automated eddy current inspections of complex, irregular ... · automated eddy current inspections...
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Automated Eddy Current
Inspections of Complex,
Irregular Surfaces
Eric Shell, Matt Gardner
Wyle – Dayton, OH
ATA NDT Forum
23 Sept 2010
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23 September 2010 ATA NDT Forum 2010
Background • Wyle’s 7-axis Eddy Current Inspection System (ECIS) is used by the
USAF and allied nations to inspect military engine components for:
– Small surface cracks
– Machining-induced surface anomalies
• Fully automated – operator loads the part and necessary probes,
enters part number identification information, and presses start
• All steps of the inspection are independent of the operator:
– Instrument setup /
standardization of sensitivity
– Part scanning and data collection
– Data analysis
– Data archiving
– Accept / Reject of part
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23 September 2010 ATA NDT Forum 2010
New Challenge • Most geometries can be programmed using a few simple
equation-based axis movements
• Most engine components have tight dimensional
tolerances
• Recent more complex geometries require:
– up to 6 coordinated axes
– probes with an automated indexing axis
• Attention is required to ensure:
– Probe stays normal and in contact during inspection
– Sufficient coverage with the expected flaw sensitivity
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23 September 2010 ATA NDT Forum 2010
Overview
• Scan contours mapped from solid model of part
• Part coordinate data are extracted to text files
• Automated creation of scan plan software
• Recent ECIS hardware/software improvements allow
inspection of complex regions and shapes
• Results in an easier implementation for high resolution
scanning of complex surfaces
An inspection development method was created
to automate robot manipulation programming and
inspection of complex surfaces:
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23 September 2010 ATA NDT Forum 2010
Example Inspection Area
• Cylindrical feature that is askew from the conical OD
• Must inspect the non-uniform fillet radius and around the base of the fillet
• Not easily defined by Cartesian coordinate equations
• Many possible ways to transform scanning into machine axes
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23 September 2010 ATA NDT Forum 2010
Approach
1. Define scans in the 3D solid model cad file
2. Extract scan coordinates to a massive text file
3. Parse the file to obtain part local coordinates
4. Matlab-based development program:
– analyzes and organizes the scan points
– calculates machine coordinates based on the
specific probe dimensions
– creates CNC commands and ECIS code to control
the probe scanning and inspection processing
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23 September 2010 ATA NDT Forum 2010
Scan Definition
• 3D solid model of the
part is used to define
scan coordinates that
cover the requirement
area
• Unigraphics NX6 with
Advanced Designer
Bundle
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23 September 2010 ATA NDT Forum 2010
Scan Definition Procedure
• Extract isocline curves at the required index
spacing
• Each isocline curve is defined by the fixed
probe tip angle and probe body axis angle
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23 September 2010 ATA NDT Forum 2010
Scan Definition Procedure
• Abnormal ovoid curve isocline created near
base of the fillet
• This fillet angle is small enough angle that the
compliance of the shoe will keep it normal to
the surface
• Abnormal cluster is removed
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23 September 2010 ATA NDT Forum 2010
Scan Definition Procedure
• Continue scan curves by offsetting by the
index distance to encompass the required
inspection surface area
• The probe and sensor are
aligned normal to the part
side wall
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Z
X 23 September 2010 ATA NDT Forum 2010
Scan Definition Procedure
• Local working coordinate system is created for the feature
• Coordinate system origin is located at bottom center of the part
• Z-axis is aligned to the part axis of rotation
• X-axis is aligned along the axis of the desired feature
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23 September 2010 ATA NDT Forum 2010
Scan Definition Procedure
• Create point sets along each curve at a
specified incremental arc length
• These points are then queried for their locations
with respect to the working coordinate system
• Results in a large text file
with a lot of needless data
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23 September 2010 ATA NDT Forum 2010
Raw Output File • As an example, there are
24,562 coordinate points for this feature
A lot of extra
information is
included
(most already
deleted here)
A search for
XC, YC, ZC
gives needed
data
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23 September 2010 ATA NDT Forum 2010
Part Scan Coordinates
• The output file is parsed and re-organized into individual scans – Minimize the number of
simultaneous scanning axes
– Keep the sensor normal to the part
• This geometry requires 4 axes to scan and 4 additional axes (including one on the probe) to index between scans and geometries
-16.5 -16.4 -16.3
6.8
7
7.2
7.4
7.6
7.8
8
-16.5 -16.4 -16.3-0.6-0.4-0.200.20.40.6
6.8
7
7.2
7.4
7.6
7.8
8
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23 September 2010 ATA NDT Forum 2010
Machine Scan Coordinates
• Part coordinates must be transformed
into machine coordinates
• Account for the probe dimensions and
variable tip angle
• Specify active and inactive axes
-16.5-16.4-16.3-0.50
0.5
6.8
7
7.2
7.4
7.6
7.8
8
-28.25-28.2-28.15-28.1-0.5
0
0.5
7.5
8
8.5
9
-16.5 -16.4 -16.3-0.6-0.4-0.200.20.40.6
6.8
7
7.2
7.4
7.6
7.8
8
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23 September 2010 ATA NDT Forum 2010
Inspection Probe and Sensor
• Probe has a small footprint with an adjustable angle shoe to match the isoclines as extracted from the solid model
• The probe tip angle can be adjusted between scans but not while scanning
• A split D differential reflection sensor is used to minimize environmental and geometrical signals while providing sensitivity to small surface cracks
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23 September 2010 ATA NDT Forum 2010
Inspection
• The tip angle and
probe axis angle is
incremented each
scan to keep coil
normal to surface
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23 September 2010 ATA NDT Forum 2010
Inspection Results
• A notched feature was inspected,
resulting in a somewhat confusing set of
eddy current “A-scans” or scan buffers of
varying lengths:
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23 September 2010 ATA NDT Forum 2010
Inspection Data C-scan
• An easier visualization of the data would be a
transformed rectangular C-scan plotted in
degrees to align radial features
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23 September 2010 ATA NDT Forum 2010
Data Processing
• Filtering is performed to improve the flaw S:N ratio and suppress geometry-related signals
• Analog HP filter is applied to avoid DC saturation of the digital signal sampler
• A filter similar to a rectifying bandpass is applied prior to signal thresholding for flaw detection
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23 September 2010 ATA NDT Forum 2010
Data Visualization
• A polar 3D plotting tool has been created to view the data in a more intuitive display
• Allows easy identification of location of indications
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23 September 2010 ATA NDT Forum 2010
Data Visualization (3D)
• With registration of the inspection data into part coordinates, the data can be plotted on a solid model.
• The inspection data can provide feedback on: - machining issues - lifing model - potential crack initiation sites
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23 September 2010 ATA NDT Forum 2010
Future Application
• Some geometries may have large dimensional tolerances, yet require inspection for small surface defects or cracks
– IBR / Blisk blade repairs, for example
• In this case, we could use the presented algorithm to generate automated scan patterns from CMM data, obtained on the ECIS or from customer-supplied data
• The inspection scanning would be automatically customized to the dimensions of each specific part
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23 September 2010 ATA NDT Forum 2010
Data Presentation
• As the collection of data becomes more complex, there is an increasing need for tools to display, process, and analyze the data more intuitively
• With the permanent digital record of inspection data, many new capabilities are enabled
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23 September 2010 ATA NDT Forum 2010
ECView Program
• New Matlab-based program created for: – Data Visualization, Manipulation, and Analysis
– Inspection Development and Debugging
– Displaying Data on CAD Models
– Performing Signal Measurements and Analysis
– Flaw Characterization
– Offline Signal Processing and Algorithm Development
– Virtual Re-Inspection of Archived Data
• Comprehensive capabilities for importing and exporting of data or images into common formats – Images (.png, .jpg, .bmp, .tif, .pdf)
– Data (.csv, .txt, .prn, .mat)
– Customer-driven automated flaw reports
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23 September 2010 ATA NDT Forum 2010
ECview – Visualization
• Movable pointer
• Movable zoom window
• Polar plotting of surfaces
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23 September 2010 ATA NDT Forum 2010
ECview – Development/Debugging
• Coverage Verification
• Signal Processing
Algorithm Development
S:N =
0.3
S:N =
3.1
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23 September 2010
ECview – 3D Plotting
• Plotting of data on solid part models
• Could be used with FEA models
• Helps visualize machining issues
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23 September 2010
ECview – Measurements
• Signal Statistics
• Linear Distance
• Frequency
• Signal to Noise
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23 September 2010
ECview – Signal Processing
• Hardware/software frequency
filter simulation
• Replication of ECIS-proprietary
filters
• Platform for new signal
processing development
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23 September 2010
ECview – Virtual Re-Inspection
• Capability to re-process archived raw
inspection data while effectively changing:
─ calibration characteristics (notch
values, phase rotation, processing)
─ inspection threshold / flaw size
requirements
─ signal processing algorithms
• Enables retroactive requirement changes
• Enables more efficient algorithm
development
─ collect once, then optimize processing
• Easily modified for various re-inspection
goals
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23 September 2010
ECview – Input / Output
• Input Options: – All ECIS raw data files (.prn)
– Delimited text files (.csv, .txt)
– Matlab files (.mat)
– Binary ECIS database files (.dat, .#)
– Aerotech Nscope files (.nsc)
• Output Options: – Delimited text files
– Excel workbook
– Matlab files
– Image files (.png, .jpg, .bmp, .tif, .pdf)
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23 September 2010 ATA NDT Forum 2010
Summary
• A generalized inspection routine has been developed to inspect along curves defined in a 3D solid model.
• The approach has been validated on complex fillets.
• A new postprocessing / data visualization program has been developed that will allow for further indication characterization.