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An apparatus for inspecting samples that may include a curvature that varies from sample to sample comprises a scanning element, a feed mechanism, and a pivot mechanism. The scanning element transmits and receives a signal to and from the sample as the sample passes by, thereby building an image or profile of the sample. The feed mechanism includes a drive motor coupled to a series of pulleys and belts that form an open-ended chain. The pulleys rotate when driven by the drive motor and are coupled to an array of rollers that rotate as well to propel a inspection sample past the scanning element. The pivot mechanism includes a series of primary and secondary links that also form an open-ended chain. The primary links are coupled to the rollers and the combination pivots in unison to form an arc that matches the curvature of the sample in order to maintain a fixed distance between the sample and the scanning element.

Inventors: W. Robert Nelson, C. Tim Harbaugh
Original Assignee: Spirit AeroSystems, Inc.
Primary Examiner: J M Saint Surin
Attorney: Hovey Williams LLP
Current U.S. Classification: 73/618; 73/583; 73/635; 73/640; 73/641

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Citations

Cited PatentFiling dateIssue dateOriginal AssigneeTitle
US3678736Aug 3, 1970Jul 25, 1972MACHINE WITH IMPROVED OPERATING HEAD TRAVERSING WORKPIECES WITH CURVED SURFACES
US3771354Dec 6, 19711973RAPID ULTRASONIC INSPECTION APPARATUS
US3913388Jul 18, 19741975APPARATUS FOR ULTRASONIC TESTING OF
US4065976Sep 20, 1976Jan 3, 1978Stanford Research InstituteMechanical scanning method and apparatus for ultrasonic imaging, or the like
US4100809Jul 23, 1976Jul 18, 1978Method for excitation and reception of ultrasonic plate waves in workpieces and devices for realizing same
US4117733Dec 20, 1976Oct 3, 1978Kraftwerk Union AktiengesellschaftTest system carrier for ultrasonic testing of nozzle seams, pipe connection seams and nozzle corners in pressure vessels, particularly reactor pressure vessels of nuclear power plants
US4258319Sep 5, 1978Mar 24, 1981Nippon Kokan Kabushiki KaishaSurface defect detecting apparatus for use with rotating circularly shaped metallic material
US4312230Feb 15, 1980Jan 26, 1982Republic Steel CorporationMethod and apparatus for pipe inspection
US4375167May 18, 1981Mar 1, 1983Bethlehem Steel CorporationUltrasonic transducer suspension system for on-line high speed ultrasonic inspection of flat rolled products
US4398421Dec 23, 1981Aug 16, 1983Hartford Steam Boiler Inspection and Insurance CompanyUltrasonic thickness measuring apparatus and method
US5064340Jan 23, 1989Nov 12, 1991Genmark AutomationPrecision arm mechanism
US6637266Feb 20, 2002Oct 28, 2003Non-destructive inspection, testing and evaluation systems for intact aircraft and components and method therefore
US7637162Oct 1, 2007Dec 29, 2009Spirit AeroSystems, Inc.Mechanism for adaptive contour compliance

Referenced by

Citing PatentFiling dateIssue dateOriginal AssigneeTitle
US8079264Jul 29, 2010Dec 20, 2011Spirit AeroSystems, Inc.Mechanism for adaptive contour compliance

Claims

1. A non-destructive inspection apparatus for inspecting samples that may include a curvature that varies from sample to sample, the apparatus comprising:

a scanning element, operable to transmit a signal to a sample and receive a signal from the sample;

a feed mechanism, operable to guide the sample past the scanning element, the feed mechanism including:
a plurality of pulleys and a plurality of belts that form an open-ended chain, wherein each belt provides a link between two pulleys,
a drive motor, coupled to the plurality of pulleys and the plurality of belts such that the drive motor can drive the series of pulleys to rotate generally synchronously and in the same direction,
an array of rear elements including an array of rear shafts, an array of rear gears, and an array of rear rollers, wherein each rear element includes a rear shall rigidly attached to a rear gear and a rear roller, and
an array of front elements including an array of front shafts, an array of front gears, and an array of front rollers, wherein each front element includes a front shaft rigidly attached to a front gear and a front roller, such that the array of rear gears contacts the array of front gears such that rotation of the array of rear elements in one direction causes rotation of the array of front elements in the opposite direction; and
a pivot mechanism, operable to adapt the feed mechanism to the curvature of the sample in order to maintain a constant distance between the scanning element and the sample, the pivot mechanism including a plurality of primary links operable to pivot in response to the shape of the sample.

2. The apparatus of claim 1, further comprising an encoder in communication with the feed mechanism, operable to monitor the position of the sample as the sample is propelled past the scanning element.

3. The apparatus of claim 1, further comprising a frame, which supports the scanning element, the feed mechanism, and the pivot mechanism.

4. The apparatus of claim 1, wherein each one the of primary links includes a head and a tail such that the head of one primary link couples with the tail of the next primary link and each one the of primary links is operable to pivot about a point where the primary link is coupled to another primary link, and each one of the primary links is further coupled to one of the shafts of the rear array of elements at the point where one primary link is coupled to another primary link, such that as the primary links pivot, components of the feed mechanism move in relation to one another.

5. The apparatus of claim 4, wherein a plurality of secondary links couple the tail of one primary link to the head of the primary link that is two links away, to provide global connection of the pivot mechanism so that when one of the primary links pivots, all of the primary links pivot generally in unison to form an arc, thereby adapting the feed mechanism to the curvature of the sample.

6. The apparatus of claim 1, wherein the feed mechanism further includes a plurality of swing arms that couples the array of rear shafts to the array of front shafts such that the array of rear elements is generally aligned with the array of front elements to form pairs of elements including pairs of gears, pairs of shafts, and pairs of rollers, and such that the array of front elements can swing about the array of rear elements.

7. The apparatus of claim 6, wherein the array of rear shafts is coupled to the plurality of pulleys such that the drive motor is operable to drive the plurality of pulleys and the array of rear elements to rotate generally synchronously and in one direction and the array of front elements to rotate generally synchronously and in the opposite direction.

8. The apparatus of claim 7, wherein the rear roller of each pair of rollers contacts one side of the sample and the front roller of each pair of rollers contacts the other side of the sample and the feed mechanism further includes a plurality of springs that apply pressure to the swing arms to force the front rollers to swing about the rear rollers, thereby allowing the front rollers to press the sample against the rear rollers.

9. The apparatus of claim 8, wherein the feed mechanism further includes a plurality of stoppers that limit the swing angle of the array of front rollers about the array of rear rollers in order to allow the sample to pass through each pair of rollers.

10. A non-destructive inspection apparatus for inspecting samples that may include a curvature that varies from sample to sample, the apparatus comprising:

a scanning element, operable to transmit a signal to a sample and receive a signal from the sample;

a feed mechanism, operable to guide the sample past the scanning element, the feed mechanism including:
a plurality of pulleys and a plurality of belts that form an open-ended chain, wherein each belt provides a link between two pulleys,
a drive motor, coupled to the plurality of pulleys and the plurality of belts such that the drive motor can drive the series of pulleys to rotate generally synchronously and in the same direction,
an array of rear elements including an array of rear shafts, an array of rear gears, and an array of rear rollers, wherein each rear element includes a rear shaft rigidly attached to a rear gear and a rear roller; and
a pivot mechanism, operable to adapt the feed mechanism to the curvature of the sample in order to maintain a constant distance between the scanning element and the sample, the pivot mechanism including:
a plurality of primary links operable to pivot in response to the shape of the sample,
wherein each one the of primary links includes a head and a tail such that the head of one primary link couples with the tail of the next primary link and each one the of primary links is operable to pivot about a point where the primary link is coupled to another primary link, and each one of the primary links is further coupled to one of the shafts of the rear array of elements at the point where one primary link is coupled to another primary link, such that as the primary links pivot, components of the feed mechanism move in relation to one another, and
wherein a plurality of secondary links couple the tail of one primary link to the head of the primary link that is two links away, to provide global connection of the pivot mechanism so that when one of the primary links pivots, all of the primary links pivot generally in unison to form an arc, thereby adapting the feed mechanism to the curvature of the sample.

11. The apparatus of claim 10, further comprising an encoder in communication with the feed mechanism, operable to monitor the position of the sample as the sample is propelled past the scanning element.

12. The apparatus of claim 10, further comprising a frame, which supports the scanning element, the feed mechanism, and the pivot mechanism.

13. The apparatus of claim 10, wherein the feed mechanism further includes an array of front elements including an array of front shafts, an array of front gears, and an array of front rollers, wherein each front element includes a front shaft rigidly attached to a front gear and a front roller, such that the array of rear gears contacts the array of front gears such that rotation of the array of rear elements in one direction causes rotation of the array of front elements in the opposite direction.

14. The apparatus of claim 10, wherein the feed mechanism further includes a plurality of swing arms that couples the array of rear shafts to the array of front shafts such that the array of rear elements is generally aligned with the array of front elements to form pairs of elements including pairs of gears, pairs of shafts, and pairs of rollers, and such that the array of front elements can swing about the array of rear elements.

15. The apparatus of claim 14, wherein the array of rear shafts is coupled to the plurality of pulleys such that the drive motor is operable to drive the plurality of pulleys and the array of rear elements to rotate generally synchronously and in one direction and the array of front elements to rotate generally synchronously and in the opposite direction.

16. The apparatus of claim 15, wherein the rear roller of each pair of rollers contacts one side of the sample and the front roller of each pair of rollers contacts the other side of the sample and the feed mechanism further includes a plurality of springs that apply pressure to the swing arms to force the front rollers to swing about the rear rollers, thereby allowing the front rollers to press the sample against the rear rollers.

17. The apparatus of claim 16, wherein the feed mechanism further includes a plurality of stoppers that limit the swing angle of the array of front rollers about the array of rear rollers in order to allow the sample to pass through each pair of rollers.

Drawings