Patent Description:
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 recalibrated 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.

<CIT>, in accordance with its abstract, states a scanner device for performing nondestructive testing of a tube, which includes an ultrasonic probe, a waveguide secured relative to the probe, and an encoder secured relative to the probe. The waveguide has a surface contoured in relation to a radius of a tube to be inspected, and the encoder provides a signal indicative of a location of the probe relative to the tube as the probe, waveguide, and encoder are moved in a direction of a longitudinal axis of the tube.

<CIT>, in accordance with its abstract, states an ultrasound probe assembly which comprises a housing and a wedge, wherein wedges configured for pipes of different diameter may be interchanged in the assembly. Four wheels are attached to the housing, there being a front wheel pair and a rear wheel pair. Wheels of each pair are positioned on either side of a linear probe array, wherein the distance between wheels in each pair in a direction perpendicular to the array length is as small as possible. A position encoder monitors the position of the assembly during scanning, and a push lock switch is used to disable the encoder and the data acquisition while indexing to a new scan position on the pipe.

<CIT>, in accordance with its abstract, states a scanning device for performing ultrasonic nondestructive testing of a tube, comprising a housing; the housing having bottom surface that is concavely curved with cavities to accommodate a waveguide assembly and an encoder assembly; where the waveguide assembly comprises a waveguide and a probe that are in communication with one another; the waveguide having at least one surface that is contoured to match an outer surface of the tube; where the waveguide facilitates the transmission of ultrasonic signals into the tube generated by the probe; and where the encoder assembly comprises a spring loaded wheel that contacts the tube; and where the encoder assembly provides a signal indicative of a location of the probe relative to a position on the tube as the scanning device is moved in a direction of a longitudinal axis of the tube.

<CIT>, in accordance with its abstract, states an ultrasonic flaw detector for detecting irregularities in an object, such as a pipe, having a segment of annular cross-section. The detector includes a transducer with an involute transmitting surface for sending ultrasonic signals into the object at equal non-radial angles of incidence. The detector further includes transmission apparatus for maintaining a constant physical relationship between the transducer and the pipe and interpretive apparatus for correlating reflections of ultrasonic signals within the object with irregularities.

<CIT>, in accordance with its abstract, states an ultrasonic probe deployment device in which an ultrasound-transmitting liquid forms the portion of the ultrasonic wave path in contact with the surface being inspected. A seal constrains flow of the liquid. The seal is not rigid and conforms to variations in the shape and unevenness of the inspection surface, thus forming a seal (although possibly a leaky seal) around the liquid.

<CIT>, in accordance with its abstract, states a system and a method for ultrasonic inspection of multiple or varying radii of a composite part. The system may comprise one or more ultrasonic pulser/receivers, one or more ultrasonic transducer arrays, a probe body or shoe to hold and position the array(s), ultrasonic data acquisition application software to drive the array(s), and ultrasonic data acquisition application software to select the signal response for each column of pixels to be displayed.

<CIT>, in accordance with its abstract, states a system and method for ultrasonic inspection of a variable and irregular shape. The system comprises one or more ultrasonic pulser/receivers, one or more ultrasonic transducer arrays, a shoe or jig to hold and position the array(s), data acquisition software to drive the array(s), and data analysis software to select a respective return signal for each pixel to be displayed. This system starts with information about the general orientation of the array relative to the part and a general predicted part shape. More specific orientation of the transmitted ultrasound beams relative to the part surface is done electronically by phasing the elements in the array(s) to cover the expected surface as well as the full range of part surface variability.

<CIT>, in accordance with its abstract, states apparatus and methods for ultrasonic inspection of elongated composite members in a single scan pass using pulse echo phased arrays operating in a bubbler method. The system concept is automated by integrating an inspection probe assembly to a robot and using the robot to move the inspection probe assembly along the part; and by integrating tooling fixtures that move out of the way as the inspection probe assembly travels along the length of the part during the inspection. In addition, the system allows for generally elongated composite members having lengthwise variation in shape, curvature and dimensions.

<CIT>, in accordance with its abstract, states: an ultrasonic probe performs non-destructive inspection of a corner radius of a part. According to one embodiment, an ultrasonic probe includes an ultrasonic sensor array, and a shoe for holding the sensor array and moving the sensor array along the radius of the part. The shoe includes means for adjusting the sensor array so all ultrasonic beams from the sensor array have the same water path distance to a center of the radius, and for adjusting the sensor array so that all beams pass through the center of the radius.

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.

Aspects of the invention to which this patent application relates are set out in the independent claims. Optional features of aspects are set out in the dependent claims.

The described features, structures, advantages, and/or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more examples, including embodiments and/or implementations. In the following description, numerous specific details are provided to impart a thorough understanding of examples of the subject matter of the present disclosure. One skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and/or methods of a particular example, embodiment, or implementation. In other instances, additional features and advantages may be recognized in certain examples, embodiments, and/or implementations that may not be present in all examples, embodiments, or implementations. Further, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter.

In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be rendered by reference to specific examples that are illustrated in the appended drawings. Understanding that these drawings depict only typical examples of the subject matter, they are not therefore to be considered to be limiting of its scope, which is defined solely by the appended claims. The subject matter will be described and explained with additional specificity and detail through the use of the drawings, in which:.

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 to <FIG>, according to some examples, disclosed herein is an ultrasonic inspection system <NUM> for inspecting parts <NUM> using ultrasonic beams. The ultrasonic inspection system <NUM> includes a robot <NUM> and an end effector <NUM>. The robot <NUM> is an industrial robot that is automated, programmable, and capable of movement on three or more axis. The end effector <NUM> is coupled to and movable by the robot <NUM>. In certain examples, the end effector <NUM> is removably (e.g., releasably) coupled to the robot <NUM>. The end effector <NUM> includes an ultrasonic inspection probe <NUM> operable to generate ultrasonic beams. The end effector <NUM> additionally includes a compliance interface assembly <NUM>. The ultrasonic inspection probe <NUM> is coupled to the robot <NUM> via the compliance interface assembly <NUM>. The robot <NUM> is operable to move the end effector <NUM> relative to a part <NUM> being inspected such that, while the ultrasonic inspection probe <NUM> generates the ultrasonic beams, the ultrasonic inspection probe <NUM> rides along an exterior surface of the part <NUM> being inspected. As the ultrasonic inspection probe <NUM> rides along the exterior surface of the part <NUM>, the compliance interface assembly <NUM> is configured to provide compliance (e.g., flex or cushioning) for the ultrasonic inspection probe <NUM> and movement of the ultrasonic inspection probe <NUM> relative to the robot <NUM> in appropriate directions. For example, the compliance interface assembly <NUM> may include one or more springs to allow the ultrasonic inspection probe <NUM> to accommodate variations in the surface of the part <NUM> being inspected and a gimbal mechanism to allow the ultrasonic inspection probe <NUM> to swivel as the ultrasonic inspection probe <NUM> moves along undulations in the surface of the part <NUM> being inspected.

According to certain examples, as shown in <FIG>, the ultrasonic inspection probe <NUM> includes a probe body <NUM> and an interface plate <NUM>. In general, the ultrasonic inspection probe <NUM> is configured to inspect parts with an externally radiused surface, such as a rounded stiffener having an outside radius <NUM>. The interface plate <NUM> is removably attachable to the probe body <NUM>. In <FIG>, <FIG>, and <FIG>, the interface plate <NUM> is removably attached to the probe body <NUM>. The probe body <NUM> is directly attached to the compliance interface assembly <NUM>. In some examples, the probe body <NUM> is directly attached to the compliance interface assembly <NUM> in a substantially permanent, non-removable, manner. In other words, attaching the probe body <NUM> to and removing the probe body <NUM> from the compliance interface assembly <NUM> is more labor intensive and more complex than attaching the interface plate <NUM> to and removing the interface plate <NUM> from the probe body <NUM>. For this reason, for testing different parts each having a different shape, the ultrasonic inspection system <NUM> utilizes replacement of just the interface plate <NUM> rather than the entire ultrasonic inspection probe <NUM> or the entire end effector <NUM>.

The probe body <NUM> includes a plate attachment surface <NUM> and the interface plate <NUM> includes a body attachment surface <NUM>. The body attachment surface <NUM> is removably attachable to the plate attachment surface <NUM> to form an attachment interface <NUM> therebetween. In other words, the plate attachment surface <NUM> of the probe body <NUM> and the body attachment surface <NUM> of the interface plate <NUM> are configured to mate with each other to form the attachment interface <NUM>. Accordingly, a shape of the plate attachment surface <NUM> complements the shape of the body attachment surface <NUM>. In one example, the body attachment surface <NUM> of the interface plate <NUM> is configured to nestably engage the plate attachment surface <NUM> of the probe body <NUM>. In a certain example, the body attachment surface <NUM> seats flush against the plate attachment surface <NUM> when the interface plate <NUM> is removably attached to the probe body <NUM>. The plate attachment surface <NUM> and the body attachment surface <NUM> can have any of various shapes. In the illustrated example, the plate attachment surface <NUM> is a concave surface with a circular arc shape and the body attachment surface <NUM> is a convex surface with a circular arc shape. The concavity of the plate attachment surface <NUM> of the probe body <NUM> facilitates placement of an arc-shaped ultrasonic array <NUM> within the probe body <NUM>. However, in alternative examples, the plate attachment surface <NUM> and the body attachment surface <NUM> have a non-circular arc shape, have a non-flat non-arc shape, or are flat.

Removable attachment of the body attachment surface <NUM> to the plate attachment surface <NUM> is facilitated by one or more fasteners <NUM> in some examples. As shown in <FIG> and <FIG>, in one example, the ultrasonic inspection probe <NUM> includes multiple fasteners <NUM> (e.g., four fasteners <NUM>). The fasteners <NUM> are configured to extend through aligned holes in the probe body <NUM> and the interface plate <NUM>. More specifically, in the illustrated example, the probe body <NUM> includes holes <NUM> open to the plate attachment surface <NUM> and the interface plate <NUM> includes holes <NUM> extending entirely through the interface plate <NUM> and open to the body attachment surface <NUM>. Either the holes <NUM> or the holes <NUM> include internal threads for engaging external threads of the fasteners <NUM>. When the plate attachment surface <NUM> is mated to the body attachment surface <NUM>, each one of the holes <NUM> in the probe body <NUM> is aligned with a corresponding one of the holes <NUM> in the interface plate <NUM>. When aligned, a corresponding one of the fasteners <NUM> is extendable into the aligned holes to engage the threads of the threaded hole. In the illustrated example, the holes <NUM> of the probe body <NUM> include threads to engage the threads of the fasteners <NUM> after the fastener passes through the holes <NUM> of the interface plate <NUM>. Threadable engagement between the fasteners <NUM> and the threads of the holes <NUM> allow the fasteners <NUM> to be tightened to attach the interface plate <NUM> to the probe body <NUM> or be loosened to remove the interface plate <NUM> from the probe body <NUM>. 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 plate <NUM> to the probe body <NUM> can be used.

The probe body <NUM> includes and houses an ultrasonic array <NUM> (see, e.g., <FIG>, <FIG>, <FIG>, and <FIG>). The ultrasonic array <NUM> is non-movably fixed to the probe body <NUM> and includes a plurality of ultrasound elements <NUM>. In one example, each ultrasonic element <NUM> is operable to generate an ultrasonic beam <NUM>. The collection of ultrasonic beams <NUM> generated by the ultrasound elements <NUM> of the ultrasonic array <NUM> define an ultrasonic field <NUM>. In some examples, the ultrasound elements <NUM> are arranged in a side-by-side manner, such that one ultrasound element <NUM> is directly adjacent at least one other ultrasound element <NUM>.

The ultrasound elements <NUM> are arranged relative to each other into a particularly shaped formation to define a shape of the ultrasonic array <NUM>. The shape of the ultrasonic array <NUM> depends on the desired directionality of the ultrasonic beams <NUM> generated by the ultrasound elements <NUM> of the ultrasonic array <NUM> (see, e.g., <FIG>). Moreover, the directionality of a given ultrasonic beam <NUM> depends on the orientation of the ultrasonic element <NUM> that generated the ultrasonic beam <NUM>. In the illustrated example, the ultrasound elements <NUM> are arranged into a circular arc having a first radius r1. In other words, the ultrasonic array <NUM> has a circular-arc shape. The ultrasound elements <NUM>, being arranged in a circular arc, generate ultrasonic beams <NUM> that pass through the center <NUM> of the circular arc. In other words, every ultrasonic beam <NUM> generated by the ultrasonic array <NUM> passes through the center of the circular arc defined by the ultrasonic array <NUM>.

Referring to <FIG>, <FIG>, <FIG>, and <FIG>, the probe body <NUM> includes a body internal cavity <NUM>. The ultrasonic array <NUM> is fixedly positioned within the body internal cavity <NUM>. Accordingly, the body internal cavity <NUM> is shaped to fit the ultrasonic array <NUM> in the body internal cavity <NUM>. The body internal cavity <NUM> is open at the plate attachment surface <NUM>.

The probe body <NUM> additionally includes an aperture <NUM> open to the body internal cavity <NUM>. As shown in <FIG>, the aperture <NUM> allows a power-communications line <NUM> to be coupled to the ultrasonic array <NUM>. The power-communications line <NUM> extends through the aperture <NUM> from a location external to the probe body <NUM> (e.g., at a controller of the ultrasonic inspection system <NUM>), through the aperture <NUM>, and into power and/or communications coupling engagement with the ultrasonic array <NUM>.

With further reference to <FIG>, the probe body <NUM> also includes a first fluid supply line <NUM> formed in the probe body <NUM>. As shown in <FIG>, the first fluid supply line <NUM> extends through the probe body <NUM>. The first fluid supply line <NUM> is configured to receive fluid from a fluid source line <NUM>, which can be fluidly coupled to a fluid source external to the probe body <NUM>. The fluid source supplies a coupling fluid to the first supply line <NUM> via the fluid source line <NUM>. The coupling fluid is configured to provide a fluid medium between the ultrasonic array <NUM> and a surface of the part <NUM> being inspected, which helps propagate the ultrasonic beams <NUM> from the ultrasonic array <NUM> to the surface of the part <NUM>.

As shown in <FIG>, the interface plate <NUM> further includes a part inspection surface <NUM> on an opposite side of the interface plate <NUM> as the body attachment surface <NUM>. The part inspection surface <NUM> is fixed or is non-adjustable. Accordingly, the shape of the part inspection surface <NUM> is not flexible and cannot be changed in certain examples. The part inspection surface <NUM> is shaped to complement a shape of the part <NUM> being inspected. In other words, at least a portion of the part inspection surface <NUM> has substantially the same shape as the surface of the part <NUM> being inspected. In an example, the part inspection surface <NUM> is configured to interface with the part <NUM> being inspected. In this manner, the part inspection surface <NUM> is able to ride along the surface of the part <NUM> being inspected with little to no offset between the part inspection surface <NUM> and the surface of the part <NUM>. According to one example shown in <FIG>, the part <NUM> includes a convex circular-arc shaped external surface, having a second radius r2, along which the part inspection surface <NUM> rides while inspecting the part <NUM>. Accordingly, the part inspection surface <NUM> has a part-riding portion <NUM> with a concave circular-arc shape having the second radius r2. In some examples, as shown in <FIG> and <FIG>, the part inspection surface <NUM> may include clearance portions <NUM> that flank the part-riding portion <NUM>. The clearance portions <NUM> do not have the same shape as the part <NUM>. Instead, the clearance portions <NUM> are shaped to allow the ultrasonic inspection probe <NUM> to avoid interference with the part <NUM> as the ultrasonic inspection probe <NUM> is moved into riding position on the part <NUM>.

The part <NUM> shown in <FIG> is a hat stringer. However, the part <NUM> can be any of various parts having a similar convex circular-arc shaped external surface along which the part inspection surface <NUM> rides as the part <NUM> is inspected by the ultrasonic inspection probe <NUM>.

Referring to <FIG> and <FIG>, the interface plate <NUM> additionally includes a fluid reservoir pocket <NUM> formed in and open to both the body attachment surface <NUM> and the part inspection surface <NUM>. In other words, the fluid reservoir pocket <NUM> extends from the body attachment surface <NUM> to the part inspection surface <NUM>. When the interface plate <NUM> and the probe body <NUM> are removably attached, the fluid reservoir pocket <NUM> is open to the body internal cavity <NUM>. As shown in <FIG>, the interface plate <NUM> also includes at least one second fluid supply line (e.g., second fluid supply lines 172A-C) open to the fluid reservoir pocket <NUM>. In the illustrated example, the interface plate <NUM> includes three second fluid supply lines 172A-C. Each one of the three second fluid supply lines 172A-C is open to the fluid supply line <NUM> of the probe body <NUM> when the probe body <NUM> and the interface plate <NUM> are removably attached. Accordingly, fluid supplied to the fluid supply line <NUM> flows into the second fluid supply lines 172A-C and subsequently into the fluid reservoir pocket <NUM> and the body internal cavity <NUM>. The second fluid supply lines 172A-C are separated and spaced apart from each other such that fluid flowing from them into the fluid reservoir pocket <NUM> enters the fluid reservoir pocket <NUM> at spaced apart locations, thus promoting uniform filling of the fluid in the fluid reservoir pocket <NUM>. To allow fluid to flow into and out of the fluid reservoir pocket <NUM> during an inspection procedure, the interface plate <NUM> also includes one or more exit ports <NUM> (see, e.g., <FIG> and <FIG>) extending from the fluid reservoir pocket <NUM> to outside the interface plate <NUM>.

Now referring to <FIG>, in some examples, the second radius r2 of the part-riding portion <NUM> of the part inspection surface <NUM> is less than the first radius r1 of the ultrasonic array <NUM>. Moreover, a top-center location of the part inspection surface <NUM> of the interface plate <NUM> is a distance D1 away from a top-center location of the body attachment surface <NUM> of the interface plate <NUM>. The distance D1 is selected such that, when the interface plate <NUM> is removably attached to the probe body <NUM>, the ultrasonic array <NUM> is concentric or substantially concentric with the part-riding portion <NUM> of the part inspection surface <NUM> of the interface plate <NUM>. In other words, the circular arc defined by the ultrasonic array <NUM> and the circular arc of the part inspection surface <NUM> share or substantially share the same center <NUM>, from which the radii of the ultrasonic array <NUM> and the part inspection surface <NUM> are 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 array <NUM> is concentric or substantially concentric with the part-riding portion <NUM> of the part inspection surface <NUM> of the interface plate <NUM> and the ultrasonic beams <NUM> generated by the ultrasonic array <NUM> pass through the shared center <NUM>, when the part-riding portion <NUM> is riding on the circular-arc shaped portion of the part <NUM>, the ultrasonic beams <NUM> are normal or substantially normal to the surface of the part <NUM>. When the interface plate <NUM> is removably attached to the probe body <NUM>, the concentricity of the part inspection surface <NUM> and the ultrasonic array <NUM> allows each ultrasonic beam <NUM>, generated by the plurality of ultrasound elements <NUM>, to be normal or substantially normal to the part inspection surface <NUM> at an intersection of each ultrasonic beam <NUM> and the part inspection surface <NUM>. Accordingly, when the inspection surface <NUM> is riding on a circular-arc shaped surface of the part <NUM>, with the radius of the surface of the part <NUM> being substantially equal to the second radius r2 of the part inspection surface <NUM>, each ultrasonic beam <NUM> is normal to the surface of the part <NUM> at an intersection of each ultrasonic beam <NUM> and the surface of the part <NUM>. The ultrasonic beams <NUM> contacting and penetrating the part <NUM> at an angle normal to the surface of the part promotes accuracy, reliability, and an increase in the detectible range of anomalies within the part <NUM>. As used herein, substantially normal means within <NUM> degrees of normal.

Referring now to <FIG>, according to some examples, the ultrasonic inspection probe <NUM> includes the probe body <NUM> and a plurality of interface plates. The plurality of interface plates are interchangeably removably attachable to the probe body <NUM> to inspect differently-shaped parts <NUM>. Each one of the plurality of interface plates includes the same general features as the interface plate <NUM> described above, with like numbers referring to like features. However, each one of the plurality of interface plates has a differently shaped part inspection surface <NUM> than any other of the plurality of interface plates to complement the shape of a corresponding one of the differently-shaped parts <NUM>. For example, in the illustrated implementation, the ultrasonic inspection probe <NUM> includes a first interface plate 124A, a second interface plate 124B, and a third interface plate 124C. The circular-arc shaped part-riding portion <NUM> of the part inspection surface <NUM> of each one of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C are shaped to have the second radius r2, a third radius r3, and a fourth radius r4, respectively. The third radius r3 is greater than the second radius r2 and the fourth radius r4 is less than the second radius r2. The second radius r2 is substantially equal to the radius of a circular-arc shaped surface of a first one of the parts <NUM>, the third radius r3 is substantially equal to the radius of a circular-arc shaped surface of a second one of the parts <NUM>, and the fourth radius r4 is substantially equal to the radius of a circular-arc shaped surface of a second one of the parts <NUM>. 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 surfaces <NUM> of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C are differently shaped, the body attachment surfaces <NUM> of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C have the same shape. Accordingly, each of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C can be removably attached to and removed from the plate attachment surface <NUM> of the probe body <NUM> in the same manner, as described below with reference to the method <NUM>. In this manner, the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C are interchangeably removably attachable to the probe body <NUM>.

When any one of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C is removably attached to the probe body <NUM>, each ultrasonic beam <NUM> generated by the plurality of ultrasound elements <NUM> is normal to the part inspection surface <NUM> of the corresponding one of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C at an intersection of each ultrasonic beam <NUM> and the part inspection surface. Because the first radius r1 of the ultrasonic array <NUM> and the body attachment surfaces <NUM> of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C are fixed, and the second radius r2, the third radius r3, and the fourth radius r4 are different, to maintain concentricity between the part inspection surfaces <NUM> of the ultrasonic array <NUM> and the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C when attached to the probe body <NUM>, the distances between part inspection surfaces <NUM> and the body attachment surfaces <NUM> of the first interface plate 124A, the second interface plate 124B, and the third interface plate 124C are different. For example, the distance D1 between the top-center locations of the body attachment surface <NUM> and the part inspection surface <NUM> of the first interface plate 124A is more than the distance D2 between the top-center locations of the body attachment surface <NUM> and the part inspection surface <NUM> of the second interface plate 124B. Likewise, the distance D3 between the top-center locations of the body attachment surface <NUM> and the part inspection surface <NUM> of the third interface plate 124C is more than the distance D1 between the top-center locations of the body attachment surface <NUM> and the part inspection surface <NUM> of the first interface plate 124A.

Although, in the illustrated example, the ultrasonic inspection probe <NUM> includes three interchangeable interface plates, in other examples, the ultrasonic inspection probe <NUM> includes two or at least four interchangeable interface plates. The probe body <NUM> and the interface plate <NUM> can be made of any of various materials. For example, in certain implementations, either one or both of the probe body <NUM> and the interface plate <NUM> is made of a polymeric material. In certain examples, the interface plate <NUM> has a one-piece, monolithic, construction.

Referring now to <FIG>, according to alternative examples, an ultrasonic inspection probe <NUM> is shown. The ultrasonic inspection probe <NUM> is configured to provide features and functionality at least similar to the ultrasonic inspection probe <NUM> shown and described previously. Accordingly, unless otherwise indicated, like numbers between the ultrasonic inspection probe <NUM> and the ultrasonic inspection probe <NUM> refer to like features. The descriptions of the like features in the ultrasonic inspection probe <NUM> provided above apply to the like features in the ultrasonic inspection probe <NUM> unless otherwise noted. Like the ultrasonic inspection probe <NUM>, the ultrasonic inspection probe <NUM> can form part of the end effector <NUM> of the ultrasonic inspection system <NUM> of <FIG>. For example, the ultrasonic inspection probe <NUM> can be coupled to the robot <NUM> via the compliance interface assembly <NUM>.

In general, instead of being configured to inspect an externally radiused surface, like the ultrasonic inspection probe <NUM>, the ultrasonic inspection probe <NUM> is configured to inspect a part <NUM> with an internally radiused surface, such as a flanged component. Referring to <FIG>, in one example, the part <NUM> includes an internal or inside radius <NUM>, which has a sixth radius r6 and can be inspected using the ultrasonic inspection probe <NUM> as shown.

Referring to <FIG>, according to the illustrated examples, the ultrasonic inspection probe <NUM> includes a probe body <NUM> and an interface plate <NUM>. The interface plate <NUM> is removably attachable to the probe body <NUM>. In <FIG>, <FIG>, and <FIG>, the interface plate <NUM> is removably attached to the probe body <NUM>, which can be directly attached to the compliance interface assembly <NUM> as described above. In the same manner at the ultrasonic inspection probe <NUM>, for testing different parts each having a different shape, the ultrasonic inspection system <NUM> can utilize replacement of just the interface plate <NUM> rather than the entire ultrasonic inspection probe <NUM> or the entire end effector <NUM>.

The probe body <NUM> includes a first plate attachment surface 240A, a second plate attachment surface 240B, and a third plate attachment surface 240C. The first plate attachment surface 240A and the second plate attachment surface 240B are spaced apart from each other and the third plate attachment surface 240C is interposed between the first plate attachment surface 240A and the second plate attachment surface 240B. Correspondingly, the interface plate <NUM> includes a first body attachment surface 241A, a second body attachment surface 241B, and a third body attachment surface 241C (see, e.g., <FIG>). The first body attachment surface 241A is removably attachable to the first plate attachment surface 240A, the second body attachment surface 241B is removably attachable to the second plate attachment surface 240B, and the third body attachment surface 241C is removably attachable to the third plate attachment surface 240C. In other words, the first body attachment surface 241A and the first plate attachment surface 240A are configured to mate with each other, the second body attachment surface 241B and the second plate attachment surface 240B are configured to mate with each other, and the third body attachment surface 241C and the third plate attachment surface 240C are configured to mate with each other. Accordingly, a shape of the first plate attachment surface 240A complements the shape of the first body attachment surface 241A, a shape of the second plate attachment surface 240B complements the shape of the second body attachment surface 241B, and a shape of the third plate attachment surface 240C complements the shape of the third body attachment surface 241C.

In one example, the first body attachment surface 241A and the second body attachment surface 241B of the interface plate <NUM> are flat surfaces configured to seat flush against flat surfaces of the first plate attachment surface 240A and the second plate attachment surface 240B, respectively. The first body attachment surface 241A and the second body attachment surface 241B are angled relative to each other. Correspondingly, the first plate attachment surface 240A and the second plate attachment surface 240B are angled relative to each other. The angled surfaces help to secure and support the interface plate <NUM> in a proper position relative to the probe body <NUM>. The third body attachment surface 241C and the third plate attachment surface 240C are curved (e.g., non-flat) in some examples to facilitate nestable engagement between the third body attachment surface 241C and the third plate attachment surface 240C. The attachment surfaces of the ultrasonic inspection probe <NUM> can have shapes, other than those described above, in alternative examples.

Removable attachment of the first plate attachment surface 240A, the second plate attachment surface 240B, and the third plate attachment surface 240C to the first body attachment surface 241A, the second body attachment surface 241B, and the third body attachment surface 241C is facilitated by at least one fastener <NUM> in some examples. As shown in <FIG>, in one example, the ultrasonic inspection probe <NUM> includes a single fastener <NUM> (i.e., only one fastener). The fastener <NUM> is configured to extend through aligned holes in the probe body <NUM> and the interface plate <NUM>. More specifically, in the illustrated example, the probe body <NUM> includes a hole <NUM> and the interface plate <NUM> includes a hole <NUM> extending entirely through the interface plate <NUM>. Either the hole <NUM> or the hole <NUM> includes internal threads for engaging external threads of the fastener <NUM>.

When the plate attachment surfaces of the probe body <NUM> are mated to the corresponding body attachment surfaces of the interface plate <NUM>, the hole <NUM> in the probe body <NUM> is aligned with the hole <NUM> in the interface plate <NUM>. When aligned, the fastener <NUM> is extendable into the aligned holes to engage the threads of the threaded hole. In the illustrated example, the hole <NUM> of the probe body <NUM> include threads to engage the threads of the fastener <NUM> after the fastener passes through the hole <NUM> of the interface plate <NUM>. Threadable engagement between the fastener <NUM> and the threads of the hole <NUM> allow the fastener <NUM> to be tightened to attach the interface plate <NUM> to the probe body <NUM> or be loosened to remove the interface plate <NUM> from the probe body <NUM>. 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 plate <NUM> to the probe body <NUM> can be used.

The probe body <NUM> includes and houses an ultrasonic array <NUM> (see, e.g., <FIG>). The ultrasonic array <NUM> is non-movably fixed to the probe body <NUM> and includes a plurality of ultrasound elements <NUM>. The ultrasonic array <NUM> is configured and operable in the same manner as the ultrasonic array <NUM>. Similar to the ultrasonic array <NUM>, the ultrasound elements <NUM> of the ultrasonic array <NUM> are arranged into a circular arc having a fifth radius r5 such that ultrasonic beams <NUM>, generated by the ultrasonic array <NUM>, pass through a center <NUM> of the circular arc defined by the ultrasonic array <NUM>. In other words, every ultrasonic beam <NUM> generated by the ultrasonic array <NUM> passes through the center <NUM> of the circular arc defined by the ultrasonic array <NUM>. The collection of ultrasonic beams <NUM> generated by the ultrasound elements <NUM> of the ultrasonic array <NUM> define an ultrasonic field <NUM>.

In an example, the probe body <NUM> includes a body internal cavity formed in an array receiving surface <NUM> of the probe body <NUM>. The ultrasonic array <NUM> is fixed within the body internal cavity, which can be shaped to fit the ultrasonic array <NUM> therein. The body internal cavity can be open at the array receiving surface <NUM>.

The probe body <NUM> additionally includes an aperture open to the body internal cavity. This aperture allows a power-communications line <NUM> to be coupled to the ultrasonic array <NUM>. The power-communications line <NUM> extends through the aperture from a location external to the probe body <NUM> (e.g., at a controller of the ultrasonic inspection system <NUM>), through the aperture, and into power and/or communications coupling engagement with the ultrasonic array <NUM>.

As shown in <FIG>, the interface plate <NUM> further includes a first part inspection surface <NUM> and a second part inspection surface <NUM>. The first part inspection surface <NUM> and the second part inspection surface <NUM> are configured to engage (e.g., ride on) respective surfaces of the part <NUM>. Accordingly, the shape of the first part inspection surface <NUM> and the second part inspection surface <NUM> correspond with the shape of the surfaces of the part <NUM>. In the illustrated example, at least a portion of both of the first part inspection surface <NUM> and the second part inspection surface <NUM> are flat to engage corresponding flat surfaces of the part <NUM>.

The first part inspection surface <NUM> and the second part inspection surface <NUM> are spaced apart from each other, which allows the ultrasonic array <NUM> to be interposed between the first part inspection surface <NUM> and the second part inspection surface <NUM>. As shown in <FIG>, the first part inspection surface <NUM> and the second part inspection surface <NUM> are angled relative to each other such that a first angle θ1 is defined between the first part inspection surface <NUM> and the second part inspection surface <NUM>. The first angle θ1 corresponds (e.g., is the same as) an angle defined between the two surfaces of the part <NUM> that converge to define the inside radius <NUM>. In the illustrated example, the first angle θ1 is about <NUM>-degrees. The first part inspection surface <NUM> and the second part inspection surface <NUM> engage a respective one of the surfaces of the part <NUM> that converge to define the inside radius <NUM>.

The first part inspection surface <NUM> and the second part inspection surface <NUM> are further configured to align the center <NUM> of the ultrasonic array <NUM> with a center of the inside radius <NUM> when the first part inspection surface <NUM> and the second part inspection surface <NUM> engage the respective surfaces of the part <NUM>. In other words, when the first part inspection surface <NUM> and the second part inspection surface <NUM> engage the respective surfaces of the part <NUM>, the inside radius <NUM> of the part <NUM> is concentric with the circular arc defined by the plurality of ultrasound elements <NUM> of the ultrasonic array <NUM>. Accordingly, the size, shape, and/or relative first angle θ1 of the first part inspection surface <NUM> and the second part inspection surface <NUM> is dependent on the size, shape, and/or relative angle of the respective surfaces of the part <NUM>, as well as the radius of the inside radius <NUM> of the part. As shown in <FIG>, the inside radius <NUM> has a sixth radius r6 with a center common with the center <NUM> of the circular arc of the ultrasonic array <NUM> when the first part inspection surface <NUM> and the second part inspection surface <NUM> are properly engaged with the part <NUM>. Because the first part inspection surface <NUM> and the second part inspection surface <NUM> ensure the ultrasonic array <NUM> and the inside radius <NUM> are concentric with each other, they also ensure the ultrasonic beams <NUM> generated by the ultrasonic array <NUM> pass through the shared center <NUM> and thus are normal to the surface of the inside radius <NUM> of the part <NUM>.

Referring now to <FIG>, according to some examples, the ultrasonic inspection probe <NUM> includes the probe body <NUM> and a plurality of interface plates. The plurality of interface plates are interchangeably removably attachable to the probe body <NUM> to inspect differently-shaped parts <NUM> (e.g., differently sized inside radii). Each one of the plurality of interface plates includes the same general features as the interface plate <NUM> described above, with like numbers referring to like features. However, each one of the plurality of interface plates has a differently configured first part inspection surface <NUM> and second part inspection surface <NUM> than any other of the plurality of interface plates to complement a shape of a corresponding one of the differently-shaped parts <NUM>. For example, in the illustrated implementation, the ultrasonic inspection probe <NUM> includes a first interface plate 224A, a second interface plate 224B, and a third interface plate 224C. The first part inspection surfaces <NUM> and the second part inspection surfaces <NUM> of each one of the first interface plate 224A, the second interface plate 224B, and the third interface plate 224C are configured to define, between the surfaces, a first angle θ1, a second angle θ2, and a third angle θ2, respectively. The second angle θ2 is greater than the first angle θ1 and the third angle θ3 is less than the first angle θ1, but the radius r5 of the ultrasonic array <NUM> is the same. According to some examples, the sixth radius r6 of the inside radius <NUM> of the part <NUM> for which the first interface plate 224A is configured to inspect can be smaller than the sixth radius r6 of the inside radius <NUM> of the part <NUM> for which the second interface plate 224B is configured to inspect. Likewise, in the same examples, the sixth radius r6 of the inside radius <NUM> of the part <NUM> for which the first interface plate 224A is configured to inspect can be greater than the sixth radius r6 of the inside radius <NUM> of the part <NUM> for which the third interface plate 224C is configured to inspect.

While the first part inspection surfaces <NUM> and the second part inspection surfaces <NUM> of the first interface plate 224A, the second interface plate 224B, and the third interface plate 224C are differently shaped, the first body attachment surfaces 241A, the second body attachment surfaces 241B, and the third body attachment surfaces 241C of the first interface plate 224A, the second interface plate 224B, and the third interface plate 224C have the same shape. Accordingly, each of the first interface plate 224A, the second interface plate 224B, and the third interface plate 224C can be removably attached to and removed from the probe body <NUM> in the same manner, as described below with reference to the method <NUM>. In this manner, the first interface plate 224A, the second interface plate 224B, and the third interface plate 224C are interchangeably removably attachable to the probe body <NUM>.

As shown in <FIG>, according to certain examples, the method <NUM> of inspecting parts, such as parts each having a differently-shaped surface to be inspected, includes (block <NUM>) removably attaching a first interface plate 124A to a probe body <NUM>. The method <NUM> also includes (block <NUM>) riding a first part inspection surface <NUM> of the first interface plate 124A along a first one of the parts <NUM>. The method <NUM> additionally includes (block <NUM>) directing ultrasonic beams <NUM>, generated from an ultrasonic array <NUM> of the probe body <NUM> and fixed relative to the probe body <NUM>, toward the first one of the parts while riding the first part inspection surface <NUM> of the first interface plate 124A along the first one of the parts <NUM>.

In some examples of the method <NUM>, the method <NUM> further includes (block <NUM>) removing the first interface plate 124A from the probe body <NUM> and (block <NUM>) removably attaching a second interface plate 124B to the probe body <NUM> in place of the first interface plate 124A. The method <NUM> also includes (block <NUM>) riding a second part inspection surface <NUM> of the second interface plate 124B along a second one of the parts <NUM>. The method <NUM> additionally includes (block <NUM>) directing ultrasonic beams <NUM>, generated from the ultrasonic array <NUM> of the probe body <NUM>, toward the second one of the parts <NUM> while riding the second part inspection surface <NUM> of the second interface plate 124B along the second one of the parts <NUM>.

According to some examples, the method <NUM> is executed using the ultrasonic inspection system <NUM>, including the robot <NUM> and the end effector <NUM>. For example, the robot <NUM> can 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 system <NUM> additionally 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 method <NUM> of inspecting parts is fully automated. For example, the robot <NUM> can 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 robot <NUM> and the plate exchange system.

In the above description, certain terms may be used such as "up," "down," "upper," "lower," "horizontal," "vertical," "left," "right," "over," "under" and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an "upper" surface can become a "lower" surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms "including," "comprising," "having," and variations thereof mean "including but not limited to" unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. Further, the term "plurality" can be defined as "at least two.

Additionally, instances in this specification where one element is "coupled" to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, "adjacent" does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.

As used herein, the phrase "at least one of", when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, "at least one of" means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, "at least one of item A, item B, and item C" may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, "at least one of item A, item B, and item C" may mean, 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 some other suitable combination.

Claim 1:
An ultrasonic inspection probe (<NUM>) for inspecting parts (<NUM>), the ultrasonic inspection probe (<NUM>) comprising:
a probe body (<NUM>), comprising an ultrasonic array (<NUM>) and a plate attachment surface (<NUM>), wherein: the ultrasonic array (<NUM>) comprises a plurality of ultrasound elements (<NUM>) arranged in a first circular arc having a first radius (r1); each of the ultrasound elements (<NUM>) is selectively operable to generate an ultrasonic beam (<NUM>); and each of the ultrasound elements (<NUM>) is fixed relative to the plate attachment surface (<NUM>); and
an interface plate (<NUM>), comprising a body attachment surface (<NUM>), removably attachable to the plate attachment surface (<NUM>) of the probe body (<NUM>), and a part inspection surface (<NUM>), shaped to complement a shape of one of the parts (<NUM>), and wherein, when the body attachment surface (<NUM>) of the interface plate (<NUM>) is removably attached to the plate attachment surface (<NUM>) of the probe body (<NUM>), each ultrasonic beam (<NUM>) generated by the plurality of ultrasound elements (<NUM>) is substantially normal to the part inspection surface (<NUM>) at an intersection of each ultrasonic beam (<NUM>) and the part inspection surface (<NUM>);
wherein the part inspection surface (<NUM>) defines a second circular arc having a second radius (r2), the second radius (r2) is smaller than the first radius (r1), and the first circular arc and the second circular arc are substantially concentric when the body attachment surface (<NUM>) of the interface plate (<NUM>) is removably attached to the plate attachment surface (<NUM>) of the probe body (<NUM>).