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E-raamat: Robotic Nondestructive Testing Technology [Taylor & Francis e-raamat]

  • Formaat: 496 pages, 32 Tables, black and white; 274 Line drawings, black and white; 140 Halftones, black and white; 414 Illustrations, black and white
  • Ilmumisaeg: 27-Sep-2022
  • Kirjastus: CRC Press
  • ISBN-13: 9781003212232
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  • Taylor & Francis e-raamat
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Robotic Nondestructive Testing TechnologySuurem pilt
  • Formaat: 496 pages, 32 Tables, black and white; 274 Line drawings, black and white; 140 Halftones, black and white; 414 Illustrations, black and white
  • Ilmumisaeg: 27-Sep-2022
  • Kirjastus: CRC Press
  • ISBN-13: 9781003212232
Teised raamatud teemal:
Taylor & Francis e-raamatudRohkem infot Taylor & Francis e-raamatute kohta
Raamatu kodulehekülg: https://www.taylorfrancis.com/books/9781003212232
The content of this book includes a variety of nondestructive testing (NDT) methods, with many introductions to testing and application cases. The book proposes new ultrasonic testing technology for complex workpieces. It is hard for traditional NDT technology to realize the automatic detection of complex curved components, especially the automatic high-precision nondestructive detection of curved-surface components with variable curvature, variable thickness and complex contour. Therefore, the robotic NDT technique as a combination of manipulator technique and NDT technique can further improve the efficiency and accuracy of NDT. Robotic NDT Technique combines the physical principle of nondestructive testing with the flexible motion control of spatial attitude of articulated manipulator. With NDT as the constraint, it controls the motion attitude and azimuth angle of a transmitting and receiving transducer. Thus traditional NDT technique has developed from plane to curved surface, from 2D to many dimensions and from artificiality to intelligence, into a unique and systematic interdisciplinary robotic NDT technique.
Preface xv
Author xix
Chapter 1 Introduction
1(22)
1.1 Background
3(4)
1.1.1 Automatic NDT Methods of Complex Components
4(1)
1.1.2 Development Trend of Robotic NDT Technique
5(2)
1.2 Basis Of Manipulator
7(4)
1.2.1 Type and Structure of Manipulators
8(1)
1.2.2 Working Mode of Manipulators
8(3)
1.3 Mathematical Relationship Between The Coordinate System And Euler Angle
11(12)
1.3.1 Definition of a Manipulator Coordinate System
11(3)
1.3.2 Relationship between Position & Attitude and Coordinate System
14(1)
1.3.2.1 Position Description
14(1)
1.3.2.2 Attitude Description
15(1)
1.3.2.3 Spatial Homogeneous Coordinate Transformation
15(2)
1.3.3 Quaternion and Coordinate Transformation
17(4)
References
21(2)
Chapter 2 Method of Acoustic Waveguide UT
23(32)
2.1 Wave Equation And Plane Wave Solution
23(10)
2.1.1 Acoustic Wave Equation For An Ideal Fluid Medium
23(8)
2.1.2 Plane Wave And Solutions Of Wave Equations
31(2)
2.2 Ultrasonic Reflection And Transmission At The Interface
33(5)
2.3 Analysis Of Sound Field In An Acoustic Waveguide Tube
38(13)
2.4 Measurement Of Sound Field In An Acoustic Waveguide Tube
51(4)
References
53(2)
Chapter 3 Planning Method of Scanning Trajectory on Free-Form Surface
55(28)
3.1 Mapping Relations Between Multiple Coordinate Systems
55(4)
3.1.1 Translation, Rotation and Transformation Operators
55(1)
3.1.1.1 Translation Operator
55(1)
3.1.1.2 Rotation Operator
56(1)
3.1.1.3 Transformation Operator
57(1)
3.1.2 Equivalent Rotation and Quaternion Equation
57(1)
3.1.2.1 Representation in an Angular Coordinate System
58(1)
3.1.2.2 Representation in an Equivalent Axial Angular Coordinate System
59(1)
3.2 Surface Split And Reconstruction Based On Nubrs
59(6)
3.2.1 Parametric Spline Curve and Surface Split Method
59(1)
3.2.2 Scanning of Non-uniform Rational B-Splines (NURBS)
60(1)
3.2.3 Surface Construction Based on Differential Equation and Interpolation Algorithm
61(4)
3.3 Surface Scanning Trajectory Algorithm Based On Cad/Cam
65(8)
3.3.1 Generation of Discrete Point Data of Free-Form Surface
67(4)
3.3.2 Coordinate Transformation Under The Constraint Of Ultrasonic Testing (Ut) Principle
71(2)
3.4 Scanning Trajectory Smoothness Judgment And Data Discretization Processing
73(10)
3.4.1 Wavelet Processing Method of Surface Data
73(2)
3.4.2 Handling and Judgment of Surface Smoothness
75(5)
References
80(3)
Chapter 4 Single-Manipulator Testing Technique
83(50)
4.1 Composition Of A Single-Manipulator Testing System
84(9)
4.1.1 Workflow of a Testing System
84(1)
4.1.2 Principle of Equipment Composition
85(8)
4.2 Planning Of Scanning Trajectory
93(11)
4.2.1 Ultrasonic/Electromagnetic Testing Parameters
93(9)
4.2.2 Trajectory Planning Parameters
102(2)
4.3 Calibration And Alignment Of Assembly Error
104(10)
4.3.1 Method of Coordinate System Alignment
104(3)
4.3.2 Alignment Method Based on Ultrasonic A-Scan Signal
107(3)
4.3.3 Error Compensation Strategy and Gauss-Seidel Iteration
110(2)
4.3.4 Positioning Error Compensation
112(2)
4.4 Manipulator Position/Attitude Control And Compensation
114(14)
4.4.1 Kinematics Analysis
114(8)
4.4.2 End-Effector Position Error and Compensation Strategy
122(4)
4.4.3 Method of Joint Position/Attitude Feedback
126(2)
4.5 Method Of Synchronization Between Position And Ultrasonic Signal
128(5)
References
132(1)
Chapter 5 Dual-Manipulator Testing Technique
133(48)
5.1 Basic Principle Of Ultrasonic Transmission Detection
134(2)
5.1.1 Basic Principles of Ultrasonic Reflection and Ultrasonic Transmission
134(1)
5.1.1.1 Basic Principle of Ultrasonic Reflection Detection
134(1)
5.1.1.2 Basic Principle of Ultrasonic Transmission Detection
134(1)
5.1.1.3 Comparison between the Elements of an Ultrasonic Reflection Method and Those of an Ultrasonic Transmission Method
135(1)
5.1.2 Ultrasonic Transmission Testing of Curved Workpieces
135(1)
5.1.2.1 Principle of Reflection and Transmission of Ultrasonic Wave Incident on Curved Workpieces
135(1)
5.1.2.2 Principle of Refraction of Ultrasonic Wave Incident on a Curved Surface
136(1)
5.2 Composition Of A Dual-Manipulator Testing System
136(14)
5.2.1 Hardware Structures in a Dual-Manipulator Testing System
137(1)
5.2.1.1 Six-DOF Articulated Manipulator
138(3)
5.2.1.2 Manipulator Controller
141(1)
5.2.1.3 Data Acquisition Card
142(1)
5.2.1.4 Ultrasonic Signal Transceiver System
142(1)
5.2.1.5 Water-Coupled Circulation System
143(1)
5.2.2 Upper Computer Software of a Dual-Manipulator Testing System
144(1)
5.2.2.1 Overall Design of Upper Computer Software
144(1)
5.2.2.2 Data Acquisition
145(1)
5.2.2.3 Synchronous Control of Dual Manipulator
145(3)
5.2.2.4 Automatic Scanning Imaging Module
148(1)
5.2.3 Lower Computer Software of a Dual-Manipulator Testing System
149(1)
5.3 Mapping Relation Between Dual-Manipulator Base Coordinate Systems
150(20)
5.3.1 Transformation Relationship between Base Coordinate Systems
151(1)
5.3.1.1 Definition of Parameters of a Manipulator Coordinate System
151(1)
5.3.1.2 Solution of an Unified Variable Method
152(3)
5.3.1.3 Solving with a Homogeneous Matrix Method
155(2)
5.3.2 Orthogonal Normalization of Rotation Matrix
157(1)
5.3.2.1 Basis of Lie Group and Lie Algebra
157(3)
5.3.2.2 Orthogonalization of Rotation Matrix Identity
160(2)
5.3.3 Experiment of Dual-Manipulator Base Coordinate Transformation Relationship
162(4)
5.3.4 Analysis of Transformation Relation Error
166(4)
5.4 Dual-Manipulator Motion Constraints During Testing
170(11)
5.4.1 Constraints on the Position and Attitude of Dual-Manipulator End-Effectors in the Testing of Equi-Thickness Workpiece
171(4)
5.4.2 Constraints on the Position and Attitude of Dual-Manipulator End-Effectors in the Testing of Variable-Thickness Workpiece
175(4)
References
179(2)
Chapter 6 Error Analysis in Robotic NDT
181(18)
6.1 Kinematics Analysis For Robotic Testing Process
181(6)
6.1.1 Establishment of the Coordinate System in a Moving Device
181(1)
6.1.2 Matrix Representation of the Position/Attitude Relationship between Coordinate Systems
182(2)
6.1.3 Coordinated Motion Relation between Manipulator and Turntable
184(2)
6.1.4 Matrix Representation of Coordinated Motion Relation
186(1)
6.2 Planning Of Motion Path In The Testing Process
187(6)
6.2.1 Algorithm of Detection Path Generation
187(2)
6.2.2 Resolving of Manipulator Motion Path
189(4)
6.3 Error Sources In Robotic Ut Process
193(6)
6.3.1 Geometric Error in Path Copying
194(1)
6.3.2 Localization Error in Manipulator Motion
195(1)
6.3.3 Clamping Error of Tested Component
196(2)
References
198(1)
Chapter 7 Error and Correction in Robotic Ultrasonic Testing
199(22)
7.1 Ultrasonic Propagation Model
199(9)
7.1.1 Fluctuation of Sound Pressure in an Ideal Fluid Medium
200(3)
7.1.2 Expression of Sound Pressure Amplitude
203(1)
7.1.3 Superposition of Multiple Gaussian Beams
204(1)
7.1.4 Influence of the Curved Surface on Ultrasonic Propagation
205(3)
7.2 3D Point Cloud Matching Algorithm Based On Normal Vector Angle
208(5)
7.2.1 Matching Features of 3D Point Clouds
209(1)
7.2.2 Calculation of the Normal Vector on a Curved Surface
209(1)
7.2.3 Identification and Elimination of Surface Boundary Points
210(1)
7.2.4 Calculation of Spatial Position/Attitude Deviation of 3D Point Cloud
211(2)
7.3 Correction Experiment For 3D Point Cloud Collection And Installation Deviation
213(8)
7.3.1 Steps of 3D Point Cloud Matching
213(2)
7.3.2 Simulation Verification of Position/Attitude Deviation Correction Algorithm
215(2)
7.3.3 Experiment and Detection Verification of Curved-Component Deviation Correction
217(2)
References
219(2)
Chapter 8 Kinematic Error and Compensation in Robotic Ultrasonic Testing
221(22)
8.1 Three-Dimensional Spatial Distribution Model Of Robotic UT Error
221(7)
8.1.1 Model of Manipulator Localization Error
221(4)
8.1.2 Relationship between Distance Error and Kinematic Parameter Error
225(2)
8.1.3 Three-Dimensional Spatial Distribution of Errors
227(1)
8.2 Feedback Compensation Model Of Robotic UT Error
228(5)
8.2.1 Principle of Error Feedback Compensation
229(1)
8.2.2 Calculation of Kinematic Parameter Errors
230(2)
8.2.3 Step of Feedback Compensation of Kinematic Parameter Error
232(1)
8.3 Design And Application Of Bi-Hemispheric Calibration Block
233(10)
8.3.1 Design of Bi-hemispheric Calibration Block
233(2)
8.3.2 Method of UT System Compensation with Bi-hemispheric Calibration Error
235(2)
8.3.3 Application of Calibration Block in Kinematic Parameter Error Compensation
237(5)
References
242(1)
Chapter 9 Dual-Manipulator Ultrasonic Testing Method for Semi-Closed Components
243(30)
9.1 Problems Faced By The Ultrasonic Automatic Testing Of Semi-Closed Curved Composite Components
243(1)
9.2 Method Of Planning The Dual-Manipulator Trajectory In The Ultrasonic Testing Of Semi-Closed Components
244(13)
9.2.1 Coordinate Systems in Dual-Manipulator and Their Relations
244(5)
9.2.2 Method of Planning the X-Axis Constrained Trajectory in the Ultrasonic Testing of Semi-Closed Component
249(5)
9.2.3 Experimental Verification of the Trajectory Planning Method with X-Axis Constraint
254(3)
9.3 Analysis And Optimization Of Vibration Characteristics Of Special-Shaped Extension Arm Tool
257(16)
9.3.1 Calibration of Static Characteristics of Special-Shaped Extension Arm Tool
258(4)
9.3.2 Improved S-Curve Acceleration Control Algorithm
262(8)
9.3.3 Trajectory Interpolation Based on Improved S-Curve Acceleration Control
270(2)
References
272(1)
Chapter 10 Calibration Method of Tool Center Frame on Manipulator
273(20)
10.1 Representation Method Of Tool Parameters
273(2)
10.2 Four-Attitude Calibration Method In TCF
275(4)
10.2.1 Calibration of the Position of Tool-End Center Point
275(3)
10.2.2 Calibration of the Attitude of End Center Point of Special-Shaped Tool
278(1)
10.3 Correction Of Four-Attitude Calibration Error Of Tool Center Frame
279(8)
10.4 Four-Attitude TCF Calibration Experiment
287(3)
10.4.1 TCF Calibration Experiment Of Special-Shaped Tip Tool
287(1)
10.4.2 Verification Experiment Of TCF Calibration Result Of Special-Shaped Tip Tool
288(2)
10.5 Four-Attitude TCF Calibration Experiment Of Special-Shaped Extension Arm
290(3)
References
291(2)
Chapter 11 Robotic Radiographic Testing Technique
293(30)
11.1 Basic Principle Of X-Ray Ct Testing
293(4)
11.1.1 Theory of X-ray Attenuat ion
293(2)
11.1.2 Mathematical Basis of Industrial CT Imaging
295(2)
11.2 Composition Of A Robotic X-Ray Ct Testing System
297(1)
11.3 Acquisition, Display And Correction Of X-Ray Projection Data
298(12)
11.3.1 Principle and Working Mode of a Flat Panel Detector
298(4)
11.3.2 Implementation of X-ray Image Acquisition and Real-Time Display Software
302(3)
11.3.3 Analysis of the Factors Affecting the Quality of X-ray Projection Images
305(5)
11.4 Cooperative Control Of X-Ray Detection Data And Manipulator Position And Attitude
310(8)
11.4.1 Design of Collaborative Control Concept
310(2)
11.4.2 Method of Manipulator Motion Control Programming in Lower Computer
312(2)
11.4.3 Modes of Communication and Control of Upper and Lower Computers
314(2)
11.4.4 Implementation Method of Cooperative Control Software
316(2)
11.5 An Example Of Hollow Complex Component Under Test
318(5)
References
321(2)
Chapter 12 Robotic Electromagnetic Eddy Current Testing Technique
323(26)
12.1 Basic Principle Of Electromagnetic Eddy Current Testing
323(14)
12.1.1 Characteristics of Electromagnetic Eddy Current Testing
323(1)
12.1.2 Principle of Electromagnetic Eddy Current Testing
324(1)
12.1.2.1 Electromagnetism Induction Phenomenon
324(1)
12.1.2.2 Faraday's Law of Electromagnetic Induction
325(1)
12.1.2.3 Self-Inductance
325(1)
12.1.2.4 Mutual Inductance
326(1)
12.1.3 Eddy Current and Its Skin Effect
326(2)
12.1.4 Impedance Analysis Method
328(2)
12.1.4.1 Impedance Normalization
330(1)
12.1.4.2 Effective Magnetic Conductivity and Characteristic Frequency
331(4)
12.1.5 Electromagnetic Eddy Current Testing Setup
335(2)
12.2 Composition Of A Robotic Electromagnetic Eddy Current Testing System
337(5)
12.2.1 Hardware Composition
337(3)
12.2.2 Software Composition
340(2)
12.3 Method Of Electromagnetic Eddy Current Detection Imaging
342(7)
12.3.1 Display Method of Eddy Current Signals
343(1)
12.3.2 Method of Eddy Current C-Scan Imaging
344(3)
References
347(2)
Chapter 13 Manipulator Measurement Method for the Liquid Sound Field of an Ultrasonic Transducer
349(68)
13.1 Model Of An Ultrasonic Transduction System
349(15)
13.1.1 Equivalent Circuit Model of an Ultrasonic Transducer
351(6)
13.1.2 Ultrasonic Excitation and Propagation Medium
357(7)
13.2 Sound Field Model Of An Ultrasonic Transducer Based On Spatial Pulse Response
364(14)
13.2.1 Theory of Sound Field in an Ultrasonic Transducer
364(5)
13.2.2 Sound Field of a Planar Transducer
369(4)
13.2.3 Sound Field of a Focusing Transducer
373(5)
13.3 Measurement Model And Method Of Sound Field Of An Ultrasonic Transducer
378(22)
13.3.1 Ball Measurement Method of Sound Field of an Ultrasonic Transducer
378(14)
13.3.2 Hydrophone Measurement Method of Sound Field of an Ultrasonic Transducer
392(8)
13.4 Sound-Field Measurement System Of Robotic Ultrasonic Transducer
400(5)
13.4.1 Composition of a Hardware System
402(1)
13.4.2 Composition of a Software System
403(2)
13.5 Measurement Verification Of Sound Field Of Manipulator Transducer
405(12)
13.5.1 Measurement of Sound Field of a Planar Transducer
405(1)
13.5.2 Measurement of Sound Field of Focusing Transducer
406(9)
References
415(2)
Chapter 14 Robotic Laser Measurement Technique for Solid Sound Field Intensity
417(34)
14.1 Solid Sound Field And Its Measurement Method
417(3)
14.1.1 Definition, Role and Measurement Significance of Solid Sound Field
417(1)
14.1.2 Current Domestic and Overseas Measurement Methods and Their Problems
418(2)
14.2 Sound Source Characteristics Of Solid Sound Field And Its Characterization Parameters
420(12)
14.2.1 Structure and Characteristics of Exciter Sound Source
420(4)
14.2.2 Characterization Method of Solid Sound Field
424(1)
14.2.2.1 Analytical Method
424(2)
14.2.2.2 Semi-Analytical Method
426(1)
14.2.2.3 Numerical Method
426(2)
14.2.2.4 Measurement Method of Ultrasonic Intensity in Solids
428(4)
14.3 Composition Of A Robotic Measurement System For Sound Field Intensity
432(8)
14.3.1 Hardware Composition
433(4)
14.3.2 Software Function
437(3)
14.4 Principle Of Laser Measurement For Sound Field Intensity Distribution
440(4)
14.4.1 Measurement Principle of Laser Displacement Interferometer
440(2)
14.4.2 Measurement Principle of Normal Displacement of Sound Wave
442(2)
14.5 Measurement Method For Transverse Wave And Longitudinal Wave By A Dual-Laser Vibrometer
444(2)
14.6 Application Of A Sound Field Intensity Measurement Method
446(5)
References
449(2)
Chapter 15 Typical Applications of Single-Manipulator NDT Technique
451(36)
15.1 Configuration Of A Single-Manipulator NDT System
452(1)
15.2 An Application Example Of Robotic NDT To Rotary Components
453(16)
15.2.1 Structure of Clamping Device
453(1)
15.2.2 Correction of Perpendicularity and Eccentricity of Principal Axis
454(3)
15.2.3 Generation and Morphological Analysis of Defects in Rotary Components
457(2)
15.2.4 Analysis of Error and Uncertainty in the Ultrasonic Detection of Defects inside Rotary Components
459(4)
15.2.5 Application Examples of Robotic NDT of Rotary Components
463(6)
15.3 Robotic NDT Method For Blade Defects
469(6)
15.3.1 Robotic Ultrasonic NDT of Blades
469(1)
15.3.2 Detection by Ultrasonic Vertical Incidence
470(2)
15.3.3 Ultrasonic Surface-Wave Detection Method
472(3)
15.4 Robotic NDT Method For Blade Defects
475(12)
15.4.1 Principle of Ultrasonic Thickness Measurement
475(2)
15.4.2 Calculation Method of Echo Sound Interval Difference
477(2)
15.4.3 Thickness Measurement Method with Autocorrelation Analysis
479(7)
References
486(1)
Chapter 16 Typical Applications of Dual-Manipulator NDT Technique
487
16.1 Configuration Of A Dual-Manipulator NDT System
487(2)
16.1.1 NDT Method for Large Components: Dual-Manipulator Synchronous-Motion Ultrasonic Testing
487(1)
16.1.2 NDT Method for Small Complex Components: Dual-Manipulator Synergic-Motion Ultrasonic Testing
488(1)
16.2 An Application Example Of Dual-Manipulator Ultrasonic Transmission Detection
489
16.2.1 Ultrasonic C-Scan Detection of a Large-Diameter Semi-closed Rotary Component
489(2)
16.2.2 Ultrasonic C-Scan Detection of a Small-Diameter Semi-closed Rotary Component
491(1)
16.2.3 Ultrasonic C-Scan Detection of a Rectangular Semi-closed Box Component
492(1)
16.2.4 Ultrasonic Testing of an Acoustic Waveguide Tube
493(3)
References
496
Chunguang Xu is a professor at Beijing Institute of Technology, Beijing, China. He earned his PhD in mechanical manufacturing from Beijing Institute of Technology in 1995. His current research interests include ultrasonic testing and manipulator control.
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