ultrasound elements, each selectively operable to generate an ultrasonic beam and each fixed relative to the plate attachment surface. The ultrasonic array also comprises an interface plate, comprising a body attachment surface, removably attachable to the plate attachment surface of the probe body, and a part inspection surface, shaped to complement a shape of one of the parts. The preceding subject matter of this paragraph characterizes example 17 of the present disclosure.

Additionally disclosed herein is a method of inspecting parts. The method comprises removably attaching a first interface plate to a probe body. The method also comprises riding a first part inspection surface of the first interface plate along a first one of the parts. The method further comprises, while riding the part inspection surface of the interface plate along the first one of the parts, directing ultrasonic beams, generated from an ultrasonic array of the probe body and fixed relative to the probe body, toward the first one of the parts. The preceding subject matter of this paragraph characterizes example 18 of the present disclosure.

The method further comprises removing the first interface plate from the probe body. The method also comprises removably attaching a second interface plate to the probe body in place of the first interface plate. The method additionally comprises riding a second part inspection surface of the second interface plate along a second one of the parts. The second one of the parts is shaped differently than the first one of the parts. The method further comprises while riding the part inspection surface of the second interface plate along the second one of the parts, directing ultrasonic beams, generated from the ultrasonic array of the probe body, toward the second one of the parts. The preceding subject matter of this paragraph characterizes example 19 of the present disclosure, wherein example 19 also includes the subject matter according to example 18, above.

The step of removably attaching the first interface plate to the probe body comprises tightening at least one fastener. The step of removing the first interface plate from the probe body comprises loosening the at least one fastener. The step of removably attaching the second interface plate to the probe body in place of the first interface plate comprises tightening the at least one fastener. The preceding subject matter of this paragraph characterizes example 20 of the present disclosure, wherein example 20 also includes the subject matter according to example 19, above.

DETAILED DESCRIPTION

Reference throughout this specification to “one example,” “an example,” or similar language means that a particular feature, structure, or characteristic described in connection with the example is included in at least one example of the present disclosure. Appearances of the phrases “in one example,” “in an example,” and similar language throughout this specification may, but do not necessarily, all refer to the same example. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more examples of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more examples.

Disclosed herein is an ultrasonic inspection system for inspecting parts and a corresponding method. The ultrasonic inspection system includes an ultrasonic inspection tool that helps inspect multiple, differently-shaped, parts, using the same ultrasonic inspection tool. More specifically, by using a common probe body and multiple differently-shaped interface plates that are interchangeably removably attachable to the common probe body, multiple, differently-shaped, parts can be inspected without swapping out the entire ultrasonic inspection tool. Because the common probe body houses the ultrasonic array necessary for ultrasonic inspection, the interface plates can be more inexpensively made and manufactured. Additionally, the interface plates can be exchanged easier and quicker compared to swapping out an entire ultrasonic inspection tool for another. Accordingly, the present ultrasonic inspection system and method of inspecting parts disclosed herein provides a more inexpensive, efficient, and simple alternative to conventional ultrasonic testers and testing methods.

Referring toFIG. 1, according to some examples, disclosed herein is an ultrasonic inspection system100for inspecting parts104using ultrasonic beams. The ultrasonic inspection system100includes a robot102and an end effector110. The robot102is an industrial robot that is automated, programmable, and capable of movement on three or more axis. The end effector110is coupled to and movable by the robot102. In certain examples, the end effector110is removably (e.g., releasably) coupled to the robot102. The end effector110includes an ultrasonic inspection probe120operable to generate ultrasonic beams. The end effector110additionally includes a compliance interface assembly112. The ultrasonic inspection probe120is coupled to the robot102via the compliance interface assembly112. The robot102is operable to move the end effector110relative to a part104being inspected such that, while the ultrasonic inspection probe120generates the ultrasonic beams, the ultrasonic inspection probe120rides along an exterior surface of the part104being inspected. As the ultrasonic inspection probe120rides along the exterior surface of the part104, the compliance interface assembly112is configured to provide compliance (e.g., flex or cushioning) for the ultrasonic inspection probe120and movement of the ultrasonic inspection probe120relative to the robot102in appropriate directions. For example, the compliance interface assembly112may include one or more springs to allow the ultrasonic inspection probe120to accommodate variations in the surface of the part104being inspected and a gimbal mechanism to allow the ultrasonic inspection probe120to swivel as the ultrasonic inspection probe120moves along undulations in the surface of the part104being inspected.

According to certain examples, as shown inFIGS. 2-8, the ultrasonic inspection probe120includes a probe body122and an interface plate124. In general, the ultrasonic inspection probe120is configured to inspect parts with an externally radiused surface, such as a rounded stiffener having an outside radius109. The interface plate124is removably attachable to the probe body122. InFIGS. 2, 4, and 6-8, the interface plate124is removably attached to the probe body122. The probe body122is directly attached to the compliance interface assembly112. In some examples, the probe body122is directly attached to the compliance interface assembly112in a substantially permanent, non-removable, manner. In other words, attaching the probe body122to and removing the probe body122from the compliance interface assembly112is more labor intensive and more complex than attaching the interface plate124to and removing the interface plate124from the probe body122. For this reason, for testing different parts each having a different shape, the ultrasonic inspection system100utilizes replacement of just the interface plate124rather than the entire ultrasonic inspection probe120or the entire end effector110.

The probe body122includes a plate attachment surface140and the interface plate124includes a body attachment surface141. The body attachment surface141is removably attachable to the plate attachment surface140to form an attachment interface126therebetween. In other words, the plate attachment surface140of the probe body122and the body attachment surface141of the interface plate124are configured to mate with each other to form the attachment interface126. Accordingly, a shape of the plate attachment surface140complements the shape of the body attachment surface141. In one example, the body attachment surface141of the interface plate124is configured to nestably engage the plate attachment surface140of the probe body122. In a certain example, the body attachment surface141seats flush against the plate attachment surface140when the interface plate124is removably attached to the probe body122. The plate attachment surface140and the body attachment surface141can have any of various shapes. In the illustrated example, the plate attachment surface140is a concave surface with a circular arc shape and the body attachment surface141is a convex surface with a circular arc shape. The concavity of the plate attachment surface140of the probe body122facilitates placement of an arc-shaped ultrasonic array150within the probe body122. However, in alternative examples, the plate attachment surface140and the body attachment surface141have a non-circular arc shape, have a non-flat non-arc shape, or are flat.

Removable attachment of the body attachment surface141to the plate attachment surface140is facilitated by one or more fasteners142in some examples. As shown inFIGS. 3 and 5, in one example, the ultrasonic inspection probe120includes multiple fasteners142(e.g., four fasteners142). The fasteners142are configured to extend through aligned holes in the probe body122and the interface plate124. More specifically, in the illustrated example, the probe body122includes holes136open to the plate attachment surface140and the interface plate124includes holes138extending entirely through the interface plate124and open to the body attachment surface141. Either the holes136or the holes138include internal threads for engaging external threads of the fasteners142. When the plate attachment surface140is mated to the body attachment surface141, each one of the holes136in the probe body122is aligned with a corresponding one of the holes138in the interface plate124. When aligned, a corresponding one of the fasteners142is extendable into the aligned holes to engage the threads of the threaded hole. In the illustrated example, the holes136of the probe body122include threads to engage the threads of the fasteners142after the fastener passes through the holes138of the interface plate124. Threadable engagement between the fasteners142and the threads of the holes136allow the fasteners142to be tightened to attach the interface plate124to the probe body122or be loosened to remove the interface plate124from the probe body122. Although fasteners are utilized in the illustrated example, in other examples, other coupling devices, such as quick-releases, resilient clips/tabs, interference-fitted components, etc., that facilitate removable attachment of the interface plate124to the probe body122can be used.

The probe body122includes and houses an ultrasonic array150(see, e.g.,FIGS. 5, 6, 8, and 9). The ultrasonic array150is non-movably fixed to the probe body122and includes a plurality of ultrasound elements152. In one example, each ultrasonic element152is operable to generate an ultrasonic beam162. The collection of ultrasonic beams162generated by the ultrasound elements152of the ultrasonic array150define an ultrasonic field160. In some examples, the ultrasound elements152are arranged in a side-by-side manner, such that one ultrasound element152is directly adjacent at least one other ultrasound element152.

The ultrasound elements152are arranged relative to each other into a particularly shaped formation to define a shape of the ultrasonic array150. The shape of the ultrasonic array150depends on the desired directionality of the ultrasonic beams162generated by the ultrasound elements152of the ultrasonic array150(see, e.g.,FIG. 9). Moreover, the directionality of a given ultrasonic beam162depends on the orientation of the ultrasonic element152that generated the ultrasonic beam162. In the illustrated example, the ultrasound elements152are arranged into a circular arc having a first radius r1. In other words, the ultrasonic array150has a circular-arc shape. The ultrasound elements152, being arranged in a circular arc, generate ultrasonic beams162that pass through the center164of the circular arc. In other words, every ultrasonic beam162generated by the ultrasonic array150passes through the center of the circular arc defined by the ultrasonic array150.

Referring toFIGS. 5, 6, 8, and 9, the probe body122includes a body internal cavity148. The ultrasonic array150is fixedly positioned within the body internal cavity148. Accordingly, the body internal cavity148is shaped to fit the ultrasonic array150in the body internal cavity148. The body internal cavity148is open at the plate attachment surface140.

The probe body122additionally includes an aperture132open to the body internal cavity148. As shown inFIG. 2, the aperture132allows a power-communications line114to be coupled to the ultrasonic array150. The power-communications line114extends through the aperture132from a location external to the probe body122(e.g., at a controller of the ultrasonic inspection system100), through the aperture132, and into power and/or communications coupling engagement with the ultrasonic array150.

With further reference toFIG. 2, the probe body122also includes a first fluid supply line134formed in the probe body122. As shown inFIG. 11, the first fluid supply line134extends through the probe body122. The first fluid supply line134is configured to receive fluid from a fluid source line116, which can be fluidly coupled to a fluid source external to the probe body122. The fluid source supplies a coupling fluid to the first supply line134via the fluid source line116. The coupling fluid is configured to provide a fluid medium between the ultrasonic array150and a surface of the part104being inspected, which helps propagate the ultrasonic beams162from the ultrasonic array150to the surface of the part104.

As shown inFIGS. 3-9, the interface plate124further includes a part inspection surface128on an opposite side of the interface plate124as the body attachment surface141. The part inspection surface128is fixed or is non-adjustable. Accordingly, the shape of the part inspection surface128is not flexible and cannot be changed in certain examples. The part inspection surface128is shaped to complement a shape of the part104being inspected. In other words, at least a portion of the part inspection surface128has substantially the same shape as the surface of the part104being inspected. In this manner, the part inspection surface128is able to ride along the surface of the part104being inspected with little to no offset between the part inspection surface128and the surface of the part104. According to one example shown inFIG. 8, the part104includes a convex circular-arc shaped external surface, having a second radius r2, along which the part inspection surface128rides while inspecting the part104. Accordingly, the part inspection surface128has a part-riding portion166with a concave circular-arc shape having the second radius r2. In some examples, as shown inFIGS. 8 and 9, the part inspection surface128may include clearance portions168that flank the part-riding portion166. The clearance portions168do not have the same shape as the part104. Instead, the clearance portions168are shaped to allow the ultrasonic inspection probe120to avoid interference with the part104as the ultrasonic inspection probe120is moved into riding position on the part104.

The part104shown inFIG. 8is a hat stringer. However, the part104can be any of various parts having a similar convex circular-arc shaped external surface along which the part inspection surface128rides as the part104is inspected by the ultrasonic inspection probe120.

Referring toFIGS. 3-6 and 8, the interface plate124additionally includes a fluid reservoir pocket130formed in and open to both the body attachment surface141and the part inspection surface128. In other words, the fluid reservoir pocket130extends from the body attachment surface141to the part inspection surface128. When the interface plate124and the probe body122are removably attached, the fluid reservoir pocket130is open to the body internal cavity148. As shown inFIGS. 11 and 12, the interface plate124also includes at least one second fluid supply line (e.g., second fluid supply lines172A-C) open to the fluid reservoir pocket130. In the illustrated example, the interface plate124includes three second fluid supply lines172A-C. Each one of the three second fluid supply lines172A-C is open to the fluid supply line134of the probe body122when the probe body122and the interface plate124are removably attached. Accordingly, fluid supplied to the fluid supply line134flows into the second fluid supply lines172A-C and subsequently into the fluid reservoir pocket130and the body internal cavity148. The second fluid supply lines172A-C are separated and spaced apart from each other such that fluid flowing from them into the fluid reservoir pocket130enters the fluid reservoir pocket130at spaced apart locations, thus promoting uniform filling of the fluid in the fluid reservoir pocket130. To allow fluid to flow into and out of the fluid reservoir pocket130during an inspection procedure, the interface plate124also includes one or more exit ports144(see, e.g.,FIGS. 7 and 12) extending from the fluid reservoir pocket130to outside the interface plate124.

Now referring toFIG. 9, in some examples, the second radius r2of the part-riding portion166of the part inspection surface128is less than the first radius r1of the ultrasonic array150. Moreover, a top-center location of the part inspection surface128of the interface plate124is a distance D1away from a top-center location of the body attachment surface141of the interface plate124. The distance D1is selected such that, when the interface plate124is removably attached to the probe body122, the ultrasonic array150is concentric or substantially concentric with the part-riding portion166of the part inspection surface128of the interface plate124. In other words, the circular arc defined by the ultrasonic array150and the circular arc of the part inspection surface128share or substantially share the same center164, from which the radii of the ultrasonic array150and the part inspection surface128are defined. As used herein, two circular arcs are substantially concentric when a normal drawn from the first arc is substantially normal to the second arc.

Because the ultrasonic array150is concentric or substantially concentric with the part-riding portion166of the part inspection surface128of the interface plate124and the ultrasonic beams162generated by the ultrasonic array150pass through the shared center164, when the part-riding portion166is riding on the circular-arc shaped portion of the part104, the ultrasonic beams162are normal or substantially normal to the surface of the part104. When the interface plate124is removably attached to the probe body122, the concentricity of the part inspection surface128and the ultrasonic array150allows each ultrasonic beam162, generated by the plurality of ultrasound elements152, to be normal or substantially normal to the part inspection surface128at an intersection of each ultrasonic beam162and the part inspection surface128. Accordingly, when the inspection surface128is riding on a circular-arc shaped surface of the part104, with the radius of the surface of the part104being substantially equal to the second radius r2of the part inspection surface128, each ultrasonic beam162is normal to the surface of the part104at an intersection of each ultrasonic beam162and the surface of the part104. The ultrasonic beams162contacting and penetrating the part104at an angle normal to the surface of the part promotes accuracy, reliability, and an increase in the detectible range of anomalies within the part104. As used herein, substantially normal means within 1.5 degrees of normal.

Referring now toFIG. 10, according to some examples, the ultrasonic inspection probe120includes the probe body122and a plurality of interface plates. The plurality of interface plates are interchangeably removably attachable to the probe body122to inspect differently-shaped parts104. Each one of the plurality of interface plates includes the same general features as the interface plate124described above, with like numbers referring to like features. However, each one of the plurality of interface plates has a differently shaped part inspection surface128than any other of the plurality of interface plates to complement the shape of a corresponding one of the differently-shaped parts104. For example, in the illustrated implementation, the ultrasonic inspection probe120includes a first interface plate124A, a second interface plate124B, and a third interface plate124C. The circular-arc shaped part-riding portion166of the part inspection surface128of each one of the first interface plate124A, the second interface plate124B, and the third interface plate124C are shaped to have the second radius r2, a third radius r3, and a fourth radius r4, respectively. The third radius r3is greater than the second radius r2and the fourth radius r4is less than the second radius r2. The second radius r2is substantially equal to the radius of a circular-arc shaped surface of a first one of the parts104, the third radius r3is substantially equal to the radius of a circular-arc shaped surface of a second one of the parts104, and the fourth radius r4is substantially equal to the radius of a circular-arc shaped surface of a second one of the parts104. As used herein, a surface that is differently shaped relative to another surface can refer to differently sized surfaces with the same general shape (e.g., circular).

While the part inspection surfaces128of the first interface plate124A, the second interface plate124B, and the third interface plate124C are differently shaped, the body attachment surfaces141of the first interface plate124A, the second interface plate124B, and the third interface plate124C have the same shape. Accordingly, each of the first interface plate124A, the second interface plate124B, and the third interface plate124C can be removably attached to and removed from the plate attachment surface140of the probe body122in the same manner, as described below with reference to the method300. In this manner, the first interface plate124A, the second interface plate124B, and the third interface plate124C are interchangeably removably attachable to the probe body122.

When any one of the first interface plate124A, the second interface plate124B, and the third interface plate124C is removably attached to the probe body122, each ultrasonic beam162generated by the plurality of ultrasound elements152is normal to the part inspection surface128of the corresponding one of the first interface plate124A, the second interface plate124B, and the third interface plate124C at an intersection of each ultrasonic beam162and the part inspection surface. Because the first radius r1of the ultrasonic array150and the body attachment surfaces141of the first interface plate124A, the second interface plate124B, and the third interface plate124C are fixed, and the second radius r2, the third radius r3, and the fourth radius r4are different, to maintain concentricity between the part inspection surfaces128of the ultrasonic array150and the first interface plate124A, the second interface plate124B, and the third interface plate124C when attached to the probe body122, the distances between part inspection surfaces128and the body attachment surfaces141of the first interface plate124A, the second interface plate124B, and the third interface plate124C are different. For example, the distance D1between the top-center locations of the body attachment surface141and the part inspection surface128of the first interface plate124A is more than the distance D2between the top-center locations of the body attachment surface141and the part inspection surface128of the second interface plate124B. Likewise, the distance D3between the top-center locations of the body attachment surface141and the part inspection surface128of the third interface plate124C is more than the distance D1between the top-center locations of the body attachment surface141and the part inspection surface128of the first interface plate124A.

Although, in the illustrated example, the ultrasonic inspection probe120includes three interchangeable interface plates, in other examples, the ultrasonic inspection probe120includes two or at least four interchangeable interface plates. The probe body122and the interface plate124can be made of any of various materials. For example, in certain implementations, either one or both of the probe body122and the interface plate124is made of a polymeric material. In certain examples, the interface plate124has a one-piece, monolithic, construction.

Referring now toFIGS. 13-19, according to alternative examples, an ultrasonic inspection probe220is shown. The ultrasonic inspection probe220is configured to provide features and functionality at least similar to the ultrasonic inspection probe120shown and described previously. Accordingly, unless otherwise indicated, like numbers between the ultrasonic inspection probe120and the ultrasonic inspection probe220refer to like features. The descriptions of the like features in the ultrasonic inspection probe120provided above apply to the like features in the ultrasonic inspection probe220unless otherwise noted. Like the ultrasonic inspection probe120, the ultrasonic inspection probe220can form part of the end effector110of the ultrasonic inspection system100ofFIG. 1. For example, the ultrasonic inspection probe220can be coupled to the robot102via the compliance interface assembly112.

In general, instead of being configured to inspect an externally radiused surface, like the ultrasonic inspection probe120, the ultrasonic inspection probe220is configured to inspect a part204with an internally radiused surface, such as a flanged component. Referring toFIG. 19, in one example, the part204includes an internal or inside radius209, which has a sixth radius r6and can be inspected using the ultrasonic inspection probe220as shown.

Referring toFIGS. 13 and 14, according to the illustrated examples, the ultrasonic inspection probe220includes a probe body222and an interface plate224. The interface plate224is removably attachable to the probe body222. InFIGS. 13, 15, and17-19, the interface plate224is removably attached to the probe body222, which can be directly attached to the compliance interface assembly112as described above. In the same manner at the ultrasonic inspection probe120, for testing different parts each having a different shape, the ultrasonic inspection system100can utilize replacement of just the interface plate224rather than the entire ultrasonic inspection probe220or the entire end effector110.

The probe body222includes a first plate attachment surface240A, a second plate attachment surface240B, and a third plate attachment surface240C. The first plate attachment surface240A and the second plate attachment surface240B are spaced apart from each other and the third plate attachment surface240C is interposed between the first plate attachment surface240A and the second plate attachment surface240B. Correspondingly, the interface plate224includes a first body attachment surface241A, a second body attachment surface241B, and a third body attachment surface241C (see, e.g.,FIGS. 14-16). The first body attachment surface241A is removably attachable to the first plate attachment surface240A, the second body attachment surface241B is removably attachable to the second plate attachment surface240B, and the third body attachment surface241C is removably attachable to the third plate attachment surface240C. In other words, the first body attachment surface241A and the first plate attachment surface240A are configured to mate with each other, the second body attachment surface241B and the second plate attachment surface240B are configured to mate with each other, and the third body attachment surface241C and the third plate attachment surface240C are configured to mate with each other. Accordingly, a shape of the first plate attachment surface240A complements the shape of the first body attachment surface241A, a shape of the second plate attachment surface240B complements the shape of the second body attachment surface241B, and a shape of the third plate attachment surface240C complements the shape of the third body attachment surface241C.

In one example, the first body attachment surface241A and the second body attachment surface241B of the interface plate224are flat surfaces configured to seat flush against flat surfaces of the first plate attachment surface240A and the second plate attachment surface240B, respectively. The first body attachment surface241A and the second body attachment surface241B are angled relative to each other. Correspondingly, the first plate attachment surface240A and the second plate attachment surface240B are angled relative to each other. The angled surfaces help to secure and support the interface plate224in a proper position relative to the probe body222. The third body attachment surface241C and the third plate attachment surface240C are curved (e.g., non-flat) in some examples to facilitate nestable engagement between the third body attachment surface241C and the third plate attachment surface240C. The attachment surfaces of the ultrasonic inspection probe220can have shapes, other than those described above, in alternative examples.

Removable attachment of the first plate attachment surface240A, the second plate attachment surface240B, and the third plate attachment surface240C to the first body attachment surface241A, the second body attachment surface241B, and the third body attachment surface241C is facilitated by at least one fastener242in some examples. As shown inFIGS. 13 and 14, in one example, the ultrasonic inspection probe220includes a single fastener242(i.e., only one fastener). The fastener242is configured to extend through aligned holes in the probe body222and the interface plate224. More specifically, in the illustrated example, the probe body222includes a hole236and the interface plate224includes a holes238extending entirely through the interface plate224. Either the hole236or the hole238includes internal threads for engaging external threads of the fastener242.

When the plate attachment surfaces of the probe body222are mated to the corresponding body attachment surfaces of the interface plate224, the hole236in the probe body222is aligned with the hole238in the interface plate224. When aligned, the fastener242is extendable into the aligned holes to engage the threads of the threaded hole. In the illustrated example, the hole236of the probe body222include threads to engage the threads of the fastener242after the fastener passes through the hole238of the interface plate224. Threadable engagement between the fastener242and the threads of the hole236allow the fastener242to be tightened to attach the interface plate224to the probe body222or be loosened to remove the interface plate224from the probe body222. Although a fastener is utilized in the illustrated example, in other examples, other coupling devices, such as a quick-release, a resilient clip/tab, an interference-fitted component, etc., that facilitate removable attachment of the interface plate224to the probe body222can be used.

The probe body222includes and houses an ultrasonic array250(see, e.g.,FIGS. 15-19). The ultrasonic array250is non-movably fixed to the probe body222and includes a plurality of ultrasound elements252. The ultrasonic array250is configured and operable in the same manner as the ultrasonic array150. Similar to the ultrasonic array150, the ultrasound elements252of the ultrasonic array250are arranged into a circular arc having a fifth radius r5such that ultrasonic beams262, generated by the ultrasonic array250, pass through a center264of the circular arc defined by the ultrasonic array250. In other words, every ultrasonic beam262generated by the ultrasonic array250passes through the center264of the circular arc defined by the ultrasonic array250. The collection of ultrasonic beams262generated by the ultrasound elements252of the ultrasonic array250define an ultrasonic field260.

In an example, the probe body222includes a body internal cavity formed in an array receiving surface290of the probe body222. The ultrasonic array250is fixed within the body internal cavity, which can be shaped to fit the ultrasonic array250therein. The body internal cavity can be open at the array receiving surface290.

The probe body222additionally includes an aperture open to the body internal cavity. This aperture allows a power-communications line214to be coupled to the ultrasonic array250. The power-communications line214extends through the aperture from a location external to the probe body222(e.g., at a controller of the ultrasonic inspection system100), through the aperture, and into power and/or communications coupling engagement with the ultrasonic array250.

As shown inFIGS. 15-19, the interface plate224further includes a first part inspection surface292and a second part inspection surface294. The first part inspection surface292and the second part inspection surface294are configured to engage (e.g., ride on) respective surfaces of the part204. Accordingly, the shape of the first part inspection surface292and the second part inspection surface294correspond with the shape of the surfaces of the part204. In the illustrated example, at least a portion of both of the first part inspection surface292and the second part inspection surface294are flat to engage corresponding flat surfaces of the part204.

The first part inspection surface292and the second part inspection surface294are spaced apart from each other, which allows the ultrasonic array250to be interposed between the first part inspection surface292and the second part inspection surface294. As shown inFIG. 19, the first part inspection surface292and the second part inspection surface294are angled relative to each other such that a first angle θ1is defined between the first part inspection surface292and the second part inspection surface294. The first angle θ1corresponds (e.g., is the same as) an angle defined between the two surfaces of the part204that converge to define the inside radius209. In the illustrated example, the first angle θ1is about 90-degrees. The first part inspection surface292and the second part inspection surface294engage a respective one of the surfaces of the part204that converge to define the inside radius209.

The first part inspection surface292and the second part inspection surface294are further configured to align the center264of the ultrasonic array250with a center of the inside radius209when the first part inspection surface292and the second part inspection surface294engage the respective surfaces of the part204. In other words, when the first part inspection surface292and the second part inspection surface294engage the respective surfaces of the part204, the inside radius209of the part204is concentric with the circular arc defined by the plurality of ultrasound elements252of the ultrasonic array250. Accordingly, the size, shape, and/or relative first angle θ1of the first part inspection surface292and the second part inspection surface294is dependent on the size, shape, and/or relative angle of the respective surfaces of the part204, as well as the radius of the inside radius209of the part. As shown inFIG. 19, the inside radius209has a sixth radius r6with a center common with the center264of the circular arc of the ultrasonic array250when the first part inspection surface292and the second part inspection surface294are properly engaged with the part204. Because the first part inspection surface292and the second part inspection surface294ensure the ultrasonic array250and the inside radius209are concentric with each other, they also ensure the ultrasonic beams262generated by the ultrasonic array250pass through the shared center264and thus are normal to the surface of the inside radius209of the part204.

Referring now toFIG. 20, according to some examples, the ultrasonic inspection probe220includes the probe body222and a plurality of interface plates. The plurality of interface plates are interchangeably removably attachable to the probe body222to inspect differently-shaped parts104(e.g., differently sized inside radii). Each one of the plurality of interface plates includes the same general features as the interface plate224described above, with like numbers referring to like features. However, each one of the plurality of interface plates has a differently configured first part inspection surface292and second part inspection surface294than any other of the plurality of interface plates to complement a shape of a corresponding one of the differently-shaped parts204. For example, in the illustrated implementation, the ultrasonic inspection probe220includes a first interface plate224A, a second interface plate224B, and a third interface plate224C. The first part inspection surfaces292and the second part inspection surfaces294of each one of the first interface plate224A, the second interface plate224B, and the third interface plate224C are configured to define, between the surfaces, a first angle θ1, a second angle θ2, and a third angle θ2, respectively. The second angle θ2is greater than the first angle θ1and the third angle θ3is less than the first angle θ1, but the radius r5of the ultrasonic array150is the same. According to some examples, the sixth radius r6of the inside radius209of the part204for which the first interface plate224A is configured to inspect can be smaller than the sixth radius r6of the inside radius209of the part204for which the second interface plate224B is configured to inspect. Likewise, in the same examples, the sixth radius r6of the inside radius209of the part204for which the first interface plate224A is configured to inspect can be greater than the sixth radius r6of the inside radius209of the part204for which the third interface plate224C is configured to inspect.

While the first part inspection surfaces292and the second part inspection surfaces294of the first interface plate224A, the second interface plate224B, and the third interface plate224C are differently shaped, the first body attachment surfaces241A, the second body attachment surfaces241B, and the third body attachment surfaces241C of the first interface plate224A, the second interface plate224B, and the third interface plate224C have the same shape. Accordingly, each of the first interface plate224A, the second interface plate224B, and the third interface plate224C can be removably attached to and removed from the probe body222in the same manner, as described below with reference to the method300. In this manner, the first interface plate224A, the second interface plate224B, and the third interface plate224C are interchangeably removably attachable to the probe body222.

Although, in the illustrated example, the ultrasonic inspection probe220includes three interchangeable interface plates, in other examples, the ultrasonic inspection probe220includes two or at least four interchangeable interface plates. The probe body222and the interface plate224can be made of any of various materials. For example, in certain implementations, either one or both of the probe body222and the interface plate224is made of a polymeric material. In certain examples, the interface plate224has a one-piece, monolithic, construction.

As shown inFIG. 21, according to certain examples, the method300of inspecting parts, such as parts each having a differently-shaped surface to be inspected, includes (block302) removably attaching a first interface plate124A to a probe body122. The method300also includes (block304) riding a first part inspection surface128of the first interface plate124A along a first one of the parts104. The method300additionally includes (block306) directing ultrasonic beams162, generated from an ultrasonic array150of the probe body122and fixed relative to the probe body122, toward the first one of the parts while riding the first part inspection surface128of the first interface plate124A along the first one of the parts104.

In some examples of the method300, the method300further includes (block308) removing the first interface plate124A from the probe body122and (block310) removably attaching a second interface plate124B to the probe body122in place of the first interface plate124A. The method300also includes (block312) riding a second part inspection surface128of the second interface plate124B along a second one of the parts104. The method300additionally includes (block314) directing ultrasonic beams162, generated from the ultrasonic array150of the probe body122, toward the second one of the parts104while riding the second part inspection surface128of the second interface plate124B along the second one of the parts104.

According to some examples, the method300is executed using the ultrasonic inspection system100, including the robot102and the end effector110. For example, the robot102can be selectively operable to move a probe body relative to parts to ride part inspection surfaces of interface plates, removably attached to the probe body, along surfaces of the parts to inspect the parts. Also not shown, the ultrasonic inspection system100additionally includes a plate exchange system that stores multiple interface plates and facilitates removal of one interface plate from the probe body to the plate exchange system and removable attachment of another interface plate to the probe body from the plate exchange system. Some or part of the method300of inspecting parts is fully automated. For example, the robot102can be operable to remove interface plates from and attach interface plates to the probe body, using the plate exchange system, in an autonomous manner. In one example, the interface plates are attached to and removed from the probe body by tightening and loosening, respectively, one or more fasteners, which can be performed autonomously using the robot102and the plate exchange system.