Automated full matrix capture for industrial processes

Roy H. Brown, S. Gareth Pierce, Ian Collison, Ben Dutton, Jerzy Dziewierz, Joseph Jackson, Timothy Lardner, Charles MacLeod, Maxim Morozov

Research output: Chapter in Book/Report/Conference proceedingConference contribution book

1 Citation (Scopus)

Abstract

Full matrix capture (FMC) ultrasound can be used to generate a permanent re-focusable record of data describing the geometry of a part; a valuable asset for an inspection process. FMC is a desirable acquisition mode for automated scanning of complex geometries, as it allows compensation for surface shape in post processing and application of the total focusing method. However, automating the delivery of such FMC inspection remains a significant challenge for real industrial processes due to the high data overhead associated with the ultrasonic acquisition. The benefits of NDE delivery using six-axis industrial robots are well versed when considering complex inspection geometries, but such an approach brings additional challenges to scanning speed and positional accuracy when combined with FMC inspection. This study outlines steps taken to optimize the scanning speed and data management of a process to scan the diffusion bonded membrane of a titanium test plate. A system combining a KUKA robotic arm and a reconfigurable FMC phased array controller is presented. The speed and data implications of different scanning methods are compared, and the impacts on data visualization quality are discussed with reference to this study. For the 0.5 m2 sample considered, typical acquisitions of 18 TB/m2 were measured for a triple back wall FMC acquisition, illustrating the challenge of combining high data throughput with acceptable scanning speeds.
LanguageEnglish
Title of host publication41st Annual Review of Progress in Quantitative Nondestructive Evaluation
Subtitle of host publicationVolume 34
EditorsDale E. Chimenti, Leonard J. Bond
Pages1967-1976
Number of pages10
Volume1650
DOIs
Publication statusPublished - 31 Mar 2015

Fingerprint

Scanning
Inspection
Geometry
Ultrasonics
Robotic arms
Data visualization
Industrial robots
Information management
Titanium
Throughput
Membranes
Controllers
Processing

Keywords

  • industrial processes
  • robotics
  • antenna arrays
  • data managment
  • industrial inspection

Cite this

Brown, R. H., Pierce, S. G., Collison, I., Dutton, B., Dziewierz, J., Jackson, J., ... Morozov, M. (2015). Automated full matrix capture for industrial processes. In D. E. Chimenti, & L. J. Bond (Eds.), 41st Annual Review of Progress in Quantitative Nondestructive Evaluation: Volume 34 (Vol. 1650, pp. 1967-1976) https://doi.org/10.1063/1.4914824
Brown, Roy H. ; Pierce, S. Gareth ; Collison, Ian ; Dutton, Ben ; Dziewierz, Jerzy ; Jackson, Joseph ; Lardner, Timothy ; MacLeod, Charles ; Morozov, Maxim. / Automated full matrix capture for industrial processes. 41st Annual Review of Progress in Quantitative Nondestructive Evaluation: Volume 34. editor / Dale E. Chimenti ; Leonard J. Bond. Vol. 1650 2015. pp. 1967-1976
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Brown, RH, Pierce, SG, Collison, I, Dutton, B, Dziewierz, J, Jackson, J, Lardner, T, MacLeod, C & Morozov, M 2015, Automated full matrix capture for industrial processes. in DE Chimenti & LJ Bond (eds), 41st Annual Review of Progress in Quantitative Nondestructive Evaluation: Volume 34. vol. 1650, pp. 1967-1976. https://doi.org/10.1063/1.4914824

Automated full matrix capture for industrial processes. / Brown, Roy H.; Pierce, S. Gareth; Collison, Ian; Dutton, Ben; Dziewierz, Jerzy; Jackson, Joseph; Lardner, Timothy; MacLeod, Charles; Morozov, Maxim.

41st Annual Review of Progress in Quantitative Nondestructive Evaluation: Volume 34. ed. / Dale E. Chimenti; Leonard J. Bond. Vol. 1650 2015. p. 1967-1976.

Research output: Chapter in Book/Report/Conference proceedingConference contribution book

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AB - Full matrix capture (FMC) ultrasound can be used to generate a permanent re-focusable record of data describing the geometry of a part; a valuable asset for an inspection process. FMC is a desirable acquisition mode for automated scanning of complex geometries, as it allows compensation for surface shape in post processing and application of the total focusing method. However, automating the delivery of such FMC inspection remains a significant challenge for real industrial processes due to the high data overhead associated with the ultrasonic acquisition. The benefits of NDE delivery using six-axis industrial robots are well versed when considering complex inspection geometries, but such an approach brings additional challenges to scanning speed and positional accuracy when combined with FMC inspection. This study outlines steps taken to optimize the scanning speed and data management of a process to scan the diffusion bonded membrane of a titanium test plate. A system combining a KUKA robotic arm and a reconfigurable FMC phased array controller is presented. The speed and data implications of different scanning methods are compared, and the impacts on data visualization quality are discussed with reference to this study. For the 0.5 m2 sample considered, typical acquisitions of 18 TB/m2 were measured for a triple back wall FMC acquisition, illustrating the challenge of combining high data throughput with acceptable scanning speeds.

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Brown RH, Pierce SG, Collison I, Dutton B, Dziewierz J, Jackson J et al. Automated full matrix capture for industrial processes. In Chimenti DE, Bond LJ, editors, 41st Annual Review of Progress in Quantitative Nondestructive Evaluation: Volume 34. Vol. 1650. 2015. p. 1967-1976 https://doi.org/10.1063/1.4914824