Automated NDT inspection for large and complex geometries of composite materials

Large components with complex geometries, made of composite materials, have become very common in modern structures. To cope with future demand projections, it is necessary to overcome the current non-destructive testing (NDT) bottlenecks encountered during the inspection phase of manufacture. This thesis investigates several aspects of the introduction of automation within the inspection process of complex parts. The use of six-axis robots for product inspection and non-destructive testing systems is the central investigation of this thesis. The challenges embraced by the research include the development of a novel controlling approach for robotic manipulators and of novel path-planning strategies. The integration of robot manipulators and NDT data acquisition instruments is optimized. An effective and reliable way to encode the NDT data through the interpolated robot feedback positions is implemented. The viability of the new external control method is evaluated experimentally. The observed maximum position and orientation errors are respectively within 2mm and within 1 degree, over an operating envelope of 3m³. A new software toolbox (RoboNDT), aimed at NDT technicians, has been developed during this work. RoboNDT is intended to transform the robot path-planning problem into an easy step of the inspection process. The software incorporates the novel path-planning algorithms developed during this research and is shaped to overcome practical limitations of current OLP software. The software has been experimentally validated using scans on real high value aerospace components. RoboNDT delivers tool-path errors that are lower than the errors given by commercial off-line path-planning software. For example the variability of the standoff is within 10 mm for the tool-paths created with the commercial software and within 4.5 mm for the RoboNDT tool-paths, over a scanned area of 1.6m². The output of this research was used to support a 3-year industrial project, called IntACom and led by TWI on behalf of major aerospace sponsors. The result is a demonstrator system, currently in use at TWI Technology Centre, which is capable of inspecting complex geometries with high throughput. The IntACom system can scan real components 2.8 times faster than traditional 3-DoF scanners deploying phased-array inspection and 6.7 times faster than commercial gantry systems deploying traditional single-element inspection.Large components with complex geometries, made of composite materials, have become very common in modern structures. To cope with future demand projections, it is necessary to overcome the current non-destructive testing (NDT) bottlenecks encountered during the inspection phase of manufacture. This thesis investigates several aspects of the introduction of automation within the inspection process of complex parts. The use of six-axis robots for product inspection and non-destructive testing systems is the central investigation of this thesis. The challenges embraced by the research include the development of a novel controlling approach for robotic manipulators and of novel path-planning strategies. The integration of robot manipulators and NDT data acquisition instruments is optimized. An effective and reliable way to encode the NDT data through the interpolated robot feedback positions is implemented. The viability of the new external control method is evaluated experimentally. The observed maximum position and orientation errors are respectively within 2mm and within 1 degree, over an operating envelope of 3m³. A new software toolbox (RoboNDT), aimed at NDT technicians, has been developed during this work. RoboNDT is intended to transform the robot path-planning problem into an easy step of the inspection process. The software incorporates the novel path-planning algorithms developed during this research and is shaped to overcome practical limitations of current OLP software. The software has been experimentally validated using scans on real high value aerospace components. RoboNDT delivers tool-path errors that are lower than the errors given by commercial off-line path-planning software. For example the variability of the standoff is within 10 mm for the tool-paths created with the commercial software and within 4.5 mm for the RoboNDT tool-paths, over a scanned area of 1.6m². The output of this research was used to support a 3-year industrial project, called IntACom and led by TWI on behalf of major aerospace sponsors. The result is a demonstrator system, currently in use at TWI Technology Centre, which is capable of inspecting complex geometries with high throughput. The IntACom system can scan real components 2.8 times faster than traditional 3-DoF scanners deploying phased-array inspection and 6.7 times faster than commercial gantry systems deploying traditional single-element inspection

Cost-effective robot for steep slope crops monitoring

This project aims to develop a low cost, simple and robust robot able to autonomously monitorcrops using simple sensors. It will be required do develop robotic sub-systems and integrate them with pre-selected mechanical components, electrical interfaces and robot systems (localization, navigation and perception) using ROS, for wine making regions and maize fields

Quantitative photoacoustic tomography: experimental phantom studies

Photoacoustic tomography (PAT) is a promising non-invasive imaging modality exhibiting high resolution, good contrast and specificity to light-absorbing molecules (chromophores). One of the outstanding challenges the technique faces is that PAT images, though dependent on optical absorption, are not its direct representation because they are coloured by the unknown light fluence. Theoretical studies have succeeded in quantifying optical absorption and chromophore concentration by employing model-based inversions (MBI) that can deal with the non-linearity of the problem and the fluence-related distortion. However, experimental translation has been scarce. The aim was to perform quantitative PAT (qPAT) in a rigorous experimental phantom study to show that highly-resolved 3D estimation of chromophore distributions can be achieved. The first consideration was finding a tissue-relevant and stable matrix material and chromophores. Thermoplastic PVCP was fully assessed. Its stability, intrinsic optical properties, thermoelastic efficiency and low-frequency acoustic properties were suitable. The limitation was the lack of photostability of embedded pigments. Separately, we fully characterised aqueous solutions of sulphate salts and found them to be suitable chromophores for qPAT and potential surrogates for oxy- and deoxyhemoglobin. For a phantom made of sub-mm tubes filled with sulphate solutions in an intralipid-rich background, 3D high resolution estimates of chromophore concentrations were obtained through an efficient diffusion-approximation MBI. Uncertainties in optical inputs of the MBI were tackled by assessing in silico their effect on quantification accuracy and then mitigated in the designed experiment through careful measurements. A faithful representation of the multiwavelength photoacoustic tomography images was sought by employing broadband, near-omnidirectional and high-sensitivity sensors and a detection configuration and reconstruction that overcame the limited-view problem. Estimation of the chromophore ratio, analogous to the much sought-after blood oxygenation, gave a mean absolute error of 3.4 p.p., whilst normalised estimates of the two main chromophore distributions gave errors of 13.2% and 17.2%

Mobile Robots Navigation

Mobile robots navigation includes different interrelated activities: (i) perception, as obtaining and interpreting sensory information; (ii) exploration, as the strategy that guides the robot to select the next direction to go; (iii) mapping, involving the construction of a spatial representation by using the sensory information perceived; (iv) localization, as the strategy to estimate the robot position within the spatial map; (v) path planning, as the strategy to find a path towards a goal location being optimal or not; and (vi) path execution, where motor actions are determined and adapted to environmental changes. The book addresses those activities by integrating results from the research work of several authors all over the world. Research cases are documented in 32 chapters organized within 7 categories next described