AU2007200013B2 - System and method for locating and positioning an ultrasonic signal generator for testing purposes - Google Patents

Description

P/00/0II Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT (ORIGINAL) Name of Applicant: Lockheed Martin Corporation, of 6801 Rockledge Drive, Bethesda, Maryland 20817, United States of America. Actual Inventor: Thomas E Drake. Jr. 2418 5th Avenue Forth Worth, Texas 76110 United Statcs of America Address for Service: DAVIES COLLISON CAVE, Patent & Trademark Attorneys, of 1 Nicholson Street, Melbourne, 3000, Victoria, Australia Ph: 03 9254 2777 Fax: 03 9254 2770 Attorney Code: DM Invention Title: "System and method for locating and positioning an ultrasonic signal generator for testing purposes" The following statement is a full description of this invention, including the best method of performing it known to us:- SYSTEM AND METHOD FOR LOCATING AND POSITIONING AN ULTRASONIC SIGNAL GENERATOR FOR TESTING PURPOSES TECHNICAL FIELD OF THE INVENTION The present invention relates generally to a system and method for. locating and positioning an ultrasonic signal generator with respect to a tested part. In particular, the invention is directed to a system and method S for delivering a laser beam generated by a laser source to a particular point on a tested object, or for determining a precise point on the object the ultrasonic signal generator delivered the energy to, in a gantry positioning system for use in detecting material defects of a test object using ultrasonic techniques. 0 P.0PER\SEW\N21X9\Augus\3157266 amended pige Ist spdoc-20/1R/2c)9N BACKGROUND OF THE INVENTION It is desirable for a variety of applications to provide for mechanically directing a laser beam to any location within a predetermined volume or on a surface. Many 5 of these applications are tailored specifically for use within industrial manufacturing applications employing automated, robotics systems. Over the past several decades, the advent of robotics and laser light source technologies have led to many integrated systems for assembly line 10 manufacturing. For example, robotics assembly systems incorporating laser technologies are very typical in automobile and even aircraft manufacturing plants for performing such tasks as welding. For many systems, a robotic or gantry positioning 15 system having a mechanical armature is often used to direct a laser beam to a variety of locations of a single workpiece. This armature itself provides for precision directing of the laser beam from the end of the mechanical armature. A laser beam delivery system is normally 20 integrated into the gantry positioning system (GPS), particularly into the mechanical armature, for directing the laser beam from the end of the mechanical armature to any location within a predetermined volume. Specifically, the laser beam is then directed to portions of a workpiece and 25 often from various fields of view for welding, cutting, ablating, or any variety of applications employing a laser beam. Ultrasonic testing is a method which may be used to detect material defects in a objects comprised of various 30 materials. A common application for ultrasonic testing is to detect inhomogeneities in composite materials. Ultrasonic testing may be used to serve a variety of industrial needs 2 P.\OPER\SEW\21,Augustun I 572W.amended pugs 11 sp.do-20/)K121"9 including identification of defects in manufactured goods for tuning of manufacturing processes. Manufacturers of products comprising composite material may wish to identify imperfections in their articles of manufacture to modify 5 their manufacturing process to strive for greater repeatability and efficiency in their process or simply to identity problem areas within their process. Composite materials comprise many critical components within modern, high performance aircraft, and are becoming more common in 2a terrestrial applications such as the automotive industry. Composite materials are-desirable for many of their inherent attributes including lightweight, high strength, and stiffness. Particularly for aircraft application, those composite material components, which may be large and 5 complex in shape, are often flight critical necessitating strict assurance of material and structural integrity. Unfortunately, these materials are sometimes fabricated with imperfections or develop them after several hours of use. These material defects may appear as a delamination of the surface of the material, LO porosity, an inclusion, debonds between bonded sub-components, or a void within the component itself. This inhomogeneity in the structure severely weakens it, providing a situation which might result in catastrophic failure. A conventional method for detecting material defects in a composite material utilizes piezoelectric transducers in conjunction with mechanical scanners 5 mounted across the surface of the composite to detect any material imperfections. The disadvantages of the conventional methods are many, including difficulty in accommodating non-flat or evenly mildly contoured composite materials. Another disadvantage is the requirement that the transducer couple to the material via a water path. The transducer must D remain normal to the surface within ±30 during a scan. To accommodate highly contoured and complex shaped components using conventional techniques often requires extremely time-intensive test set up preparation. Laser ultrasonic testing is an alternative method that is used to identify these imperfections. For aircraft applications, particularly for military fighter aircraft, all flight critical parts fabricated of composite material must be fully inspected before installation. A GPS comprising a laser beam delivery system may be integrated with a laser ultrasonic testing system for providing automated identification of material defects of a test object. One approach is to mount the laser ultrasonic testing system comprising a laser source on the end of the mechanical armature of the GPS. The use of a GPS allows the ultrasonic testing system to be maneuvered around the test object to provide for positioning the laser source in close proximity to the test object from a multitude of locations of fields of vision. For those ultrasonic testing systems which use high power gas lasers such as CO 2 lasers, the large and bulky size of the laser complicates the integration of the ultrasonic testing system with the GPS as the end segment of the mechanical armature must be capable of supporting a significantly heavy weight at its end. The large size and bulky weight of the light source itself often 3 demands the use of a very large GPS capable of supporting the heavy weight of an ultrasonic.testing system as it is maneuvered around the test object to perform data acquisition from a variety of perspectives. Many typical laser testing systems are hampered when the ultrasonic 5 energy generator is not positioned properly relative to the part to be tested. When this happens, the test results may need to be corrected, or in the case of testing relative strengths of different parts, this test may be completely inconclusive. Further, when the ultrasonic signal is generated, the resulting ultrasonic signal affects certain areas and/or volumes of the LA tested object. To completely test an object requires that a signal ultrasonic event be generated many times throughout various places on the surface and interior to the object. By doing this numerous times, the complete object may be tested, even though some areas affected may be common to others. In this case, many systems that rely on manual positioning err on 5 a conservative side. This results in hugely overcompensated testing of the part since the overlaps are huge. Precise positioning of the ultrasonic testing device allows for scalable and efficient economies in the testing process, since the area of overlaps may be minimized. 4 C:\RPortbDCC\AXL\26)9277 I.DOC-/112/2009 SUMMARY OF THE INVENTION According to the present invention, there is provided a system that guides at least one beam of light through axes of a mechanical positioning system and directs the at least 5 one beam of light at an object under test, comprising: at least one remote light source that generates the at least one beam of light; a mechanical armature operable to receive the at least one beam of light from said at least one remote light source 10 and transmit said at least one beam of light along axes of motion of said mechanical armature via one or more optical transmission channels the said mechanical armature operating to deliver the at least one beam of light to any location within a workspace; 15 a positioning controller operable to direct that said mechanical armature be positioned according to an optical scan plan; an optical alignment system within the one or more optical transmission channels used to guide the at least one 20 beam of light through the one or more optical transmission channels; a first optical assembly that directs the at least one beam of light to the object under test, the at least one beam of light generating ultrasonic displacements in said 25 object under test; an optical receiver operable to collect light incident from the at least one beam of light on said object under test and modulated by said ultrasonic displacements in said object under test; and 30 a processor operable to determine from said collected light and display an internal structure of said object under test. 5 C:\NRPonbIU)CC\AXL\2609227_j.DOC-/12/2 () The present invention also provides a method of guiding at least one beam of light through axes of a mechanical positioning system and directing the at least one beam of light at an object under test, the method comprising the 5 steps of: generating at least one beam of light from a remote light source; injecting said at least one beam of light into a mechanical armature; 10 transmitting said at least one beam of light along axes of motion of said mechanical armature via an optical transmission channel, wherein said mechanical armature operates to deliver the at least one beam of light to any location within a workspace; 15 directing said mechanical armature be positioned according to an optical scan plan by a positioning controller; guiding the at least one beam of light through the optical transmission channel using an optical alignment 20 system positioned within said optical transmission channel; directing with a first optical assemble the at least one beam of light to the object under test, wherein said at least one beam of light generates ultrasonic displacements in said object under test; 25 collecting phase modulated light scattered by said ultrasonic displacements; and processing said phase modulated light to determine and display an internal structure of said object under test. Embodiments of the present invention employ a laser 30 ultrasonic testing system which is used to identify and detect material defects in a test object. Data is acquired of the test object and is analyzed for identifying any Sa C:NRPohb DCC\AXL\26()277. DOC-4/121I material defects in the test object and for providing the precise locations of the. Identifying material defects in composite materials, particularly those within aircraft applications, may provide aircraft designers with 5 information concerning actual life and fatigue of flight critical, composite components as well as provide manufacturers of composite components with information concerning stress and failure points of the component. The ultrasonic testing system within this invention is provided 10 and presented in detail in U.S. Patent Application, Serial No. 09/343,920, now U.S. Patent No. 6,633,384, entitled "System and Method for Laser Ultrasonic Testing" by Thomas E. Drake, Jr. Embodiments of the invention are found in an ultrasonic 15 lasing system. The laser system tests a manufactured part for various physical attributes, including specific flaws, defects, or composition of materials. The part can be housed in a gantry system that holds the part stable. An energy generator illuminates the part within energy and the part 20 emanates energy from that illumination. Based on the emanations from the part, the system can determined precisely where the part is in free space. The energy illumination device and the receptor have a predetermined relationship in free space. This means the location of the 25 illumination mechanism and the reception mechanism is known. Additionally, the coordinates of the actual testing device also have a predetermined relationship to the illumination device, the reception device, or both. Thus, when one fixes the points in free space where the part is relative to 30 either of the illumination device or the reception device, one can fix the point and/or orientation of the testing device to that part as well. 5b C:\NRPorblDCC\AXL\2U69277_ .DOC-4/22XH It should be noted that the results of the point and/or orientation detection may also be used in an actuator and control system. If the position of the testing device needs to be altered with respect to the tested object, the control 5 system and actuator may use the results of this determination to move the testing device relative to the tested object. To do this, either the tested object needs to be moved within the gantry system, or the testing device needs to be 10 moved relative to the tested object. Of course, these actions may occur in combination. This may be accomplished with a computer that assists in determining the position and/or orientation. This may be used to control the relative movement of the object and testing device 5c The system may also be used not to precisely position a testing device relative to anr'object, but may be used for compensation purposes as well. In this embodiment, the testing system tests the object, then the positioning system determines the relative position of the object to the position and/or 5 orientation of the testing device. When the position and/or orientation of the testing device relative to the tested object is not exact, a CAD representation of the object may be used to derive corrections based on incorrect orientation and/or positioning aspects of the system. The generating energy may be of various sorts. This includes 0 . electromagnetic as well as sonic. In the case of an electromagnetic system, various forms of this energy may be used as well. For example, the generator may generate radar waves and the receptor may detect these reflected radar waves. Or, the generator may generator coherent energy, such as a laser, that bathes the object. The reception apparatus may be a camera or other optical receiver such as a photoelectric detector. In this case, the various lightings, and optical characteristics of the light receptor, such as focal point of the receptor, allow one to determine the spatial orientation of the generating device and the receiving device in space relative to the object. Or, another energy, such as sonic energy, may be used in a sonar-type system. 6 BRIEF DESCRIPTION OF THE DRAWINGS For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings in which like reference 5 numerals indicate like features and wherein: FIGURE 1 shows one embodiment of a gantry positioning and ultrasonic testing system with an integral laser beam delivery system; and FIGURE 2 shows a particular embodiment of FIGURE 1 of gantry positioning and ultrasonic testing system with an integral laser beam .0 delivery system. FIGURE 3 depicts-a-flow-char-t-illustrating the-method-of.the.pres.ent. invention. FIGURE 4 is a diagram showing the operational units of an embodiment of the invention. 5 FIGURE 5 is a diagram of a specific embodiment of the system of FIGURE 4. FIGURE 6 is a diagram detailing the use of the system of FIGURE 4 with a multi-axis laser positioning system. FIGUREs 7 and 8 are diagrams detailing the potential relationships D inherent in the system of FIGURE 4. FIGURE 9 is a diagram detailing a process of how the system of FIGURE 4 can operate. 7 C.NRPonbDCC\AXL\2609277_. DOC-4/121/209 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Preferred embodiments of the present invention are illustrated in the FIGUREs, like numerals being used to refer to like and corresponding parts of the various 5 drawings. The present invention employs a gantry positioning system with an integral laser beam delivery system for delivering a laser beam delivered by a remote laser source to a test object for performing ultrasonic testing to detect 10 any material defects in the test object. The gantry positioning system provides for scanning the entire test object from various fields of view to map out the test object using laser ultrasonic techniques. Data are recorded from all of the fields of view and later processed to 15 provide for not only the detection of any such material defects, but also their location within the test object. FIGURE 1 and FIGURE 2 show one embodiment 40 of a gantry positioning and ultrasonic testing system with an integral laser beam delivery system. A laser beam is 20 generated by a remote laser source 31 and inserted into the optical transmission channel of a first gantry member 32. Each gantry member of the gantry positioning system comprises an optical alignment system similar to that described in FIGURE 2 for guiding the laser beam through the 25 gantry positioning system and for delivering it to a test object 35 for performing ultrasonic testing. The gantry positioning system is comprised of a number of gantry members pivotally connected. At each of these pivotal connections is a gantry actuator for controlling the shape 30 of the gantry positioning system which provides for positioning the end gantry member 34 to any location within the desired workspace in which the test object 35 is 8 C:NRPonblDCC\AXL\269277_i.DOC-4/1 21209 located. Permitting the gantry positioning system to be manipulated around the workspace of the test object 35 allows for performing ultrasonic testing using an ultrasonic testing system 36 from a variety of fields of view. 5 Additionally, a laser beam conditioning system 37 may be used to provide for minimizing the divergence of the laser beam as it exits the end gantry member 34 of the gantry positioning system and is delivered to the test object 35. The laser beam conditioning system 37 could likewise be 10 included within the optical transmission channels 22 of the gantry segments of the GPS to provide for conditioning and minimizing the divergence of the beam as it propagates through the GPS. FIGURE 2 shows a particular embodiment 40 of FIGURE 1 15 of a gantry positioning and ultrasonic testing system with an integral laser beam delivery system. The gantry positioning system is comprised of a plurality of vertical supports beams 41 which support two runway beams 42 which run 8a parallel to one another. A bridge beam 43 spans between the two runway beams and is powered' using a bridge beam actuator 44 for providing translation in a first direction, depicted as the X direction in the TOP VIEW shown in FIGURE 2. A carriage 45 is mounted on top of the bridge beam 43 and is powered 5 using a carriage actuator 46 for providing translation in another direction which is orthogonal to the first direction. This second direction is depicted as the Y direction in the TOP VIEW shown in FIGURE 2. Extending downward from the bridge beam 43 is a Z-mast 47, whose length is variable and is controlled using a Z-mast actuator 48. The Z-mast provides for .0 translation in a third direction, orthogonal to the first two directions. This third direction is depicted as the Z direction in tha SIDE VIEW shown in. FIGURE 2. By providing movement in three orthogonal positions and delivering a laser beam throughout the system, the particular embodiment shown in FIGURE 2 5 of a gantry positioning system provides for emitting the laser beam 11 at any location within the workspace of the test object 35 allows for performing ultrasonic testing using an ultrasonic testing system from a variety of field of view, similarly to the capability shown in FIGURE 1. Also in similar fashion to FIGURE 1, a laser beam conditioning system 37 may be used to provide for minimizing the divergence of the laser beam 11 as it exits the end of the Z-mast 47 of this particular embodiment of a gantry positioning system and is delivered to the test object 35. The laser beam conditioning system 37 could likewise be included within the optical transmission channels 22 of the gantry segments of the GPS to provide for conditioning. and minimizing the divergence of the beam as it propagates through the GPS. If even more spatial control is desired for directing the laser beam 11 from the end of the Z-mast 47, a rotation attachment platform 49 may be attached to the end of the Z-mast allowing additional directional control and delivering of the laser beam 11 to the test object 35. FIGURE 3 depicts a flow chart illustrating the method of the present invention. The present invention defines robotic position and optical scan-plans for optimum laser ultrasonic testing performance. The optical scan plans can be generated based on the part geometry derived from CAD models, actual measurements, and FIGURE-of-merit parameters defined by laser ultrasonic testing limitations for a particular material type. Requirements may include: (1) Defining part and fixture orientations in the work cell for repeatable low-cost positioning of the part (this may be a computer 9 defined task based on part CAD models, part center of gravity, holding fixture design, robotic reach, etc. Or it could be a task defined by the system operator where the part location and fixture design is manually defined based on experience); 5 (2) Maintaining an optimum distance to the part surface based on the system depth-of-field (for example 2.5m +-0.5m); (3) Limiting laser angle of incidence (this will be material 0 dependent, +-45 degrees for some, +-30 for others, also some materials may be extremely spe.c-ul.ar and on-axis views avoided) (4). Verifying 100% part coverage with some overlap of scanned regions; and 5 (5) Optimizing throughput by scanning only areas where valid data can be collected with a minimum of robotic repositions. The present invention has the ability to map laser ultrasonic testing image data. Flat-field laser ultrasonic testing scan data can be projected 2 onto a true 3D surface. This accurately associates ultrasonic data with the true measurement point on the surface. This can be implemented in several ways. First, an integrated measurement system can be used for measuring the surface geometry and providing a one-to-one map between the laser ultrasonic testing data and the measured 3D surface coordinate. Second, the location of the part in the work cell along with the CAD geometry can be used to map the data to the surface. This 3D reconstructed image clearly indicates if the scan coverage is complete and will display proper spatial registration of the individual laser ultrasonic testing scan regions on the part surface. A second method is not dependent on point-by-point reconstruction based 0 on measured values but instead is concerned with the orientation of the part relative to the laser ultrasonic testing scan view. The principle errors in this method arise from the accuracy that the component is located within the work cell and the positioning/pointing errors of the laser ultrasonic testing sensor. This provides the benefits of improved data interpretation capabilities, reduced labor cost due to improved analysis features, increased throughput, enhanced testing capabilities for complex structures, and improved archive format for use as reference baseline on subsequent in 10 service inspections. Potential for automated image comparison directly between different parts or the same part at different service intervals. The present invention provides a calibration method for 3D beam pointing. This measurement and calibration procedure corrects for errors in 5 the beam-pointing vector of the laser ultrasonic testing system. This includes all errors due to the 5-axis gantry positioning system and from the optical alignment and pointing of the two-axis optical scanner. This information can be used as required to generated corrected 3D reconstructed images. tO . Addi-t-iona-1-1-y, t-he present i-nvent-ion provi-des robotic co-l-tis-i-on a-voidance methods-. A colLis-ion avoidance sy-stem Eomr t-he pars gant-ry r-obot includes the ability to avoid both permanent and temporary objects. Permanent objects include the gantry structure and other fixed hardware inside the work envelope. Temporary objects include parts, part fixtures, 5 and transportation carts. These provide a significant improvement in avoiding mechanical disaster. Current estimate for downtime due to severe robotic collision is as high as 8 weeks. FIGURE 4 is a diagram showing the operational units of an embodiment of 0 the invention. An object 100 is to be scanned by the ultrasonic testing system. In the invention, an energy illuminator 102 bathes the object with some form of energy, and an energy reception mechanism that detects energy emanating from the object and associated with the energy imparted by the energy illumination device 102. The illumination generator and the energy reception mechanism 104 are linked with each other in a predetermined spatial relationship. The predetermined spatial relationship may be fixed, such as being fixed together on one part. Or the relationship may be alterable, with the energy receptive mechanism and the energy illumination generator being present on differing D controllable bodies. In any case, the energy reception mechanism is also associated with the energy generator of the testing mechanism in another predetermined spatial relationship. Again, the predetermined spatial relationship may be fixed, such as being fixed together on one part. Or the relationship may be alterable, with the energy receptive mechanism and the energy illumination generator being present on differing controllable bodies. The energy illumination generator generates energy and directs it to the object. The energy emanating from the object is detected by the energy receptive mechanism. The characteristics of the emanating energy may be 11 determined, and a precise point on the object may be characterized due to these detected'energies. The energy illumination generator may be a laser, or other type of electromagnetic energy generator, such as a low power radar system. In the 5 case of the radar energy, the energy receptive mechanism can determine the shape of the object, and since the energy receptive mechanism and the energy illumination generator have a predetermined spatial relationship, and another predetermined spatial relationship exists with respect to the energy generation device of the testing system, a precise location in space of the 0 energy gene-ration-dev-ice. may be derived from the measurement. .Re.1atedl.y., a s.onax t.yp sy-em may be .,mplJeRented as well. In .thir case, the energy would be sonic in nature, rather than electromagnetic. In another embodiment, the energy illumination generator may be a visible light or laser. In this case, the energy receptive mechanism can be 5 a camera, or electronic photo detector. In this manner, the precise position of the energy generation used for ultrasonic testing may be pinpointed in space. This can be accomplished prior to the testing phase, so that efficient sweeps of the object may be performed, or afterwards, such that corrections can be applied to the measurement of the object. FIGURE 5 is a diagram of a specific embodiment of the system of FIGURE 4. In this embodiment, the energy illuminator is a laser or other type of source of visible electromagnetic energy, and the energy reception mechanism is a camera. FIGURE 6 is a diagram detailing the use of the system of FIGURE 4 with a multi-axis laser generation system. The energy illumination generator laser and the energy receptive mechanism camera are co-located on a laser head that pivots and moves in space. The energy illumination generator laser can be the ultrasonic testing laser, or may be a different sort altogether. FIGUREs 7 and 8 are diagrams detailing the relationships inherent in the system of FIGURE 4. FIGURE 4 deals mainly with the optical type systems. Other relationships and equations may exist for other types of positioning systems, such as phase reversal equations, time reflectometry equations, and the like. From the diagram the relationships among the similar triangles yields the following results: 12 TANa= f TANG D2 D Z 2ZO D ZD Da D-D2 2Z TAN(0-a)=-= = z z Z D-ZTANOG. D TAN(0I-a= z = TANG 0 Z= D TAN(O -a)+ TANGO Z(y) = D DD TAN[TAN-1( )- TAN~'( )]+ 2ZO f 2ZO This way may derive several relationships. These relationships include: Dy o = AND a =-->TAN( 0 -a) G 0 -a 2ZO f D Z_ Z(y); D ZO f Df dZ -Zo ZO Z _ 2 dy yZo2 f Df [- 0 Df Df dZ- Zozdy Df[I. -J ] Df Thus, several basic equations arise from the optical system thus described. The basic equations are: 13 Z[1 - - Df yzoz = Z -o Df 1 1 1 y = Df(---)(2' -ZO)= Df( ) Z0Z Zo Z dZ(y) = Z 0 dy Df[ -YZ0

]

2 Df

Z

0 2 dy

Z

0 2 dy

Z

2 dy dZ (Z-) oY zd D}4- z )-]2 2 Df z z

Z

2 dy dZ(Z)= Df Thus, in relation to FIGURE 8, the following design equations also aid in the determination of the proper system parameters. These include: FOV L TAN( )= 2 2f L FOV = 2TAN( ) 2f d - L dy=L NUM. ELEMENTS In a numerical example L = 0.5" CCD ARRAY FOV ~ 40' = f = 0.68"(17.3mm) 0.5 N=1024 = dy = 2048 D =18" dZ(Z) = 2x105( )Z2 in dZ(60) =0.072. dZ(100) = 0.2" 5 Thus, the optic system of FIGURE 7 and 8 can determine the spatial orientation of the part with a high degree of precision. As such, the results of spatial profiling system can be used in a control circuitry to move relative positions of the object and testing system. FIGURE 9 is a. diagram. detailing a process of how the system of FIGURE 4 0 can operate. In one embodiment of the invention, as associated CAD device supplies a representation of the tested part to the system. The head of the 14 C:\RPonbl\DCC\AXL\2609277_1 DOC4112/2009 laser testing assembly has multiple degrees of kinetic freedom, allowing the head to be positioned very precisely. In this embodiment, the testing head is placed in proximity with the part to be tested, and the system then 5 determines the proper positioning corrections for the testing to begin. The testing implement is positioned properly with relation to the object and the testing process begins. The CAD generated surface is then melded with the 10 testing results. This enables an operator to quickly and easily identify features associated with the tested object, such as faults, stresses, imperfections, and the like, or, instead of specific points, the testing data may be compared in a scale of acceptable versus unacceptable. In this case, 15 the shaded area might indicate areas that fail to reach threshold testing. This could be used to identify specific manufacturing steps that need to be assessed or changed. In another related embodiment, the testing of the part may generate results for a specific area of the part, 20 indicated by the shaded area of the first panel of FIGURE 8. The entire part may be quickly tested, since the precise positioning mechanism allows the testing system to minimize the overlap associated with specific individual testing actions. This could dramatically increase the speed at which 25 parts are tested. It should be noted that the system need not position the testing device. The system can be used to position the part, or the testing device, either singly or in combination. The energy illumination generator and the 30 energy receptive mechanism may also exist on separate frames or supports than the positioning system. For example, the energy illumination device and the energy-receiving device 15 P \OPERkSE W2 A n\nIAugus 15726, mendeded pges 1s spadoc-20/W2100 may be positioned on supports of the gantry system. This system may move the object within the gantry system or may move the testing device, or both. It should be noted that this system might be used in 5 any testing system that generates ultrasonic energy. While a laser based system is described, it should be noted that other forms of testing based on reading emitted energy should be encompassed by the invention. Although the present invention has been described in 10 detail, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as described by the appended claims. Throughout this specification and the claims which 15 follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of 20 integers or steps. The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that 25 that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. 16

Claims (21)

1. A system that guides at least one beam of light through axes of a mechanical positioning system and directs the at 5 least one beam of light at an object under test, comprising: at least one remote light source that generates the at least one beam of light; a mechanical armature operable to receive the at least one beam of light from said at least one remote light source 10 and transmit said at least one beam of light along axes of motion of said mechanical armature via one or more optical transmission channels the said mechanical armature operating to deliver the at least one beam of light to any location within a workspace; 15 a positioning controller operable to direct that said mechanical armature be positioned according to an optical scan plan; an optical alignment system within the one or more optical transmission channels used to guide the at least one 20 beam of light through the one or more optical transmission channels; a first optical assembly that directs the at least one beam of light to the object under test, the at least one beam of light generating ultrasonic displacements in said 25 object under test; an optical receiver operable to collect light incident from the at least one beam of light on said object under test and modulated by said ultrasonic displacements in said object under test; and 30 a processor operable to determine from said collected light and display an internal structure of said object under test. 17 C:\NRPonbl\DCC\AXL\2609277 1.DOC-4/I12/2)9

2. A system that guides a beam of light through axes of a mechanical positioning system and directs the beam of light at an object under test as defined in Claim 1 wherein said 5 mechanical armature further comprises a plurality of segments pivotally connected and operated using actuators that direct said mechanical armature within said workspace.

3. A system that guides a beam of light through axes of a 10 mechanical positioning system and directs the beam of light at an object under test as defined in Claim 1 wherein said beam of light comprises a laser beam.

4. A system that guides a beam of light through axes of a 15 mechanical positioning system and directs the beam of light at an object under test as defined in Claim 1: wherein said first optical assemble comprises a beam conditioning system that minimizes divergence of said at least one beam of light as the at least one beam of light 20 exits said mechanical armature; and wherein the one or more optical transmission channels further comprises a beam conditioning system that minimizes divergence of said at least one beam of light as the at least one beam of light propagates within the one or more 25 optical transmission channels.

5. A system that guides a beam of light through axes of a mechanical positioning system and directs the beam of light at an object under test as defined in Claim 1: 30 wherein the system further comprises a rotation platform operable to further direct the at least one beam of light to the object under test; and 18 C:\NRPonbM\DCCAXLA2609227_ IDOC4112/2009 wherein the mechanical armature comprises a robotic type armature.

6. A system that guides a beam of light through axes of a 5 mechanical positioning system and directs the beam of light at an object under test as defined in Claim 1 wherein said axes of motion comprise gantry members pivotally connected to allow for freedom of movement in multiple directions. 10

7. A system that guides a beam of light through axes of a mechanical positioning system and directs the beam of light at an object under test as defined in Claim 1 that provides for ultrasonic testing of the object under test from a first field of view, and at least one additional field of view 15 oriented normally to said first field of view.

8. A system that guides a beam of light through axes of a mechanical positioning system and directs the beam of light at an object under test as defined in Claim 1: 20 wherein said at least one remote light source comprises a CO 2 gas laser; wherein each gantry member is associated with at least one of the one or more optical transmissions channels; and wherein at least one mirror directs the beam of light 25 between the one or more optical transmission channels.

9. A system that guides a beam of light through axes of a mechanical positioning system and directs the beam of light at an object under test as defined in Claim 8: 30 wherein said at least one mirror is located at connection points of said mechanical armature; and wherein actuators adjust an angular alignment of said 19 C:NRPonbl\DCC\AXL\26(9277 I DOC-/12/2009 at least one mirrors in response to said alignment signals.

10. A system that guides a beam of light through axes of a mechanical positioning system and directs the beam of light 5 at an object under test as defined in Claim 9 wherein the system further includes a calibration controller to correct for positioning errors of the at least one beam of light through the one or more optical transmission channels. 10

11. A system that guides a beam of light through axes of a mechanical positioning system and directs the beam of light at an object under test as defined in Claim 3 further comprising a laser beam conditioning system that minimizes divergence of said laser beam within said mechanical 15 armature.

12. A system that guides a beam of light through axes of a mechanical positioning system and directs the beam of light at an object under test as defined in Claim 11 wherein the 20 system further comprises at least one lens at predetermined locations along a propagation path of said laser beam wherein said at least one lens reshapes said laser beam as said laser beam propagates. 25

13. A system that guides a beam of light through axes of a mechanical positioning system and directs the beam of light at an object under test as defined in Claim 1 wherein said optical scan plan derives CAD data on said object under test. 30

14. A method of guiding at least one beam of light through axes of a mechanical positioning system and directing the at 20 CNRPonbl\DCC\AXL\2649277_I DOC-4/12/2009 least one beam of light at an object under test, the method comprising the steps of: generating at least one beam of light from a remote light source; 5 injecting said at least one beam of light into a mechanical armature; transmitting said at least one beam of light along axes of motion of said mechanical armature via an optical transmission channel, wherein said mechanical armature 10 operates to deliver the at least one beam of light to any location within a workspace; directing said mechanical armature be positioned according to an optical scan plan by a positioning controller; 15 guiding the at least one beam of light through the optical transmission channel using an optical alignment system positioned within said optical transmission channel; directing with a first optical assemble the at least one beam of light to the object under test, wherein said at 20 least one beam of light generates ultrasonic displacements in said object under test; collecting phase modulated light scattered by said ultrasonic displacements; and processing said phase modulated light to determine and 25 display an internal structure of said object under test.

15. A method as defined in Claim 14: wherein said mechanical armature further comprises a plurality of segments pivotally connected and operated using 30 actuators that direct said mechanical armature within said workspace; wherein said beam of light comprises a laser beam; 21 C:\NRPonbNDCCAXI\26A9277_ .DOC-4/12/219 wherein said axes of motion comprise gantry members pivotally connected to allow for freedom of movement in multiple directions; wherein the optical transmission channel is a plurality 5 of optical transmission channels, each of the plurality of optical transmission channels being associated with a gantry member; and wherein at least one mirror directs the beam of light between said optical transmission channels. 10

16. A method as defined in Claim 15 further comprising the step of conditioning the beam of light to minimize divergence of said at least one beam of light as the at least one beam of light exits said mechanical armature. 15

17. A method as defined in Claim 14 further comprising the step of directing the at least one beam of light at the object under test with a rotation platform. 20

18. A method as defined in Claim 14 that provides for ultrasonic testing of the object under test from a first field of view, and at least one additional field of view oriented normally to said first field of view and wherein said at least one remote light source comprises a CO 2 gas 25 laser.

19. A method as defined in Claim 14 further comprising the steps of: modeling said object under test with CAD or empirical 30 methods; determining an orientation of said object under test relative to said mechanical armature; 22 C.\NRPortbl\DCC\AXL\26092177 DOC4/12/2t(X9 developing said optical scan plan based on said step of modeling an object under test and determining an orientation of said object under test; and mapping said internal structure of said object under 5 test to a model of said object under test.

20. A method as defined in Claim 19 further comprising the steps of: locating said object under test within said workspace; 10 and correcting said optical scan plan for positioning errors within said workspace.

21. A system or a method, substantially as hereinbefore 15 described with reference to the accompanying drawings. 23