ULTRASONIC DEVICE

Abstract

An ultrasonic device, the device comprising at least one flexible ultrasonic transducer; and a clamp configured to mount the at least one transducer to a test object. Optionally, the clamp may comprise one or more bands and wherein the one or more bands can optionally be metal or at least part of the one or more bands may be formed of a conformable material such that the one or more bands comprises a conformable band or band portion.

Claims

1. An ultrasonic device, the device comprising: at least one flexible ultrasonic transducer; and a clamp configured to mount the at least one flexible ultrasonic transducer to a test object.

2. The device of claim 1 in which the clamp comprises one or more bands.

3. The device of claim 2, wherein at least part or all of the one or more bands is metal.

4. The device of claim 2, wherein at least part of the one or more bands is formed of a conformable material such that the one or more bands comprise a conformable band or band portion.

5. The device according to claim 4, wherein the conformable material is an elastomeric material that is stable at temperatures from −100° C. to 300° C. or higher.

6. The device according to claim 4, wherein the at least one flexible ultrasonic transducer is inserted, insertable or at least partially or fully embedded or moulded into the conformable band or band portion.

7. The device according to claim 2, wherein the at least one band is configured with a securer for locking the band to and/or selectively releasing the band from the test object and/or adjusting the tension in the band.

8. The device according to claim 1, further comprising an urging mechanism, configured to urge the at least one flexible ultrasonic transducer towards and/or onto the test object, in use.

9. The device according to claim 8, wherein the urging mechanism is configured such that position of, or the force applied by the urging mechanism on, the at least one flexible ultrasonic transducer is selectively variable or adjustable by operation of the urging mechanism.

10. The device according to claim 8, wherein the urging mechanism comprises a screw or a rotational assembly.

11. The device according to claim 10, wherein the screw or the rotational assembly is coupled to the at least one flexible ultrasonic transducer via a coupling, the coupling being configured to accommodate the rotational motion of the screw without transferring rotational motion to the at least one flexible ultrasonic transducer.

12. The device according to claim 8, comprising a conformable buffer between the coupling and/or urging mechanism and the at least one flexible ultrasonic transducer.

13. The device according to claim 12, wherein the conformable buffer is configured to withstand temperatures of 150° C., 250° C., 300° C. or higher.

14. The device of claim 1, wherein the ultrasonic device is configured to operate at temperatures between 100° C. and 500° C.

15. The device of claim 1, further comprising one or more temperature sensors integrated into the ultrasonic device.

16. The device of claim 1, wherein the at least one flexible ultrasonic transducer is arranged in a transducer array.

17. The device according to claim 1, wherein the at least one flexible ultrasonic transducer of the transducer array comprises a layer of polycrystalline, inorganic piezoelectric material on a metallic foil substrate.

18. The device of claim 17, in which each flexible ultrasonic transducer of the transducer array comprises one or more discrete electrodes provided directly on the layer of polycrystalline, inorganic piezoelectric material and the metallic foil substrate is operable as a counter electrode.

19. The device according to claim 17, in which the layer of piezoelectric material has a thickness in the range of 2 to 20 μm; and/or the layer of polycrystalline, inorganic piezoelectric material is thinner than the metallic foil substrate.

20. The device according to claim 2, comprising a plurality of flexible ultrasonic transducers distributed along the one or more bands.

21. The device according to claim 20, wherein the at least one flexible ultrasonic transducer is provided on and/or feedable from a reel or spool.

22. The device according to claim 20, wherein a plurality of the at least one flexible ultrasonic transducers have different intra-transducer spacings therebetween.

23. A method of manufacturing, repairing or assembling the ultrasonic device of claim 1, the method comprising: providing at least one flexible ultrasonic transducer and a clamp; and mounting the at least one transducer to the clamp.

24. A method comprising: mounting the ultrasonic device of claim 1 to a test object using the clamp; bringing the at least one transducer or transducer array into contact and/or onto a surface of the test object; and providing a test signal to the transducer array and/or receiving the output signal from the ultrasonic transducer array.

25. Computer readable code that, when processed by an automated manufacturing system controller, causes the automated manufacturing system to produce at least part of the ultrasonic device of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] These and other aspects of the present disclosure will now be described, by way of example only, with reference to the accompanying Figures, in which:

[0052] FIG. 1 is a perspective view of an ultrasonic device;

[0053] FIG. 2 is a perspective view of the ultrasonic device of FIG. 1, in use, mounted on a test object in the form of a pipe;

[0054] FIG. 3 is a plan view of the ultrasonic device of FIG. 1, in use, mounted on a test object in the form of a pipe;

[0055] FIG. 4 is a side elevation view of the ultrasonic device of FIG. 1, in use, mounted on a test object in the form of a pipe;

[0056] FIG. 5 is an end elevation view of the ultrasonic device of FIG. 1, in use, mounted on a test object in the form of a pipe;

[0057] FIG. 6 is a cross sectional view through the section A-A indicated on FIG. 5 through the ultrasonic device of FIG. 1, in use, mounted on a test object in the form of a pipe;

[0058] FIG. 7 is a cross sectional view through the section B-B indicated on FIG. 8 through the ultrasonic device of FIG. 1, in use, mounted on a test object in the form of a pipe;

[0059] FIG. 8 is a side elevation view of the ultrasonic device of FIG. 1, in use, mounted on a test object in the form of a pipe;

[0060] FIG. 9 is a plan view of a flexible ultrasonic transducer array that could be used in the ultrasonic device of FIG. 1;

[0061] FIG. 10 is a cross sectional side view of the ultrasonic transducer array of FIG. 9;

[0062] FIG. 11 is a perspective view of another ultrasonic device, in use, mounted on a test object in the form of a pipe;

[0063] FIG. 12 is a side elevation view of the ultrasonic device of FIG. 11, in use, mounted on a test object in the form of a pipe;

[0064] FIG. 13 is a perspective view of the ultrasonic device shown in FIG. 11;

[0065] FIG. 14 is a side view of the ultrasonic device shown in FIG. 11 in a flat configuration;

[0066] FIG. 15 is a cross sectional view through a band of the ultrasonic device shown in FIG. 11;

[0067] FIG. 16 is a flowchart of a method of assembling an ultrasonic transducer; and

[0068] FIG. 17 is a flowchart of a method of using an ultrasonic transducer.

DETAILED DESCRIPTION OF THE DRAWINGS

[0069] FIGS. 1 to 8 show an example of an ultrasonic device 5 for emitting ultrasonic waves and receiving and measuring the reflected ultrasonic waves in order to produce a signal representative of one or more parameters of the received ultrasonic waves. The specific examples shown in FIGS. 2 to 8 illustrate the use of the ultrasonic device in order to beneficially perform non-destructive testing, NDT, (e.g. wall thickness measurements) of a test object, which in this particular example is a pipe, such as an oil or other fluid or gas pipeline. However, the ultrasonic device 5 is not limited to this application and it will be appreciated that it could be used in other applications such as imaging, e.g. medical imaging, amongst others.

[0070] The device 5 comprises a device body 15, a clamp 20 and one or more ultrasonic transducers (in this example a plurality of the ultrasonic transducers are provided in an ultrasonic transducer array 25, which can be seen particularly in FIGS. 6, 7, 9 and 10).

[0071] As shown in FIGS. 9 and 10, in an example, the ultrasonic transducer array 25 is a flexible ultrasonic transducer array comprising a flexible, electrically conductive substrate 30, in this example in the form of a metal foil, with a piezoelectric layer 35 on a surface of the substrate 30. In this example, the piezoelectric layer 35 is in the form of a layer of non-polymeric, inorganic piezoelectric material, such as zinc oxide (ZnO) or aluminium nitride (AlN), optionally doped with a transition metal or transition metal compound such as vanadium. The piezoelectric layer 35 can be deposited directly onto the substrate by methods such as sputter coating and the like. In this example, the substrate 30 acts as a counter electrode and is arranged towards the test object 10 in use.

[0072] An array of electrodes 40 is provided on a surface of the piezoelectric layer 35 that is on an opposite side of the piezoelectric layer 35 to the substrate 30, such that the piezoelectric layer 35 is between the electrodes 40 and the substrate 30. Each electrode 40 is electrically connected to a corresponding electrical contact 45 by a respective conductive track 50. Each electrode and the associated portion of the piezoelectric layer 35 and substrate 30 can be considered to form a transducer of the transducer array 25. Each electrode 40 is individually addressable to drive the electrode 40 and to read out signals collected by the electrode 40. Electrically resistive dielectric material, such as photoresist e.g. SU-8, can optionally be provided between the piezoelectric layer 35 and both the conductive tracks 50 and contacts 45 and also between discrete electrodes 40, contacts 45 and conductive tracks 50 to mitigate against cross-talk.

[0073] For example, a control device (not shown) can be connected to the electrical contacts 45 to provide alternating drive signals to the electrodes 40 via the respective conductive tracks 50 in order to create a potential difference across the corresponding portions of the piezoelectric layer 35 that correspond to the driven electrode 40, so as to cause the corresponding portion of the piezoelectric layer 35 to oscillate with a frequency corresponding to that of the drive signal to thereby produce an ultrasonic wave having a corresponding frequency. Reflections of the emitted ultrasonic waves can also be received by the ultrasonic transducer array 25, causing at least portions of the piezoelectric layer 35 to oscillate, which thereby generates an electrical signal having a frequency dependent on that of the received ultrasonic wave. This can be received by the control device via the electrodes 40, conductive tracks 50 and contacts 45.

[0074] Examples of flexible ultrasonic transducers and ultrasonic transducer arrays that could be used (or at least features thereof) in the present examples are described in GB1803444.7, GB 1803257.3, GB2555835, WO2018/087560, PCT/GB2019/050567 and/or PCT/GB2019/050549, all in the name of the present applicant, and the contents of each of which are incorporated by reference as if disclosed in full herein.

[0075] The device body 15 in this example comprises a hollow metal enclosure that houses the ultrasonic transducer array 25 and any associated wiring and electronics. The device body 15 comprises an electrical connector 55 for connecting the contacts 45 of the ultrasonic transducer array 25 to the control device. The electrical connector 55 could be a microcoax connector, for example, but is not limited to this. The device body 15 comprises a plurality of feet 60, designed to engage with the test object 10 in order to securely mount the device 5 onto the test object 10.

[0076] The device body 15 is mounted onto the clamp 10, e.g. by passing part of the clamp 20 through channels in the device body, by physical connection, and/or the like. In this example, the clamp 20 comprises a plurality of bands 65. In this case the bands 65 are metal bands for strength and security, but are not limited to this. The bands 65 are configured to extend around at least part of the test object, in use, and to be selectively opened and closed. For example, the bands 65 may be configured to pass through channels in the device body 15 and to be secured by a screw, ratchet or other one-way mechanism, a lock lever, interference or press fit, a clip and/or the like.

[0077] As can be seen particularly in FIGS. 6 and 7, the flexible ultrasonic transducer array 25 is provided in the device body 15 and arranged such that an active (e.g. emitting/receiving) surface 70 or a coating such as a dielectric coating or membrane provided thereon is provided at an inner surface of the ultrasonic device 5 that is configured to abut and interface with the test object 10 in use. In the above example, the active surface is a surface of the substrate 30 that is opposite the surface of the substrate upon which the layer of piezoelectric material 35 is provided. The device comprises an urging mechanism 75 for urging the active surface of the ultrasonic transducer array 25 onto the outer surface of the test object 10.

[0078] In the example of FIGS. 1 to 8, the urging mechanism 75 comprises a screw 80 threaded into a complementary threaded channel in the top of the device body 15 so as to be screwable into the device body towards the test object 10 and out from the device body 15 away from the test object 10, in use. A proximal end 85 of the screw 80 is provided with a turning aid, such as a finger grip, and/or a slot, hex recess or other tool interface to allow the screw 80 to be easily turned.

[0079] A distal end 90 of the screw 80 engages with a coupling 95 that is provided between the screw 80 and the transducer array 25. The coupling 95 accommodates the rotational motion of the screw 80 without passing on rotational motion to the transducer array 25. Examples of suitable couplings 95 include a socket joint, bearing mechanism or the like.

[0080] The coupling 95 is also provided with a conformable buffer 100 that sits between the rest of the coupling 95 and the ultrasonic transducer 25. The buffer 100 is resiliently deformable. The conformable buffer 100 can assist the flexible ultrasonic transducer array 25 in conforming to a curved surface of the test object whilst evenly distributing force over the transducer array 25, thereby mitigating against damage to the transducer array 25. The conformable buffer 100 also provides a degree of compensation for expansion/contraction of the test object with heating. However, the conformable buffer 100 is preferably configured to withstand the elevated temperatures, which may limit material selection, ruling out conventional engineering polymers and elastomers. As such, high temperature materials such as graphite, fibre reinforced materials or certain minerals such as vermiculite may be used for the buffer 100 to provide the desired temperature and accommodating properties.

[0081] In this way, in use, the screw 80 of the urging mechanism 75 may be operated in order to apply and vary an axial force of the transducer array 25 acting to urge the active surface 70 of the transducer array 25 onto the corresponding surface of the test object 10. The urging mechanism 75 is therefore operable to achieve the desired acoustic coupling between the transducer array 25 and the test object 10, preferably without the use of a couplant such as gel that may be disadvantageous or unsuitable for high temperature or long term use.

[0082] Another example of an ultrasonic device 205 is shown in FIGS. 11 to 15. Features of the device 205 that correspond to features on the device 5 shown in FIGS. 1 to 8 are given like reference numbers but incremented by 200.

[0083] The device 205 comprises a clamp 220 and one or more ultrasonic transducers (in this example a plurality of the ultrasonic transducers are provided in a plurality of ultrasonic transducer arrays 225, which can be seen particularly in FIGS. 9, 10 and 13) located in the clamp 220. The ultrasonic transducer arrays 225 can be those shown and described in relation to FIGS. 9 and 10, for example, or as described in any of GB1803444.7, GB 1803257.3, GB2555835, WO2018/087560, PCT/GB2019/050567 and/or PCT/GB2019/050549, all in the name of the present applicants and the contents of each of which are incorporated by reference as if disclosed in full herein.

[0084] Like the clamp 20 in the device 5 of FIG. 1, the clamp 220 of FIGS. 11 to 15 comprises a band 265. However, a portion of the band 265 in the device 205 is formed from a conformable material such as an elastomer, preferably an elastomer capable of withstanding high temperatures, such as up to 200° C., 250° C. or even 300° C. Suitable elastomers could include, but are not limited to: fluoroelastomers; perfluoroelastomer; high temperature silicone blends and graphite based blends. The conformable nature of the device 205 allows it to operate without a couplant, such as a gel, thereby making it beneficial for high temperature and/or long term applications.

[0085] Specifically, the band 265 comprises a conformable material sub-band 305 formed from the conformable material and provided around a securing band 310. The band 265 can be used to fasten the device 205 around the test object 10 and provide sufficient force for couplant free operation. The band 265 can be secured and tightened with a closure mechanism 315. For example, the closure mechanism could comprise a ratchet mechanism, screw/bolt closure or worm gear arrangement, and/or the like. The securing band 310 is preferably formed from a suitably durable material such as metal, e.g. stainless steel.

[0086] The conformable material (e.g. the flexible elastomer) forming the conformable sub band 305 holds the ultrasonic transducers or transducer arrays 225. The ultrasonic transducers or transducer arrays 225 can optionally be moulded into the conformable material or may be removable inserts. The conformable material is electrically insulating and a layer of the conformable material extends between the metal securing band 310 and the ultrasonic transducers or transducer arrays 225 and/or any electronics required to operate them. This arrangement may protect the ultrasonic transducers or transducer arrays 225 by distributing force evenly. This backing of conformable material also provides a degree of compensation for expansion/contraction of the test object with heating. The ultrasonic transducers or transducer arrays 225 could optionally have integrated wiring that could be moulded through the conformable material or channelled between the conformable sub-band 305 and the metal securing band 310. Alternatively, the ultrasonic transducers or transducer arrays 225 could be fitted with a surface mount connector such as a microcoax allowing them to be hooked up with a separate wire for improved modularity.

[0087] As shown particularly in FIG. 14, the device 205 could be produced in differing lengths for varying pipe diameters or as a long reel to be cut to length for improved customisation. Lengths of the device 205 could be produced with different spacings of ultrasonic transducers or transducer arrays 225 to allow for an optimal number of ultrasonic transducers or transducer arrays 225 and placement on a given diameter of test object 10. Combining a reel system that can be cut to length, insertable ultrasonic transducers or transducer arrays 225 with the inherent mass manufacturable nature of the above arrangement could make the device 205 well suited to continuous monitoring on large infrastructure. In addition, the design of the device 205 may allow it to be made with a very low profile, if required. This would allow the device 205 to be deployed in tight confines such as close networks of piping and close to joints and corners. The low profile also makes the device 205 well suited to fitting under insulation in oil and gas pipeline applications with minimal disruption to the insulation design.

[0088] FIG. 16 illustrates a method of assembling or repairing the devices 5, 205, in which the one or more ultrasonic transducers 25, 225 are provided in the device body 15 and/or the conformable sub-band 305 (step 1605) and mounted on the clamp 20 or securing band 310 (step 1610).

[0089] FIG. 17 illustrates a method of using the devices 5, 205 in which the ultrasonic device 5, 205 is fixed to the test object 10 using the clamps 20 (step 1705). Thereafter, the urging mechanism is adjusted to force the transducers array 25 onto the test object 10 (step 1710). This may involve rotating the screw 80 or by stretching the conformable sub bands 305. Thereafter, the transducers 25 are driven using a drive signal to produce ultrasonic waves and are interrogated by a control device to receive output signals resulting from reflected ultrasonic waves being received by the transducers 25 (step 1715).

[0090] Although specific examples are described above in relation to the Figures, it will be appreciated that variations on the above examples are possible. As such, the scope of protection is defined by the claims and not by the above specific examples.

[0091] For example, although examples of piezoelectric materials being ZnO or AlN are given above, it will be appreciated that other piezoelectric materials could be used instead. Furthermore, although transition metal doped piezoelectric materials are described, it will be appreciated that non-doped piezoelectric materials could be used. In addition, although various thicknesses, dimensions, numbers and geometric arrangements of electrodes, conductive tracks and contacts are given above, it will be appreciated that other thicknesses, dimensions, numbers and geometric arrangements of electrodes, conductive tracks and contacts could be used. Indeed, although the electrodes are all shown as the same size and shape, it will be appreciated that at least some or all of the electrodes may be of different sizes and/or shapes.

[0092] Furthermore, whilst clamps in the form of bands are used, it will be appreciated that other clamping mechanisms such as gripping members, interference or press fit mechanisms and/or the like could be used. In addition, whilst various examples of suitable conformable materials have been given, it will be appreciated that other suitable conformable materials could be used.