Inspection system

An inspection system comprises a sensor array and a fluid chamber. The fluid chamber is configured to provide a fluid coupling environment between the sensor array and a structure. The fluid chamber comprises a bellows having a first side and a second side opposite the first side, wherein the first side is a flexible lip.

BACKGROUND INFORMATION

The present disclosure relates generally to inspection systems, and more specifically, to inspection systems using a fluid coupling environment. Still more particularly, the present disclosure relates to systems and methods for providing a fluid chamber between a sensor array and a structure.

Non-destructive inspection techniques are used to inspect structures for inconsistencies. Non-destructive inspection techniques do not damage the inspected structures.

Ultrasonic inspection is one form of non-destructive inspection. In ultrasonic inspection, ultrasonic waves are sent through a coupling medium and into the surface of the structure.

When ultrasonic inspections are performed by hand, the coupling medium is a gel. The gel may be undesirably expensive. Additionally, adding and removing the gel may take an undesirably large amount of time. Further, residual gel may be undesirable for the surface characteristics of the structure.

When ultrasonic inspections are performed automatically by an inspection system, the coupling medium is water. To perform an automated inspection, the entire structure to be inspected is submerged in a tank of deionized water. The inspection tanks are large and may be undesirably expensive to maintain. For large structures, such as airplane wings, an inspection tank would necessarily be exceptionally large.

Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the issues discussed above, as well as other possible issues. For example, it would be desirable to have a method and apparatus for ultrasonic inspection of structures without a gel or water tank.

SUMMARY

An illustrative example of the present disclosure provides an inspection system. The inspection system comprises a sensor array and a fluid chamber. The fluid chamber is configured to provide a fluid coupling environment between the sensor array and a structure. The fluid chamber comprises a bellows having a first side and a second side opposite the first side, wherein the first side is a flexible lip.

Another illustrative example of the present disclosure provides an inspection system. The inspection system comprises a sensor array and a fluid chamber containing the sensor array. The fluid chamber comprises a top having a fluid inlet and at least one fluid outlet, a substantially rigid spacer connected to the top, and a corrugated skirt having a flexible lip forming an opening. The spacer is configured to maintain a desired distance between the sensor and a surface of a structure. The corrugated skirt is connected to the spacer. The flexible lip is configured to contact the surface of the structure.

A further illustrative example of the present disclosure provides a method. A force is applied to an inspection system to maintain a flexible lip of a bellows of the inspection system against a surface of a structure. The bellows has a first side and a second side opposite the first side, and the first side comprises the flexible lip. A fluid is flowed into a fluid chamber configured to provide a fluid coupling environment between a sensor array of the inspection system and the surface of the structure while the force is applied to the inspection system. The fluid chamber comprises the bellows. The surface of the structure is inspected using the sensor array.

The features and functions can be achieved independently in various examples of the present disclosure or may be combined in yet other examples in which further details can be seen with reference to the following description and drawings.

DETAILED DESCRIPTION

The illustrative examples recognize and take into account one or more different considerations. For example, the illustrative examples recognize and take into account that there are two conventional methods of inspecting a structure. The illustrative examples recognize and take into account that one method is to submerge the part, which requires a large tank and large volume of water, and some parts are too delicate to submerge. The illustrative examples recognize and take into account that another method is to use a single sensor which reduces the area that can be scanned in a single pass, therefore increasing the time to scan the part.

The illustrative examples recognize and take into account that for a substantially planar structure a stream of water may be directed between an ultrasonic sensor and the structure. The stream of water acts as a fluid coupling environment when the stream of water is continuous and substantially free of bubbles between the sensor and the structure. A fluid coupling environment is also desirably a laminar flow without any discernable gaps between the sensor and the structure.

The illustrative examples recognize and take into account that a stream of water does not act as a fluid coupling environment for curved structures. Curvature of structures introduces gaps between the sensor and the surface of the structure. Thus, the illustrative examples recognize and take into account that an inspection system for ultrasonic inspection of curved structures is desirable.

The illustrative examples recognize and take into account that when using an ultrasonic sensor or sensor array to inspect composite parts, the face of the sensor or array is flat. Often, the composite part being inspected is curved, creating air gaps between the sensor face and the part. The illustrative examples recognize and take into account that for quality inspection, this gap must be filled with a fluid medium, such as gel or water.

The illustrative examples recognize and take into account that parts that have surfaces which are highly variable can only be scanned by sensor arrays when they are totally submerged. The illustrative examples recognize and take into account filling the void between the part and sensor when the part surface is curved creates too big of a void to flood with fluid in space. The illustrative examples recognize and take into account that when using only a water source, most of the water is lost on a highly variable surface. The illustrative examples recognize and take into account that loss of water allows the introduction of air between sensor and part, which results in poor data collection.

With reference now to the figures, and in particular, with reference toFIG. 1, an illustration of a block diagram of a manufacturing environment is depicted in accordance with an illustrative example. Manufacturing environment100includes inspection system102for inspection of structure104.

Structure104has surface106. In some illustrative examples, surface106has curvature108. In some illustrative examples, curvature108is complex curvature110. Complex curvature110is at least one of a varying curvature or a curvature in a plurality of axes.

For example, “at least one of item A, item B, or item C” may include, without limitation, item A, item A and item B, or item B. This example also may include item A, item B, and item C; or item B and item C. Of course, any combination of these items may be present. In other examples, “at least one of” may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or other suitable combinations.

Inspection system102comprises sensor array112and fluid chamber114. In some illustrative examples, sensor array112takes the form of ultrasonic sensor array115.

Fluid chamber114is configured to provide a fluid coupling environment between sensor array112and structure104. Fluid chamber114comprises bellows116having first side118and second side120opposite first side118. First side118comprises flexible lip122. Bellows116is formed of polymeric material124. In some examples, bellows116may instead be referred to as corrugated skirt125. Flexible lip122is configured to deform to seal against surface106of structure104.

Fluid chamber114further comprises top126connected to second side120of bellows116. Top126has fluid inlet128and at least one fluid outlet130. Top126is substantially rigid132, such that a shape of top126does not deform due to a force applied to inspection system102that deforms bellows116.

Fluid chamber114further comprises spacer134configured to maintain a desired distance between sensor array112and surface106of structure104. Spacer134is substantially rigid136to maintain the desired distance between sensor array112and surface106of structure104. A portion of spacer134extends into bellows116.

In some illustrative examples, flexible lip122is a widest portion of one corrugation of corrugations138of bellows116. In some illustrative examples, flexible lip122is configured to deform in at least two axes.

In some illustrative examples, flexible lip122is configured to use hydrostatic pressure to provide a force to maintain bellows116against surface106of structure104when fluid is present within bellows116. In these illustrative examples, hydrostatic pressure is applied to a portion of flexible lip122extending inward from bellows116.

In one example, inspection system102comprises sensor array112and fluid chamber114containing sensor array. Fluid chamber114comprises top126having fluid inlet128and at least one fluid outlet130, substantially rigid136spacer134connected to top126, and corrugated skirt125having flexible lip122forming opening140. Spacer134is configured to maintain a desired distance between sensor array112and surface106of structure104. Corrugated skirt125is connected to spacer134. Flexible lip122is configured to contact surface106of structure104.

Flexible lip122is configured to deform shape142of opening140to conform to surface106of structure104. In some illustrative examples, flexible lip122is configured to deform shape142of opening140to conform to surface106of structure104, such that a greater amount of fluid exits fluid chamber114through at least one fluid outlet130than through opening140.

Flexible lip122is configured to deform to restrict fluid flow between flexible lip122and surface106of structure104. Although flexible lip122restricts fluid flow, flexible lip122may not completely contain fluid within fluid chamber114. A seal between flexible lip122and structure104is not necessarily a perfect seal. Fluid may still flow between flexible lip122and structure104. However, flexible lip122reduces the amount of fluid flowing out of fluid chamber114and across surface106of structure104.

Surface106of structure104has curvature108, and flexible lip122is configured to continually deform to contact surface106as flexible lip122moves across surface106of structure104. When curvature108is complex curvature110, flexible lip122changes shape as inspection system102travels across surface106. When curvature108is a varying curvature, flexible lip122deforms continuously to remain contacting surface106.

Corrugated skirt125is removable, such that corrugated skirt125is interchangeable with a second corrugated skirt having a different geometry. Geometry of corrugated skirt125includes at least one of a quantity of corrugations138, a size of corrugations138, shape of corrugations138, shape142of opening140, or shape of flexible lip122.

For example, a material of bellows116is not depicted inFIG. 1. However, bellows116may be formed of any desirable flexible material. In some illustrative examples, bellows116may desirably be formed of a polymeric material.

Further, manufacturing equipment for forming bellows116is not depicted inFIG. 1. Bellows116may be formed using any desirable manufacturing method. In some illustrative examples, bellows116may be formed using injection molding or any other desirable form of molding. In another illustrative example, bellows116may be formed using three-dimensional manufacturing, such as three-dimensional printing.

Turning now toFIG. 2, an illustration of an isometric view of an inspection system is depicted in accordance with an illustrative example. Inspection system200is a physical implementation of inspection system102ofFIG. 1. Inspection system200comprises sensor array202and fluid chamber204. Fluid chamber204provides a fluid coupling environment between sensor array202and a structure. The fluid coupling environment includes fluid without an undesirable amount of bubbles or cavitation. The fluid within the fluid coupling environment has laminar flow. Fluid chamber204comprises top206, spacer208, and bellows210. Bellows210may also be referred to as a corrugated skirt.

Sensor array202is connected to and extends through top206into fluid chamber204. Spacer208is substantially rigid. A portion of spacer208extends into bellows210. Spacer208maintains a desired distance between a surface of a structure to be inspected and sensor array202.

Top206has fluid inlet212, fluid inlet214, and fluid outlets216. Fluid is introduced into fluid chamber204through fluid inlet212and fluid inlet214. Fluid exits fluid chamber204through fluid outlets216and between bellows210and the structure. In some illustrative examples, bellows210deforms such that a majority of the fluid exits through fluid outlets216. Fluid flow between bellows210and the structure is reduced by deformation of bellows210.

Turning now toFIG. 3, an illustration of a front view of an inspection system is depicted in accordance with an illustrative example. View300is a front view of inspection system200. As can be seen in view300, bellows210has corrugations302. In this illustrative example, bellows210has two and a half corrugations. Bellows210has first side304and second side306. First side304comprises flexible lip308. Flexible lip308is configured to contact a surface of a structure to be inspected. Second side306is opposite first side304. Second side306is connected to spacer208.

As can be seen in view300, inspection system200is an end effector. An end effector is a device attached to a robotic arm. Use of inspection system200may be completely automated or semi-automated.

Turning now toFIG. 4, an illustration of a bottom view of an inspection system is depicted in accordance with an illustrative example. View400is a bottom view of inspection system200. As can be seen in view400, portion402of spacer208extends through bellows210. In view400, spacer208does not have any standoffs. Instead, spacer208is substantially planar.

In other non-depicted illustrative examples, a spacer in inspection system200may have a number of standoffs extending out from the substantially planar surface of spacer208. As used herein, “a number of” when used with reference to items means one or more items. Thus, a number of standoffs means one or more standoffs. Standoffs (not depicted) help to passively align the face of sensor array202, shown inFIG. 2, perpendicular to a curved surface of a structure.

In view400, a portion of sensor array202is visible through hole404of spacer208. When fluid is introduced between sensor array202and a structure, fluid fills hole404of spacer208. The fluid will also fill bellows210.

As can be seen in view400, flexible lip308forms opening406. Flexible lip308is configured to deform a shape of opening406to conform to a surface of a structure. In some illustrative examples, flexible lip308is configured to deform the shape of opening406to conform to a surface of a structure, such that a greater amount of fluid exits fluid chamber204through at least one fluid outlet than through opening406.

Turning now toFIG. 5, an illustration of an exploded view of an inspection system is depicted in accordance with an illustrative example. View500is an exploded view of inspection system200ofFIG. 2. As can be seen in view500, sensor array202is connected to and partially extends through top206. In operation, top206is connected to spacer208, and spacer208is connected to bellows210. In operation, fluid flowing between sensor array202and a structure will be contained within fluid chamber204formed by top206, spacer208, and bellows210.

Turning now toFIG. 6, an illustration of a cross-sectional view of an inspection system is depicted in accordance with an illustrative example. View600is a cross-sectional view of inspection system200ofFIG. 2. During inspection of a structure, bellows210is compressed by a force downward on inspection system200. Bellows210will be compressed until flexible lip308is substantially even with end602of spacer208. When spacer208has standoffs, bellows210is compressed until flexible lip308is substantially even with the end of the standoffs.

Turning now toFIG. 7, an illustration of an inspection system over a structure to be inspected is depicted in accordance with an illustrative example. In view700, inspection system702is positioned over structure704. Inspection system702is a physical implementation of inspection system102ofFIG. 1. In some illustrative examples, inspection system702is substantially the same as inspection system200ofFIG. 2.

Inspection system702comprises a sensor array (not depicted) and fluid chamber705. Fluid chamber705is configured to provide a fluid coupling environment for the sensor array. Fluid chamber705includes bellows706, spacer708, and top710. Top710has at least one fluid outlet711for fluid to exit fluid chamber705.

Characteristics of inspection system702may be changed by exchanging components of inspection system702. For example, inspection system702may be changed by exchanging bellows706for another interchangeable bellows. At least one of the material or shape or size of bellows706, including the shape and size of the corrugations and the shape and size of the flexible lip, affects the deformation of bellows706. The deformation of bellows706affects the sealing of the flexible lip and the behavior of the fluid within fluid chamber705.

Inspection system702may also be altered by changing spacer708for a spacer with different dimensions or a different number of spacers. Inspection system702may be changed by changing the sensor array (not depicted) within inspection system702.

Turning now toFIG. 8, an illustration of an inspection system contacting a structure to be inspected is depicted in accordance with an illustrative example. View800is a view of inspection system702ofFIG. 7contacting surface802of structure704. As depicted, bellows706deforms such that flexible lip804of bellows706substantially conforms to curvature806of surface802of structure704.

Flexible lip804encircles an opening of inspection system702. Flexible lip804deforms the shape of the opening to conform to surface802of structure704, such that a greater amount of fluid exits fluid chamber705through at least one fluid outlet711than through the opening.

Flexible lip804deforms to restrict fluid flow between flexible lip804and surface802of structure704. Although flexible lip804may not keep all fluid from flowing between flexible lip804and surface802, less fluid flows between flexible lip804and surface802than between a rigid lip and surface802. Deformation of flexible lip804reduces the amount of fluid flowing out of the opening. However, fluid flow out of fluid chamber705, either via at least one fluid outlet711or between flexible lip804and structure704, removes air bubbles that may be present in the fluid or that may form.

Turning now toFIG. 9, an illustration of an inspection system over a structure to be inspected is depicted in accordance with an illustrative example. View900is a view of inspection system902contacting surface904of structure906prior to an application of downward force on inspection system902. Inspection system902is a physical implementation of inspection system102ofFIG. 1. Structure906is a physical implementation of structure104ofFIG. 1. As depicted, structure906has curvature908. More specifically, as depicted, structure906is substantially cylindrical.

In view900, flexible lip910of bellows912is not yet deformed. View900is a view of inspection system902prior to or following inspection of structure906.

Turning now toFIG. 10, an illustration of a front view of an inspection system contacting a structure to be inspected is depicted in accordance with an illustrative example. View1000is a view of inspection system902with a force applied to inspection system902in direction1002towards structure906. As depicted, flexible lip910of bellows912is deformed to seal against surface904of structure906.

Turning now toFIG. 11, an illustration of an isometric view of an inspection system contacting a structure to be inspected is depicted in accordance with an illustrative example. View1100is a view of inspection system902from direction11ofFIG. 10. View1100shows deformation of bellows912due to a force applied to inspection system902in direction1002ofFIG. 10.

Turning now toFIG. 12is an illustration of an isometric view of an inspection system contacting a structure to be inspected is depicted in accordance with an illustrative example. View1200is a view of inspection system902during an inspection of structure906. Inspection system902is moved along surface904of structure906in direction1202to inspect surface904.

Flexible lip910of bellows912conforms to surface904of structure906, forcing fluid out of top1204rather than allowing it to flow out around structure906. More specifically, flexible lip910of bellows912deforming to seal against surface904of structure906directs fluid out of number of fluid outlets1206. The amount of fluid flowing between flexible lip910and surface904is reduced by deformation of flexible lip910. Thus, flexible lip910restricts fluid flow between flexible lip910and structure906.

Turning now toFIG. 13, an illustration of an isometric view of a spacer is depicted in accordance with an illustrative example. Spacer1300is a physical implementation of spacer134ofFIG. 1. Spacer1300may be an implementation of spacer208ofFIG. 2.

As depicted, spacer1300has standoffs1302. Standoffs1302help to passively align a sensor array face perpendicular to a curved part face to be inspected. As depicted, standoffs1302include three standoffs. However, the number, location, and size of standoffs1302may be different for different designs of spacer1300.

FIGS. 14-15illustrate different designs for physical implementations of bellows116ofFIG. 1. A bellows design may be varied by featuring different sized corrugations, lips with flanges to help prevent the lip from folding under itself, and a curved lip surface for high radius areas.FIGS. 14-15are non-limiting examples as the number of corrugations, size of corrugations, shape of bellows, shape of lip, size of lip, and other features of the bellows may be changed based on at least one of characteristics of the surface of the structure to be inspected, fluid pressure, material of the bellows, shape of the sensor, or any other characteristic of the inspection.

Turning now toFIG. 14, an illustration of an isometric view of an interchangeable bellows is depicted in accordance with an illustrative example. Bellows1400is a physical implementation of bellows116ofFIG. 1. Bellows1400may be used to replace bellows210in inspection system200ofFIG. 2. Bellows210may be interchangeable with bellows1400ofFIG. 14.

Bellows1400has three full corrugations and one partial corrugation. The partial corrugation is less than a half corrugation. As depicted, opening1402formed by flexible lip1404is substantially square.

Turning now toFIG. 15, an illustration of an isometric view of an interchangeable bellows is depicted in accordance with an illustrative example. Bellows1500is a physical implementation of bellows116ofFIG. 1. Bellows1500may be used to replace bellows210in inspection system200ofFIG. 2. Bellows210may be interchangeable with bellows1500ofFIG. 15.

Bellows1500has three full corrugations and one partial corrugation. The partial corrugation is greater than one half corrugation. As depicted, opening1502formed by flexible lip1504is not planar. Instead, flexible lip1504is curved inwards towards second side1506of bellows1500opposite flexible lip1504.

Bellows1500may be used to inspect components with extreme curvatures. For example, bellows1500may be used on a cylinder with a relatively small diameter.

The different components shown inFIGS. 2-15may be combined with components inFIG. 1, used with components inFIG. 1, or a combination of the two. Additionally, some of the components inFIGS. 2-15may be illustrative examples of how components shown in block form inFIG. 1can be implemented as physical structures.

Turning now toFIG. 16, an illustration of a flowchart of a method for inspecting a surface of a structure is depicted in accordance with an illustrative example. Method1600may be used to inspect structure104using inspection system102ofFIG. 1. Method1600may be used by inspection system200ofFIGS. 2-12.

Method1600applies a force to an inspection system to maintain a flexible lip of a bellows of the inspection system against a surface of a structure, wherein the bellows has a first side and a second side opposite the first side, and wherein the first side comprises the flexible lip (operation1602). In some illustrative examples, applying the force to the inspection system deforms the flexible lip of the bellows to seal the fluid chamber against the structure. In some illustrative examples, applying the force to the inspection system deforms the flexible lip to restrict fluid flow between the flexible lip and the surface of the structure such that a greater amount of fluid exits the fluid chamber through at least one fluid outlet of a top of the fluid chamber than between the flexible lip and the surface of the structure.

Method1600flows a fluid into a fluid chamber configured to provide a fluid coupling environment between a sensor array of the inspection system and the surface of the structure while the force is applied to the inspection system, wherein the fluid chamber comprises the bellows (operation1604). Method1600inspects the surface of the structure using the sensor array (operation1606). Afterwards the method terminates.

For example, method1600may move the inspection system along the surface of the structure, wherein at least one of applying the force to the inspection system or hydrostatic force of the fluid flowing within the fluid chamber maintains contact between the flexible lip and the surface of the structure. In some illustrative examples, the surface of the structure has a variable curvature and the flexible lip of the bellows changes shape as the bellows moves across the surface of the structure.

The illustrative examples provide an inspection system and method for inspecting structures with curvatures, without using gel or being submerged in a tank. The illustrative examples provide a means of reducing the time to inspect composite parts without the need for large submersion tanks. These tanks are expensive to build, maintain, and require a large footprint.

The illustrative examples provide a means of filling that void without having to totally submerge the part. The illustrative examples provide a skirt that is flexible, fits around a sensor or sensor array, and has a lip that conforms to the surface of part. This creates a chamber around the sensor or array that can be filled with fluid.

The skirt is a flexible structure designed specifically to conform to a surface with variable curves, but be laterally rigid enough to travel with the rigid sensor as it is traversed across the part surface. Different skirt geometries may conform to different surface curvatures.

In some illustrative examples, the skirt is three-dimensionally printed. Being three-dimensionally printed means that this skirt can be customized to fit any sensor array. The corrugations on the side load up like a compression spring forcing the lip of the skirt to conform to the part surface. These corrugations also provide rigidity in the transverse directions so the skirt doesn't fold over as it slides across the part surface.

The description of the different illustrative examples has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the examples in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different illustrative examples may provide different features as compared to other illustrative examples. The example or examples selected are chosen and described in order to best explain the principles of the examples, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various examples with various modifications as are suited to the particular use contemplated.