In-process calibration of a non-destructive testing system used for in-process inspection of multi-pass welding

In multi-pass welding, there is increasing motivation to move towards in-process defect detection to enable real-time repair; thus avoiding deposition of more layers over a defective weld pass. All defect detection techniques require a consistent and repeatable approach to calibration to ensure that measured defect sizing is accurate. Conventional approaches to calibration employ fixed test blocks with known defect sizes, however, this methodology can lead to incorrect sizing when considering complex geometries, materials with challenging microstructure, and the significant thermal gradients present in materials during the inter-pass inspection period. To circumvent these challenges, the authors present a novel approach to calibration and introduce the concept of in-process calibration applied to ultrasonic Non-Destructive Testing (NDT). The new concept is centred around the manufacturing of a second duplication sample, containing intentionally-embedded tungsten inclusions, with identical process parameters as the main sample. Both samples are then inspected using a high-temperature robotic NDT process to allow direct comparative measurements to be established between the real part and the calibration sample. It is demonstrated that in-process weld defect detection using the in-process calibration technique can more reliably identify defects in samples which would otherwise pass the acceptance test using a traditional calibration

A quantitative investigation for deployment of mobile collaborative robots in high-value manufacturing

Component inspection is often the bottleneck in high-value manufacturing, driving industries like aerospace toward automated inspection technologies. Current systems often employ fixed arm robots, but they lack the flexibility in adapting to new components or orientations Advanced mobile robotic platforms with updated sensor technologies and algorithms have improved localization and path planning capabilities, making them ideal for bringing inspection processes directly to parts. However, mobile platforms introduce challenges in localization and maneuverability, leading to potential errors. Their positional uncertainty is higher than fixed systems due to the lack of a fixed calibrated location, posing challenges for position-sensitive inspection sensors. Therefore, it's essential to assess the positional accuracy and repeatability of mobile manipulator platforms. The KUKA KMR iiwa was chosen for its collaborative features, robust build, and scalability within the KUKA product range. The accuracy and repeatability of the mobile platform were evaluated through a series of tests to evaluate the performance of its integrated feature mapping, the effect of various speeds on positional accuracy, and the efficiency of the omnidirectional wheels for a range of translation orientations. Experimental evaluation revealed that enabling feature mapping substantially improves the KUKA KMR iiwa's performance, with accuracy gains and error reductions exceeding 90%. Repeatability errors were under 7 mm with mapping activated and around 2.5 mm in practical scenarios, demonstrating that mobile manipulators, incorporating both the manipulator and platform, can fulfil the precise requirements of industries with high precision needs. Providing a highly diverse alternative to traditional fixed-base industrial manipulators

Transforming industrial manipulators via kinesthetic guidance for automated inspection of complex geometries

The increased demand for cost-efficient manufacturing and metrology inspection solutions for complex-shaped components in High-Value Manufacturing (HVM) sectors, requires increased production throughput and precision. This drives the integration of automated robotic solutions. However, the current manipulators utilising traditional programming approaches demand specialised robotic programming knowledge and make it challenging to generate complex paths and adapt easily to unique specifications per component, resulting in an inflexible and cumbersome teaching process. Therefore, this body of work proposes a novel software system, to realize kinesthetic guidance for path planning in real-time intervals at 250 Hz utilizing an external off-the-shelf Force Torque (FT) sensor. The proposed work is demonstrated on a 500 mm2 near net shaped Wire + Arc Additive Manufacturing (WAAM) complex component with embedded defects, by teaching the inspection path for defect detection with a standard industrial robotic manipulator in a collaborative fashion and adaptively generating the kinematics resulting for uniform coupling of ultrasound inspection. The utilized method proved superior performance and speed, accelerating the programming time over online and offline approaches by an estimate of 88% to 98%. The proposed work is a unique development, retrofitting current industrial manipulators into collaborative entities, securing human job resources and achieving flexible production

Effect of the COVID-19 pandemic on surgery for indeterminate thyroid nodules (THYCOVID): a retrospective, international, multicentre, cross-sectional study

Background Since its outbreak in early 2020, the COVID-19 pandemic has diverted resources from non-urgent and elective procedures, leading to diagnosis and treatment delays, with an increased number of neoplasms at advanced stages worldwide. The aims of this study were to quantify the reduction in surgical activity for indeterminate thyroid nodules during the COVID-19 pandemic; and to evaluate whether delays in surgery led to an increased occurrence of aggressive tumours.Methods In this retrospective, international, cross-sectional study, centres were invited to participate in June 22, 2022; each centre joining the study was asked to provide data from medical records on all surgical thyroidectomies consecutively performed from Jan 1, 2019, to Dec 31, 2021. Patients with indeterminate thyroid nodules were divided into three groups according to when they underwent surgery: from Jan 1, 2019, to Feb 29, 2020 (global prepandemic phase), from March 1, 2020, to May 31, 2021 (pandemic escalation phase), and from June 1 to Dec 31, 2021 (pandemic decrease phase). The main outcomes were, for each phase, the number of surgeries for indeterminate thyroid nodules, and in patients with a postoperative diagnosis of thyroid cancers, the occurrence of tumours larger than 10 mm, extrathyroidal extension, lymph node metastases, vascular invasion, distant metastases, and tumours at high risk of structural disease recurrence. Univariate analysis was used to compare the probability of aggressive thyroid features between the first and third study phases. The study was registered on ClinicalTrials.gov, NCT05178186.Findings Data from 157 centres (n=49 countries) on 87 467 patients who underwent surgery for benign and malignant thyroid disease were collected, of whom 22 974 patients (18 052 [78 center dot 6%] female patients and 4922 [21 center dot 4%] male patients) received surgery for indeterminate thyroid nodules. We observed a significant reduction in surgery for indeterminate thyroid nodules during the pandemic escalation phase (median monthly surgeries per centre, 1 center dot 4 [IQR 0 center dot 6-3 center dot 4]) compared with the prepandemic phase (2 center dot 0 [0 center dot 9-3 center dot 7]; p<0 center dot 0001) and pandemic decrease phase (2 center dot 3 [1 center dot 0-5 center dot 0]; p<0 center dot 0001). Compared with the prepandemic phase, in the pandemic decrease phase we observed an increased occurrence of thyroid tumours larger than 10 mm (2554 [69 center dot 0%] of 3704 vs 1515 [71 center dot 5%] of 2119; OR 1 center dot 1 [95% CI 1 center dot 0-1 center dot 3]; p=0 center dot 042), lymph node metastases (343 [9 center dot 3%] vs 264 [12 center dot 5%]; OR 1 center dot 4 [1 center dot 2-1 center dot 7]; p=0 center dot 0001), and tumours at high risk of structural disease recurrence (203 [5 center dot 7%] of 3584 vs 155 [7 center dot 7%] of 2006; OR 1 center dot 4 [1 center dot 1-1 center dot 7]; p=0 center dot 0039).Interpretation Our study suggests that the reduction in surgical activity for indeterminate thyroid nodules during the COVID-19 pandemic period could have led to an increased occurrence of aggressive thyroid tumours. However, other compelling hypotheses, including increased selection of patients with aggressive malignancies during this period, should be considered. We suggest that surgery for indeterminate thyroid nodules should no longer be postponed even in future instances of pandemic escalation.Funding None.Copyright (c) 2023 Published by Elsevier Ltd. All rights reserved

Transforming Industrial Manipulators via Kinesthetic Guidance for Automated Inspection of Complex Geometries

The increased demand for cost-efficient manufacturing and metrology inspection solutions for complex-shaped components in High-Value Manufacturing (HVM) sectors requires increased production throughput and precision. This drives the integration of automated robotic solutions. However, the current manipulators utilizing traditional programming approaches demand specialized robotic programming knowledge and make it challenging to generate complex paths and adapt easily to unique specifications per component, resulting in an inflexible and cumbersome teaching process. Therefore, this body of work proposes a novel software system to realize kinesthetic guidance for path planning in real-time intervals at 250 Hz, utilizing an external off-the-shelf force–torque (FT) sensor. The proposed work is demonstrated on a 500 mm2 near-net-shaped Wire–Arc Additive Manufacturing (WAAM) complex component with embedded defects by teaching the inspection path for defect detection with a standard industrial robotic manipulator in a collaborative fashion and adaptively generating the kinematics resulting in the uniform coupling of ultrasound inspection. The utilized method proves superior in performance and speed, accelerating the programming time using online and offline approaches by an estimate of 88% to 98%. The proposed work is a unique development, retrofitting current industrial manipulators into collaborative entities, securing human job resources, and achieving flexible production