Efficient data acquisition and reconstruction for air-coupled ultrasonic robotic NDE

Abstract Non-destructive evaluation of complex parts using surface scanning techniques, such as ultrasonic testing and eddy current testing, requires complex manipulation of such sensors to ensure quantitative results. A robotic arm may function as a complex manipulator for surface scanning, controlling the position and tilt between the probe and specimen’s surface. To ensure accuracy in probe manipulation, accurate geometric information of the specimen is required. This article explores a methodology that uses structured light for physical-to-virtual reconstruction, providing submillimeter scale and accurate surface geometries. Reconstruction aids in path planning through a novel ray-triangle intersection array algorithm, establishing movements for the NDE probe to orient itself on the specimen at a constant probe to specimen surface distance, or lift-off. The proposed technique is demonstrated and validated through experimental air-coupled ultrasonic inspection of automotive CFRP composite samples with simulated flaws such as interlaminar delamination. The proposed method employs guided waves and a pitch-catch configuration of air-coupled ultrasonic probes, enabling single-side access scans. A Fanuc 100ib robot arm was used to manipulate the ultrasonic probes along a sample reconstructed with a CR-Scan 01 structured light sensor. The probes were excited at 200khz from a SonoAir system, while also recovering defect vs background information synchronized with the probe’s orientation. Additionally, a framework for potential automation is proposed, with further details to be explored in future works.