Method and apparatus for locating non-visible objects
11448793 · 2022-09-20
Assignee
Inventors
Cpc classification
B21J15/28
PERFORMING OPERATIONS; TRANSPORTING
B23B49/00
PERFORMING OPERATIONS; TRANSPORTING
G01V3/15
PHYSICS
G01V3/081
PHYSICS
G01D5/145
PHYSICS
International classification
G01V5/14
PHYSICS
G01V3/08
PHYSICS
B21J15/28
PERFORMING OPERATIONS; TRANSPORTING
B23B49/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Non-visible objects which differ in their physical properties from their surroundings by association with a variable strength magnetic field may be detected by a suitable array of sensors which can be moved relative to the object in question. By analyzing the signals from the plurality of the sensors in the array, the position of the object can be deduced relative to the array and the array moved to enable a machining guide thereon to be aligned with the non-visible object. The system is of particular value in locating apertures in wing spars when attempting to fix the skin of the wing on to them where it is important to be able to locate the correct point at which to drill a hole through the skin to coincide with the hole in the spar. By defining a magnetic field in the vicinity of the hole to identify the hole magnetically and using an array of magnetic field sensors in a base with an aperture, it is possible to shift the array so that the aperture is precisely aligned with the non-visible hole.
Claims
1. An apparatus for locating a non-visible object, the non-visible object operable to generate a magnetic field, the apparatus comprising: a base member; a machining guide; a plurality of magnetic field strength sensors, wherein the plurality of magnetic field strength sensors and the machining guide are movable together while each of the plurality of magnetic field strength sensors are fixed positionally relative to the machining guide, wherein the plurality of magnetic field strength sensors are arranged in first and second concentric circles; and a visual indicator operable to present information indicative of a displacement between the non-visible object and the machining guide; wherein each of a first subset plurality of the plurality of magnetic field strength sensors, in the first of the concentric circles, are positioned a first distance from the machining guide, wherein each of a second subset plurality of the plurality of magnetic field strength sensors, in the second of the concentric circles, are positioned a second distance from the machining guide that is greater than the first distance.
2. The apparatus of claim 1, further comprising a vacuum pad to lock the position of the base member on a surface.
3. The apparatus of claim 1, wherein the plurality of magnetic field strength sensors comprise Hall effect sensors.
4. The apparatus of claim 1, wherein the plurality of magnetic field strength sensors are arranged in a symmetrical array about the machining guide.
5. The apparatus of claim 1, wherein the machining guide is a drilling guide to provide a bore on a surface.
6. The apparatus of claim 1, further comprising a robot configured to control movement of machining guide.
7. The apparatus of claim 6, wherein the robot comprises a movable base.
8. The apparatus of claim 1, further comprising a robot arm configured to move the machining guide to a position located adjacent to the non-visible object.
9. An apparatus for locating a non-visible object, the non-visible object operable to generate a magnetic field, the apparatus comprising: a base member; a machining guide; a plurality of magnetic field strength sensors, wherein the plurality of magnetic field strength sensors and the machining guide are movable together while each of the plurality of magnetic field strength sensors are fixed positionally relative to the machine guide, wherein the plurality of magnetic field strength sensors are arranged in first and second concentric circles; a robot configured to control movement of the plurality of magnetic field strength sensors and machining guide based on measurements from the plurality of magnetic field strength sensors; wherein each of a first subset plurality of the plurality of magnetic field strength sensors, in the first of the concentric circles, are positioned a first distance from the machining guide, wherein each of a second subset plurality of the plurality of magnetic field strength sensors, in the second of the concentric circles, are positioned a second distance from the machining guide that is greater than the first distance.
10. The apparatus of claim 9, wherein the robot comprises a movable base.
11. The apparatus of claim 9, further comprising a vacuum pad to lock the position of the base member and the object relative to one another.
12. The apparatus of claim 9, wherein the plurality of magnetic field strength sensors comprise Hall effect sensors.
13. The apparatus of claim 9, wherein the plurality of magnetic field strength sensors are arranged in a symmetrical array about the machining guide.
14. The apparatus of claim 9, wherein the machining guide is a drilling guide to provide a bore on a surface.
Description
DESCRIPTION OF THE DRAWINGS
(1) By way of further explanation of the invention, and by way of illustrating how it can be put into practical use, reference is made to the accompanying drawings, in which:
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DETAILED DESCRIPTION
(11) Referring to
(12) In order to enable detection of the position of the hole 2, a magnet assembly 4 set in a suitable mounting is located relative to the hole 2 from below as shown in
(13) Located on top of plate 3 as shown in
(14) Alternative arrangements of sensors are conceivable, and two further examples are illustrated in
(15) As will be appreciated, the end of the magnet assembly 4 inserted into hole 2 is the centre location of a generally symmetric magnetic field having its maximum located in terms of the upper surface of plate 3 at the point on that upper surface which is precisely aligned with the axis of hole 2. At points on the upper surface of plate 3 more remote from that point, the magnetic field strength is less. The magnetic field strength at any point on the surface can be measured using a 1-all effect sensor.
(16) The reader will appreciate that any other magnetic field strength sensor could be used, such as an eddy current based sensor.
(17) The Hall effect sensors 12 are connected via a suitable signal-carrying cable 16 to an evaluation electronics, for example in the form of a laptop computer or PDA.
(18) It will readily be appreciated that if the array 10 is located as shown in
(19) If the array 10 is shifted from its position in
(20)
(21) The system shown on the left of the drawing corresponds to the operation as illustrated in
(22) However, the system may also be operated the “other way round”, as shown on the right of
(23) Referring now to
(24) The apparatus consists basically of a main pneumatics and power supply equipment box 30, a movable drilling guide 31 which, as can be seen, is held against the skin 21, and which contains the electronics described below and a display unit at a housing 32. Box 30 has a suitable power supply lead 37 for connecting to a source of electrical power.
(25) On the underside of the unit 31 and accordingly not visible in
(26) Unit 31 also carries two vacuum line switches 34 and 35 which can be actuated by the user of the system to hold unit 31 very firmly against skin 21, i.e. in fixed position relative thereto, and which can be adjusted to release the vacuum slightly so that unit 31 can be moved around on skin 21. Umbilical lead 36 provides air and power to unit 31 from box 30.
(27) Before using the apparatus, to locate one of the holes 22 not visible behind skin 21, a magnet is placed in one of the holes 22 so that a symmetrical magnetic field spreads out through the skin 21 and its field strength can be detected adjacent the surface of skin 21 visible in
(28) By appropriate processing of the signals received from the individual Hall effect sensors in the array on the underside of unit 31, the location of the maximum magnetic field strength point can be found and, more particularly, displayed on a simple screen display 40 set in housing 32. Display 40 can be a PDA and housing 32 a docking station. Housing 32 may be affixed by means of a suction cup to the visible side of skin 21 at any convenient point. Fixture is effected by a suction cup actuation lever 41 on housing 32 and the display 40 is connected via a signal cable 44 with the electronics in unit 31. As can be seen on display 40, the display consists of a pair of concentric circles 45, 46 and a (fixed) vertical and horizontal crossbar structure 47. The electronics are arranged to show on the screen the position of the point of maximum magnetic field strength. The crossbar structure 47 is positioned such that it corresponds to the drilling aperture 33, i.e. as unit 31 is moved, so concentric circles 45 and 46 on the display move likewise. It is accordingly very straightforward, with unit 32 stationary but unit 31 being movable, to move unit 31 into a position where the smaller circle 45 is precisely central relative to the crossbar structure 47. The positioning is easy and intuitive and analogous to aligning the target with the crosshairs in a telescopic rifle sight.
(29) Once this coincidence has been achieved, unit 31 may then be clamped firmly in position on skin 21 and aperture 33 used as a drilling guide enabling a bore to be made in skin 21 which is precisely perpendicular to the surface of skin 21 and which is precisely coincident with the bore 22 in spar 20 which carried the magnet during the positioning process. The bore may accordingly be made, unit 31 taken out of the way, a rivet inserted and fixed in position, and the process then repeated for the purpose of drilling the next hole in skin 21 to align with the next aperture 22 in the rib.
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(31) The dashed boxes in
(32) Located on the output side of power supply unit 51 is a power supply supervisor unit 62 which is used to monitor the sensor voltage supply and to indicate, for example by flashing up a message on display 40, if there is a problem.
(33) Turning now to the Hall effect sensor array, this is denoted 55 in
(34) The electronics also has an output interface 61 which can be used to control any external apparatus, for example a monitoring computer or a robot control computer.
(35) In that context, a second embodiment of the invention is now described with reference to
(36) A head 126 is then connected to the distal end of the second arm 122 with a ball joint 128. The head 126 has a magazine 130 in which is incorporated a sensor array as previously described, and which will be further described in due course with reference to
(37) Each of the elbow hinges 120, 124 and the ball joint 128, are under the control of suitable drive means as will be understood by the reader familiar with robotics. In particular, the robot 100 will be under computer control, and the motion will be imparted by suitable stepping motors or the like, with positional control sufficient to ensure the accurate positioning of the head 126. Detailed description of such features is not essential to the understanding of this embodiment of the invention.
(38) The magazine 130 is illustrated in further detail in
(39) Six head units are illustrated, which are spaced equiangularly about a central axis of the magazine. The heads comprise: a sensor array 140; a drill 142; a countersink drill 144, a polisher 146; a sealant dispenser 148; and a riveting tool 150.
(40) The magazine 130 is rotatable about its own cylindrical axis (by drive means again not illustrated for reasons of clarity), to allow presentation of each of the six units in turn by rotation of the magazine through increments of 60 degrees. The robot head is thus able to perform each of the six operations involved in inserting a rivet in a designated point in a mechanical component, the point being indicated by way of a magnetic field generating object as previously described, or on the basis of detection of a hole in an object behind the skin to be drilled, with the magnetic field to achieve this being generated behind the sensor array in such a circumstance.
(41) Thus, in this embodiment, the drilling axis is not coincident with the sensor array. In this embodiment, the drilling axis (and indeed the countersinking axis) is displaced away from the sensor array, but by a fixed amount by virtue of the fixed relationship between the sensor array 140 and the drill 142.
(42) It will be appreciated that this is but one example of a factory automation arm, or machine, which could serve to implement an embodiment of the present invention. A linear arrangement, including a linearly displaceable magazine, could also be provided. A gantry style robot could be used instead of an “arm” style machine. The level of artificial intelligence provided in such a robot is not an essential part of the present invention, as control electronics for the sensor, and thus for the magazine as a whole, should be in line with the electronics illustrated in
(43) The following clauses are provided as further descriptions of example embodiments.
(44) Clause 1—a method of locating an object that is lying behind an opaque surface, the method comprising: providing in the neighbourhood of the object a variable strength magnetic field; using an array of Hall effect magnetic sensors for sensing the magnetic field strength of the provided magnetic field at a plurality of positions relative to the object, the array of Hall effect sensors being associated geometrically with a machining guide, such that the machining guide and the array of sensors are fixed positionally one relative to the other; interrogating at least a majority of the sensors in the array to determine a value of the field strength; receiving sensor responses from the interrogated sensors, and analyzing the received sensor responses to determine the displacement between the object and the machining guide; and moving the array to a position at which the determined displacement is at a minimum, wherein so moving the array correspondingly moves the machining guide that is fixed positionally relative to the array, and wherein so moving the array also locates the machining guide immediately and centrally over a point on the opaque surface that is opposite the object lying behind.
(45) Clause 2—the method according to clause 1, wherein once the machining guide is located adjacent the surface at that point of the surface immediately and centrally overlying the object in question, the position of the array and machining guide is fixed.
(46) Clause 3—the method according to clause 2, wherein the fixation is effected by locking the array on to the surface via vacuum pads.
(47) Clause 4—the method according to clause 1, wherein the object is a hole relative to which a magnet or body of ferromagnetic material is located.
(48) Clause 5—an apparatus for locating non-visible objects positioned behind an opaque surface, which apparatus comprises: means to generate a variable strength magnetic field; a base member adapted to be placed on or against the surface; means in the base member defining a machining guide; an array of H-all effect sensors located relative to the machining guide, and means for collecting and analysing outputs from at least some of the sensors to provide an indication of the variation of the magnetic field associated with the object relative to the position of the base member.
(49) Clause 6—the apparatus according to clause 5, wherein the base member is adapted to be moved across the surface to enable the machining guide to be aligned with the object.
(50) Clause 7—the apparatus according to clause 5, and including fixing means adapted to lock the position of the base member and the object relative to one another.
(51) Clause 8—the apparatus according to clause 5, and wherein the means for analysing includes a visual display means adapted to indicate the location of the object relative to the array of sensors, and accordingly to indicate when the array is positioned with the machining guide associated therewith located closest to the non-visible object.
(52) Clause 9—the apparatus according to clause 5, wherein the array of Hall effect sensors is a cruciform array.
(53) Clause 10—the apparatus according to clause 8, wherein the visual display is a computer-driven flat display screen adapted to represent in appropriate symbolic fashion the location of the object and the location of the machining guide.
(54) Clause 11—a method of locating an object lying behind an opaque surface rendering the object non-visible, which comprises: providing in the neighbourhood of the object a variable strength magnetic field; sensing the magnetic field strength at a plurality of positions relative to the object using an array of magnetic field strength sensors, the array of magnetic field strength sensors being associated geometrically with a machining guide, such that the machining guide and the array of sensors are fixed positionally one relative to the other; interrogating the sensors to determine the value of the field strength with at least the majority of the sensors; analysing the sensor responses to determine the displacement between the object and the machining guide, and moving the array and machining guide by means of non-manual mechanical control to a position in which the displacement is a minimum.
(55) Clause 12—the method according to clause 11, wherein once the machining guide is located adjacent the surface at that point of the surface immediately and centrally overlying the object in question, the position of the array and machining guide is fixed.
(56) Clause 13—the method according to clause 11, wherein the object is a hole relative to which a magnet or body of ferromagnetic material is located.
(57) Clause 14—an apparatus for locating a non-visible object positioned behind an opaque surface, which apparatus comprises: means to generate a variable strength magnetic field; a base member adapted to be placed on or against the surface; means in the base member defining a machining guide; an array of magnetic field strength sensors located relative to the machining guide; means for collecting and analysing outputs from at least some of the sensors to provide an indication of the variation of the magnetic field associated with the object relative to the position of the base member; and means for mechanically controlling movement of the array and machining guide operable, in use, to control movement in response to analysed sensor signals.
(58) Clause 15—the apparatus for locating a non-visible object positioned behind an opaque surface, such an object being in use operable to generate a magnetic field variable with physical location, the apparatus comprising: a base member adapted to be placed on or against the surface; means in the base member defining a machining guide; an array of magnetic field strength sensors located relative to the machining guide; means for collecting and analysing outputs from at least some of the sensors to provide an indication of the variation of the magnetic field associated with the object relative to the position of the base member; and means for mechanically controlling movement of the array and machining guide operable, in use, to control movement in response to analysed sensor signals.
(59) Clause 16—the apparatus according to clause 14, wherein the means for mechanically controlling movement is a robot arm.
(60) Clause 17—the apparatus according to clause 14, wherein the means for mechanically controlling movement is operable to move the array and machining guide to a position located adjacent to the non-visible object.
(61) Clause 18—the apparatus according to clause 14, wherein the base member is adapted to be moved across the surface to enable the machining guide to be aligned with the object.
(62) Clause 19—the apparatus according to clause 14, and including fixing means adapted to lock the position of the base member and the object relative to one another.
(63) Clause 20—the apparatus according to clause 14, wherein the array of magnetic field strength sensors is a cruciform array.
(64) Clause 21—a method of locating an object lying behind an opaque surface rendering the object non-visible, which comprises: providing in the neighbourhood of the object a variable strength magnetic field; sensing the magnetic field strength at a plurality of positions relative to the object using an array of magnetic field sensors, the array of magnetic field sensors being associated geometrically with a machining guide, such that the machining guide and the array of sensors are fixed positionally one relative to the other, interrogating the sensors to determine the value of the field strength with at least the majority of the sensors; analysing the sensor responses to determine the displacement between the object and the machining guide; and moving the array and machining guide to a position in which the displacement is a minimum.
(65) Clause 22—the method in accordance with clause 21, wherein the magnetic field sensors are operable to measure field direction and including interrogating the sensors to determine the field direction with at least the majority of the sensors.
(66) Clause 23—an apparatus for locating non-visible objects positioned behind an opaque surface, which apparatus comprises: means to generate a variable strength magnetic field; a base member adapted to be placed on or against the surface; means in the base member defining a machining guide; an array of magnetic field sensors located relative to the machining guide; and means for collecting and analysing outputs from at least some of the sensors to provide an indication of the variation of the magnetic field associated with the object relative to the position of the base member.
(67) Clause 24—the apparatus in accordance with clause 23, wherein the magnetic field sensors are operable to measure field strength and direction.
(68) Clause 25—the apparatus in accordance with clause 24, wherein the magnetic field sensors are Hall effect sensors.
(69) Clause 26—the apparatus in accordance with clause 24, wherein the magnetic field sensors are operable to measure field strength in two substantially orthogonal axes, to determine a measure of field direction resolved into a plane.
(70) Clause 27—the apparatus in accordance with clause 24, wherein the magnetic field sensors are operable to measure field strength in three substantially orthogonal axes, to determine a measure of field direction.
(71) Clause 28—a method of locating an object lying behind an opaque surface rendering the object non-visible, which comprises: providing in the neighbourhood of the object a variable strength magnetic field; sensing the magnetic field strength at a plurality of positions relative to the object using an array of magnetic field strength sensors, the array of magnetic field strength sensors being associated geometrically with a machining guide, such that the machining guide and the array of sensors are fixed positionally one relative to the other; interrogating the sensors to determine the value of the field strength with at least the majority of the sensors; analysing the sensor responses to determine the displacement between the object and the machining guide; and moving the array and machining guide by means of non-manual mechanical control to a position in which the displacement is a minimum.
(72) Clause 29—an apparatus for locating a non-visible object positioned behind an opaque surface, which apparatus comprises: means to generate a variable strength magnetic field; a base member adapted to be placed on or against the surface; means in the base member defining a machining guide; an array of magnetic field strength sensors located relative to the machining guide; means for collecting and analysing outputs from at least some of the sensors to provide an indication of the variation of the magnetic field associated with the object relative to the position of the base member, and means for mechanically controlling movement of the array and machining guide operable, in use, to control movement in response to analysed sensor signals.
(73) Clause 30—an apparatus for locating a non-visible object positioned behind an opaque surface, such an object being in use operable to generate a magnetic field variable with physical location, the apparatus comprising a base member adapted to be placed on or against the surface, means in the base member defining a machining guide, an array of magnetic field strength sensors located relative to the machining guide, means for collecting and analysing outputs from at least some of the sensors to provide an indication of the variation of the magnetic field associated with the object relative to the position of the base member, and means for mechanically controlling movement of the array and machining guide operable, in use, to control movement in response to analysed sensor signals.