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

Imaging Sensors and Applications

In past decades, various sensor technologies have been used in all areas of our lives, thus improving our quality of life. In particular, imaging sensors have been widely applied in the development of various imaging approaches such as optical imaging, ultrasound imaging, X-ray imaging, and nuclear imaging, and contributed to achieve high sensitivity, miniaturization, and real-time imaging. These advanced image sensing technologies play an important role not only in the medical field but also in the industrial field. This Special Issue covers broad topics on imaging sensors and applications. The scope range of imaging sensors can be extended to novel imaging sensors and diverse imaging systems, including hardware and software advancements. Additionally, biomedical and nondestructive sensing applications are welcome

Novel Techniques for Tissue Imaging and Characterization Using Biomedical Ultrasound

The use of ultrasound technology in the biomedical field has been widely increased in recent decades. Ultrasound modalities are considered more safe and cost effective than others that use ionizing radiation. Moreover, the use of high-frequency ultrasound provides means of high-resolution and precise tissue assessment. Consequently, ultrasound elastic waves have been widely used to develop non-invasive techniques for tissue assessment. In this work, ultrasound waves have been used to develop non-invasive techniques for tissue imaging and characterization in three different applications.;Currently, there is a lack of imaging modalities to accurately predict minute structures and defects in the jawbone. In particular, the inability of 2D radiographic images to detect bony periodontal defects resulted from infection of the periodontium. They also may carry known risks of cancer generation or may be limited in accurate diagnosis scope. Ultrasonic guided waves are sensitive to changes in microstructural properties, while high-frequency ultrasound has been used to reconstruct high-resolution images for tissue. The use of these ultrasound techniques may provide means for early diagnosis of marrow ischemic disorders via detecting focal osteoporotic marrow defect, chronic nonsuppurative osteomyelitis, and cavitations in the mandible (jawbone). The first part of this work investigates the feasibility of using guided waves and high frequency ultrasound for non-invasive human jawbone assessment. The experimental design and the signal/image processing procedures for each technique are developed, and multiple in vitro studies are carried out using dentate and non-dentate mandibles. Results from both the ultrasonic guided waves analysis and the high frequency 3D echodentographic imaging suggest that these techniques show great potential in providing non-invasive methods to characterize the jawbone and detect periodontal diseases at earlier stages.;The second part of this work describes indirect technique for characterization via reconstructing high-resolution microscopic images. The availability of well-defined genetic strains and the ability to create transgenic and knockout mice makes mouse models extremely significant tools in different kinds of research. For example, noninvasive measurement of cardiovascular function in mouse hearts has become a valuable need when studying the development or treatment of various diseases. This work describes the development and testing of a single-element ultrasound imaging system that can reconstruct high-resolution brightness mode (B-mode) images for mouse hearts and blood vessels that can be used for quantitative measurements in vitro. Signal processing algorithms are applied on the received ultrasound signals including filtering, focusing, and envelope detection prior to image reconstruction. Additionally, image enhancement techniques and speckle reduction are adopted to improve the image resolution and quality. The system performance is evaluated using both phantom and in vitro studies using isolated mouse hearts and blood vessels from APOE-KO and its wild type control. This imaging system shall provide a basis for early and accurate detection of different kinds of diseases such as atherosclerosis in mouse model.;The last part of this work is initialized by the increasing need for a non-invasive method to assess vascular wall mechanics. Endothelial dysfunction is considered a key factor in the development of atherosclerosis. Flow-mediated vasodilatation (FMD) measurement in brachial and other conduit arteries has become a common method to assess the endothelial function in vivo. In spite of the direct relationship that could be between the arterial wall multi-component strains and the FMD response, direct measurement of wall strain tensor due to FMD has not yet been reported in the literature. In this work, a noninvasive direct ultrasound-based strain tensor measuring (STM) technique is presented to assess changes in the mechanical parameters of the vascular wall during post-occlusion reactive hyperemia and/or FMD, including local velocities and displacements, diameter change, local strain tensor and strain rates. The STM technique utilizes sequences of B-mode ultrasound images as its input with no extra hardware requirement. The accuracy of the STM algorithm is assessed using phantom, and in vivo studies using human subjects during pre- and post-occlusion. Good correlations are found between the post-occlusion responses of diameter change and local wall strains. Results indicate the validity and versatility of the STM algorithm, and describe how parameters other than the diameter change are sensitive to reactive hyperemia following occlusion. This work suggests that parameters such as local strains and strain rates within the arterial wall are promising metrics for the assessment of endothelial function, which can then be used for accurate assessment of atherosclerosis

Distributed Simulations for 3D Ultrasound Computer Tomography

More than 10% of all women in the western world get breast cancer. The Ultrasound Computer Tomography (USCT) project aims to provide a screening method which can detect cancer tumours at 5mm

Noninvasive Thrombolysis Using Histotripsy Pulsed Ultrasound Cavitation Therapy.

Histotripsy is a noninvasive ultrasound therapy that utilizes short, high-amplitude, focused ultrasound pulses to mechanically reduce targeted tissue structures to liquid debris by acoustic cavitation. In this work, the physical mechanisms of histotripsy and its application as a method of thrombolysis were investigated. Cavitation activity which causes tissue breakdown during histotripsy was studied by high-speed photography. It was found that cavitation clouds form due to scattering of shock waves in a focused ultrasound pulse from individual inertial cavitation bubbles. The scattered shock is a large tensile wave which expands clusters of cavitation bubbles when the tensile pressure is greater than a measured threshold of approximately 30 MPa. The interaction of this cavitation with tissue and cells was explored with a phantom containing agarose and red blood cells to measure cavitation-based mechanical damage. The observations indicated that cell lysis may be achieved by bubble-induced tensile strain upon expansion, causing membrane rupture. Based on these studies, focused histotripsy therapy transducers were designed to controllably generate cavitation clouds in the vasculature for performing thrombolysis. Transducers were integrated with ultrasound imagers to provide feedback for targeting and monitoring progress of treatment. Rapid thrombolysis was observed when histotripsy was applied to clots in-vitro, and the resulting debris was mainly subcellular and unlikely to cause embolism. Additionally, it was observed that histotripsy can attract, trap, and destroy free clot fragments in a vessel phantom. Based on these observations, a noninvasive embolus trap (NET) was developed, acting as a filter to prevent embolism during the thrombolysis procedure. An in-vivo porcine model of deep-vein thrombosis was used to evaluate the safety and efficacy of the histotripsy thrombolysis technique. These experiments demonstrated the feasibility of the treatment and suggest histotripsy can achieve rapid clot breakdown in a controlled manner.Ph.D.Biomedical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/91496/1/adamdm_1.pd

Multi-scale metrology for automated non-destructive testing systems

This thesis was previously held under moratorium from 5/05/2020 to 5/05/2022The use of lightweight composite structures in the aerospace industry is now commonplace. Unlike conventional materials, these parts can be moulded into complex aerodynamic shapes, which are diffcult to inspect rapidly using conventional Non-Destructive Testing (NDT) techniques. Industrial robots provide a means of automating the inspection process due to their high dexterity and improved path planning methods. This thesis concerns using industrial robots as a method for assessing the quality of components with complex geometries. The focus of the investigations in this thesis is on improving the overall system performance through the use of concepts from the field of metrology, specifically calibration and traceability. The use of computer vision is investigated as a way to increase automation levels by identifying a component's type and approximate position through comparison with CAD models. The challenges identified through this research include developing novel calibration techniques for optimising sensor integration, verifying system performance using laser trackers, and improving automation levels through optical sensing. The developed calibration techniques are evaluated experimentally using standard reference samples. A 70% increase in absolute accuracy was achieved in comparison to manual calibration techniques. Inspections were improved as verified by a 30% improvement in ultrasonic signal response. A new approach to automatically identify and estimate the pose of a component was developed specifically for automated NDT applications. The method uses 2D and 3D camera measurements along with CAD models to extract and match shape information. It was found that optical large volume measurements could provide suffciently high accuracy measurements to allow ultrasonic alignment methods to work, establishing a multi-scale metrology approach to increasing automation levels. A classification framework based on shape outlines extracted from images was shown to provide over 88% accuracy on a limited number of samples.The use of lightweight composite structures in the aerospace industry is now commonplace. Unlike conventional materials, these parts can be moulded into complex aerodynamic shapes, which are diffcult to inspect rapidly using conventional Non-Destructive Testing (NDT) techniques. Industrial robots provide a means of automating the inspection process due to their high dexterity and improved path planning methods. This thesis concerns using industrial robots as a method for assessing the quality of components with complex geometries. The focus of the investigations in this thesis is on improving the overall system performance through the use of concepts from the field of metrology, specifically calibration and traceability. The use of computer vision is investigated as a way to increase automation levels by identifying a component's type and approximate position through comparison with CAD models. The challenges identified through this research include developing novel calibration techniques for optimising sensor integration, verifying system performance using laser trackers, and improving automation levels through optical sensing. The developed calibration techniques are evaluated experimentally using standard reference samples. A 70% increase in absolute accuracy was achieved in comparison to manual calibration techniques. Inspections were improved as verified by a 30% improvement in ultrasonic signal response. A new approach to automatically identify and estimate the pose of a component was developed specifically for automated NDT applications. The method uses 2D and 3D camera measurements along with CAD models to extract and match shape information. It was found that optical large volume measurements could provide suffciently high accuracy measurements to allow ultrasonic alignment methods to work, establishing a multi-scale metrology approach to increasing automation levels. A classification framework based on shape outlines extracted from images was shown to provide over 88% accuracy on a limited number of samples