Airborne ultrasonic ranging is used in a variety of different engineering applications for which other positional metrology techniques cannot be used, for example in closed-cell locations, when optical line of sight is limited, and when multipath effects preclude electromagnetic-based wireless systems. Although subject to fundamental physical limitations, e.g., because of the temperature dependence of acoustic velocity in air, these acoustic techniques often provide a cost-effective solution for applications in mobile robotics, structural inspection, and biomedical imaging. In this article, the different techniques and limitations of a range of airborne ultrasonic ranging approaches are reviewed, with an emphasis on the accuracy and repeatability of the measurements. Simple time-domain approaches are compared with their frequency-domain equivalents, and the use of hybrid models and biologically inspired approaches are discussed.

Environmental and commercial drivers are leading to a circular economy, where systems and components are routinely recycled or remanufactured. Unlike traditional manufacturing, where components typically have a high degree of tolerance, components in the remanufacturing process may have seen decades of wear, resulting in a wider variation of geometries. This makes it difficult to translate existing automation techniques to perform Non-Destructive Testing (NDT) for such components autonomously. The challenge of performing automated inspections, with off-line tool-paths developed from Computer Aided Design (CAD) models, typically arises from the fact that those paths do not have the required level of accuracy. Beside the fact that CAD models are less available for old parts, these parts often differ from their respective virtual models. This paper considers flexible automation by combining part geometry reconstruction with ultrasonic tool-path generation, to perform Ultrasonic NDT. This paper presents an approach to perform custom vision-guided ultrasonic inspection of components, which is achieved through integrating an automated vision system and a purposely developed graphic user interface with a robotic work-cell. The vision system, based on structure from motion, allows creating 3D models of the parts. Also, this work compares four different tool-paths for optimum image capture. The resulting optimum 3D models are used in a virtual twin environment of the robotic inspection cell, to enable the user to select any points of interest for ultrasonic inspection. This removes the need of offline robot path-planning and part orientation for assessing specific locations on a part, which is typically a very time-consuming phase.

Unmanned aerial vehicles (UAVs) are seeing increasing adoption to automated remote and in situ inspection of industrial assets, removing the need for hazardous manned access. Aerial manipulator architectures supporting pose-decoupled exertion of force and torque would further enable UAV deployment of contact-based transducers for sub-surface structural health assessment. Herein, for the first time, we introduce an over-actuated multirotor deploying a dry-coupled ultrasonic wheel probe as a novel means of wall thickness mapping. Using bi-axial tilting propellers in a unique tricopter layout, this system performs direct thrust vectoring for efficient omnidirectional flight and application of interaction forces. In laboratory testing, we demonstrate stable and repeatable probe deployment in a variety of representative asset inspection operations. We obtain a mean absolute error (MAE) in measured thickness of under 0.10 mm when measuring an aluminum sample with varying wall thickness. This is maintained over repeated exit and reentry of surface contact and when the sample is mounted vertically or on the underside of a 45° overhang. Furthermore, when rolling the probe dynamically across the sample surface in an area scanning modality, an MAE in wall thickness below 0.28 mm is recorded. Multi-modal operational confidence bounds of the system are thereby quantitatively defined. Note to Practitioners—Motivation for this article stems from the desire to enhance the speed and level of insight into structural health currently offered through remote aerial inspection processes. We approach this by integration of a thrust vectoring multirotor platform with a dry-coupling wheel probe for aerial ultrasonic thickness measurement. This system reliably presses the probe into the target surface and obtains point measurements across various surface orientations without a stabilizing frame. This broadens applicability and permits novel inspections where couplant gel would otherwise contaminate the surface and require manual cleaning. We profile thickness along a scanned linear section, a mode suited to corrosion mapping of large surface areas such as petrochemical storage tanks, pipework, or similar assets. We also make detailed consideration toward measurement accuracy, repeatability, and localization, an aspect commonly overlooked in literature. Future work to characterize variable friction effects currently limiting rolling scan speed and measurement coverage density may be beneficial. Quantitative study of the effectiveness of dry-couplant in the presence of any uncommon surface contaminants specific to a desired use-case is also advised.

Miniature robotic vehicles are receiving increasing attention for use in nondestructive testing (NDE) due to their attractiveness in terms of cost, safety, and their accessibility to areas where manual inspection is not practical. Conventional ultrasonic inspection requires the provision of a suitable coupling liquid between the probe and the structure under test. This necessitates either an on board reservoir or umbilical providing a constant flow of coupling fluid, neither of which are practical for a fleet of miniature robotic inspection vehicles. Air-coupled ultrasound offers the possibility of couplant-free ultrasonic inspection. This paper describes the sensing methodology, hardware platform and algorithms used to integrate an air-coupled ultrasonic inspection payload into a miniature robotic vehicle platform. The work takes account of the robot's inherent positional uncertainty when constructing an image of the test specimen from aggregated sensor measurements. This paper concludes with the results of an automatic inspection of a aluminium sample.