Flexible integration of robotics, ultrasonics and metrology for the inspection of aerospace components

Carmelo Mineo, Charles MacLeod, Maxim Morozov, S. Gareth Pierce, Rahul Summan, Tony Rodden, Danial Kahani, Jonathan Powell, Paul McCubbin, Coreen McCubbin, Gavin Munro, Scott Paton, David Watson

Research output: Contribution to conferencePaper

Abstract

The performance of modern robotic manipulators has allowed research in recent years, for the development of fast automated non-destructive testing (NDT) of complex geometries. Contemporary robots are well suited for their accuracy and flexibility when adapting to new tasks. Several robotic inspection prototype systems and a number of commercial products have been created around the world. This paper describes the latest progress of a new phase of the research applied to a composite aerospace component of size 1 by 3 metres. A multi robot flexible inspection cell was used to take the fundamental research and the feasibility studies to higher technology readiness levels, all set for future industrial exploitation. The robot cell was equipped with high accuracy and high payload robots, mounted on 7 metre tracks, and an external rotary axis. A robotically delivered photogrammetry technique was first used to assess the position of the components placed within the robot working envelope and their deviation to CAD. Offline programming was used to generate a scan path for phased array ultrasonics testing (PAUT) which was implemented using high data rate acquisition from a conformable wheel probe. Real-time robot path-correction, based on force-torque control (FTC), was deployed to achieve the optimum ultrasonic coupling and repeatable data quality. New communication software was developed that enabled the simultaneous control of the multiple robots performing different tasks and the reception of accurate positional feedback positions. All aspects of the system were controlled through a purposely developed graphic user interface that enabled the flexible use of the unique set of hardware resources, the data acquisition, visualisation and analysis. This work was developed through the VIEWS project (Validation and Integration of Manufacturing Enablers for Future Wing Structures), part funded by the UK’s innovation agency (Innovate UK).

Conference

Conference43rd Review in Quantitative Nondestructive Evaluation
Abbreviated titleQNDE 2016
CountryUnited States
CityAtlanta
Period17/07/1622/07/16
Internet address

Fingerprint

Robotics
Inspection
Ultrasonics
Robots
Ultrasonic testing
Photogrammetry
Torque control
Force control
Computer programming
Nondestructive examination
User interfaces
Manipulators
Data acquisition
Computer aided design
Wheels
Visualization
Innovation
Feedback
Hardware
Geometry

Keywords

  • non-destructive testing
  • NDT
  • phased array ultrasonic testing
  • PAUT
  • force-torque control
  • FTC
  • robot control

Cite this

Mineo, C., MacLeod, C., Morozov, M., Pierce, S. G., Summan, R., Rodden, T., ... Watson, D. (Accepted/In press). Flexible integration of robotics, ultrasonics and metrology for the inspection of aerospace components. Paper presented at 43rd Review in Quantitative Nondestructive Evaluation, Atlanta, United States.
Mineo, Carmelo ; MacLeod, Charles ; Morozov, Maxim ; Pierce, S. Gareth ; Summan, Rahul ; Rodden, Tony ; Kahani, Danial ; Powell, Jonathan ; McCubbin, Paul ; McCubbin, Coreen ; Munro, Gavin ; Paton, Scott ; Watson, David. / Flexible integration of robotics, ultrasonics and metrology for the inspection of aerospace components. Paper presented at 43rd Review in Quantitative Nondestructive Evaluation, Atlanta, United States.
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abstract = "The performance of modern robotic manipulators has allowed research in recent years, for the development of fast automated non-destructive testing (NDT) of complex geometries. Contemporary robots are well suited for their accuracy and flexibility when adapting to new tasks. Several robotic inspection prototype systems and a number of commercial products have been created around the world. This paper describes the latest progress of a new phase of the research applied to a composite aerospace component of size 1 by 3 metres. A multi robot flexible inspection cell was used to take the fundamental research and the feasibility studies to higher technology readiness levels, all set for future industrial exploitation. The robot cell was equipped with high accuracy and high payload robots, mounted on 7 metre tracks, and an external rotary axis. A robotically delivered photogrammetry technique was first used to assess the position of the components placed within the robot working envelope and their deviation to CAD. Offline programming was used to generate a scan path for phased array ultrasonics testing (PAUT) which was implemented using high data rate acquisition from a conformable wheel probe. Real-time robot path-correction, based on force-torque control (FTC), was deployed to achieve the optimum ultrasonic coupling and repeatable data quality. New communication software was developed that enabled the simultaneous control of the multiple robots performing different tasks and the reception of accurate positional feedback positions. All aspects of the system were controlled through a purposely developed graphic user interface that enabled the flexible use of the unique set of hardware resources, the data acquisition, visualisation and analysis. This work was developed through the VIEWS project (Validation and Integration of Manufacturing Enablers for Future Wing Structures), part funded by the UK’s innovation agency (Innovate UK).",
keywords = "non-destructive testing, NDT, phased array ultrasonic testing, PAUT, force-torque control , FTC, robot control",
author = "Carmelo Mineo and Charles MacLeod and Maxim Morozov and Pierce, {S. Gareth} and Rahul Summan and Tony Rodden and Danial Kahani and Jonathan Powell and Paul McCubbin and Coreen McCubbin and Gavin Munro and Scott Paton and David Watson",
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Mineo, C, MacLeod, C, Morozov, M, Pierce, SG, Summan, R, Rodden, T, Kahani, D, Powell, J, McCubbin, P, McCubbin, C, Munro, G, Paton, S & Watson, D 2016, 'Flexible integration of robotics, ultrasonics and metrology for the inspection of aerospace components' Paper presented at 43rd Review in Quantitative Nondestructive Evaluation, Atlanta, United States, 17/07/16 - 22/07/16, .

Flexible integration of robotics, ultrasonics and metrology for the inspection of aerospace components. / Mineo, Carmelo; MacLeod, Charles; Morozov, Maxim; Pierce, S. Gareth; Summan, Rahul; Rodden, Tony; Kahani, Danial; Powell, Jonathan; McCubbin, Paul; McCubbin, Coreen; Munro, Gavin; Paton, Scott; Watson, David.

2016. Paper presented at 43rd Review in Quantitative Nondestructive Evaluation, Atlanta, United States.

Research output: Contribution to conferencePaper

TY - CONF

T1 - Flexible integration of robotics, ultrasonics and metrology for the inspection of aerospace components

AU - Mineo, Carmelo

AU - MacLeod, Charles

AU - Morozov, Maxim

AU - Pierce, S. Gareth

AU - Summan, Rahul

AU - Rodden, Tony

AU - Kahani, Danial

AU - Powell, Jonathan

AU - McCubbin, Paul

AU - McCubbin, Coreen

AU - Munro, Gavin

AU - Paton, Scott

AU - Watson, David

PY - 2016/5/16

Y1 - 2016/5/16

N2 - The performance of modern robotic manipulators has allowed research in recent years, for the development of fast automated non-destructive testing (NDT) of complex geometries. Contemporary robots are well suited for their accuracy and flexibility when adapting to new tasks. Several robotic inspection prototype systems and a number of commercial products have been created around the world. This paper describes the latest progress of a new phase of the research applied to a composite aerospace component of size 1 by 3 metres. A multi robot flexible inspection cell was used to take the fundamental research and the feasibility studies to higher technology readiness levels, all set for future industrial exploitation. The robot cell was equipped with high accuracy and high payload robots, mounted on 7 metre tracks, and an external rotary axis. A robotically delivered photogrammetry technique was first used to assess the position of the components placed within the robot working envelope and their deviation to CAD. Offline programming was used to generate a scan path for phased array ultrasonics testing (PAUT) which was implemented using high data rate acquisition from a conformable wheel probe. Real-time robot path-correction, based on force-torque control (FTC), was deployed to achieve the optimum ultrasonic coupling and repeatable data quality. New communication software was developed that enabled the simultaneous control of the multiple robots performing different tasks and the reception of accurate positional feedback positions. All aspects of the system were controlled through a purposely developed graphic user interface that enabled the flexible use of the unique set of hardware resources, the data acquisition, visualisation and analysis. This work was developed through the VIEWS project (Validation and Integration of Manufacturing Enablers for Future Wing Structures), part funded by the UK’s innovation agency (Innovate UK).

AB - The performance of modern robotic manipulators has allowed research in recent years, for the development of fast automated non-destructive testing (NDT) of complex geometries. Contemporary robots are well suited for their accuracy and flexibility when adapting to new tasks. Several robotic inspection prototype systems and a number of commercial products have been created around the world. This paper describes the latest progress of a new phase of the research applied to a composite aerospace component of size 1 by 3 metres. A multi robot flexible inspection cell was used to take the fundamental research and the feasibility studies to higher technology readiness levels, all set for future industrial exploitation. The robot cell was equipped with high accuracy and high payload robots, mounted on 7 metre tracks, and an external rotary axis. A robotically delivered photogrammetry technique was first used to assess the position of the components placed within the robot working envelope and their deviation to CAD. Offline programming was used to generate a scan path for phased array ultrasonics testing (PAUT) which was implemented using high data rate acquisition from a conformable wheel probe. Real-time robot path-correction, based on force-torque control (FTC), was deployed to achieve the optimum ultrasonic coupling and repeatable data quality. New communication software was developed that enabled the simultaneous control of the multiple robots performing different tasks and the reception of accurate positional feedback positions. All aspects of the system were controlled through a purposely developed graphic user interface that enabled the flexible use of the unique set of hardware resources, the data acquisition, visualisation and analysis. This work was developed through the VIEWS project (Validation and Integration of Manufacturing Enablers for Future Wing Structures), part funded by the UK’s innovation agency (Innovate UK).

KW - non-destructive testing

KW - NDT

KW - phased array ultrasonic testing

KW - PAUT

KW - force-torque control

KW - FTC

KW - robot control

UR - https://www.qndeprograms.org/

M3 - Paper

ER -

Mineo C, MacLeod C, Morozov M, Pierce SG, Summan R, Rodden T et al. Flexible integration of robotics, ultrasonics and metrology for the inspection of aerospace components. 2016. Paper presented at 43rd Review in Quantitative Nondestructive Evaluation, Atlanta, United States.