Systems and Methods for Ultrasonic Inspection
20210364480 · 2021-11-25
Assignee
Inventors
Cpc classification
International classification
G01N29/22
PHYSICS
Abstract
Disclosed is a scanning system including a mechanism base; a carriage, with a first carriage side attached to a first base side and a second carriage side connected to a drive mechanism, wherein the carriage is configured to move the mechanism base; a probe associated with the carriage, the probe having a first side and a second side; an actuator assembly including an actuator and a housing having a first side and a second side, wherein a first housing side is connected to the actuator and a second housing side is connected to the carriage; and an adjustable mount having a first side and a second side, wherein a first mount side is attached to the second housing side and the second mount side is attached to the first probe side, wherein the actuator assembly is configured to maintain the second probe side in a constant contact with an object.
Claims
1. A scanning system configured to scan an object, comprising: a mechanism base, the mechanism base having a first base side and a second base side; a carriage having a first carriage side and a second carriage side, with the first carriage side attached to the first base side and the second carriage side connected to a drive mechanism, wherein the carriage is configured to move the mechanism base in a first axial direction; a probe operably connected with the carriage, the probe having a first probe side and a second probe side; an actuator assembly including an actuator and a housing having a first housing side and a second housing side, wherein the first housing side is connected to the actuator and the second housing side is connected to the carriage; and an adjustable mount having a first mount side and a second mount side, wherein the first mount side is attached to the second side base and the second mount side is attached to the first probe side, wherein the actuator assembly is configured to maintain the second probe side in a constant contact with said object.
2. The scanning system of claim 1, further comprising: a carriage plate having a first plate side and a second plate side, wherein the first plate side is connected to the second carriage side, wherein the drive mechanism is connected to the second plate side of the carriage plate.
3. The scanning system of claim 2, further comprising: a drive rod connected to the drive mechanism and the second side of the carriage plate and configured to move the carriage in a first scanning direction.
4. The scanning system of claim 3, further comprising: a bushing at least partially encompassing a guide and configured to move the guide through the bushing.
5. The scanning system of claim 4, wherein the adjustable mount further includes an extension arm and a fork.
6. The scanning system of claim 5, wherein the second side of the actuator housing is connected to the carriage by a floating pin embedded in the actuator assembly.
7. The scanning system of claim 6, further comprising: a pressure regulator operably connected with the actuator.
8. The scanning system of claim 7, wherein the actuator is hydraulically connected to a fluid source.
9. The scanning system of claim 8, wherein the fluid is pneumatic.
10. The scanning system of claim 9, further comprising: a transceiver configured to emit a pulse into the object and to receive a pulse reflected from the object; and a position indicator configured to record a position of the transceiver.
11. The scanning system of claim 10, wherein the transceiver includes a piezoelectric element.
12. The scanning system of claim 11, wherein the transceiver is configured to convert at least one received reflected pulse into a digital signal.
13. The scanning system of claim 12, wherein the actuator includes a cylinder, a piston, and a rod, the rod having a first end and a second end, the first end of the rod is attached to the piston and the second end of the rod is attached to the second base side, and the rod is configured to move vertically with respect to the cylinder.
14. The scanning system of claim 13, further comprising: a pivot pin attached to the second end of the rod.
15. The scanning system of claim 12, wherein the actuator includes a parallelpiped structure connected to a cylinder, a piston, and a rod, the rod having a first end and a second end, the first end of the rod is operably connected with the piston, the second end of the rod is attached to the second base side, and the rod is configured to move with respect to the cylinder.
16. A method for inspecting an object using a scanner system having a probe connected to an adjustable mount operably connected with an actuator configured to maintain the probe in a constant contact force with the object, the method comprising: moving the probe along the object; maintaining the probe in a constant contact force with the object; generating a signal representative of a position of the probe on the object; emitting a pulse into the object; and receiving a pulse reflected from the object.
17. The method of claim 16, further comprising pneumatically maintaining the probe in a constant contact force with the object.
18. A non-transitory computer-readable medium having stored thereon computer-readable instructions which when executed cause the computer to perform a method for inspecting an object using a scanner system having a probe connected to an adjustable mount operably connected with an actuator configured to maintain the probe in a constant contact force with the object, the method comprising: moving the probe along the object; maintaining the probe in a constant contact force with the object; generating a signal representative of a position of the probe on the object; emitting a pulse into the object; and receiving a pulse reflected from the object.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A description of the present subject matter including various embodiments thereof is presented with reference to the accompanying drawings, the description not meaning to be considered limiting in any matter, wherein:
[0011]
[0012]
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[0015]
[0016]
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[0018]
[0019] Similar reference numerals and designators in the various figures refer to like elements.
DETAILED DESCRIPTION
[0020] Throughout the discussion below, use of the terms “about” and “approximately” are used to indicate engineering tolerances which would be well understood by a person of ordinary skill in the art for any particular application or embodiment. Further, while an order of the method steps is provided, this order is exemplary only; as will be recognized by those of skill in the art, the order of the method steps may be varied without impacting the overall efficacy of the method.
[0021]
[0022] The exemplary embodiment of
[0023] The exemplary embodiment of
[0024]
[0025] In the embodiment shown in
[0026] The force applied to the probe 140 is proportional to the pressure applied to the actuator 151. By altering the pressure applied, the compliance (stiffness) can be adjusted to allow slight amounts of vertical movement by the probe 140, which allows for better adaption over a rough surface such as the object to be measured 300. The vertical movement occurs while the probe 140 is being traversed over the surface of the object to be measured 300 in a specific pattern. The pattern can be developed based on the orientation of defect(s) to be identified as the ultrasonic inspection is largely direction depended (i.e. sound travels in specific directions). The applied pressure can be selected to provide a softer or rougher ride over the surface. Smoother movement of the probe 140 over the object to be measure 300 results in the generation of better inspection data. Pressure applied by the actuator 153 is directed approximately normal to the surface of the object to be measured 300. Hence, a majority of the pressure is directed into contact force from probe 140 onto the surface of the object to be measured 300.
[0027] In the exemplary embodiment shown in
[0028] In certain embodiments, actuator housing second side 152b is connected to the carriage 120 by a floating pivot pin 158 embedded in the actuator assembly 150. Pivot pin 158 helps preclude binding of cylinder 154 caused by a misalignment of mechanism base 110 and carriage 120. Thus, this allows for some flexibility in the system during movement over an irregular surface thereby preventing parts from jamming together. In the exemplary embodiment of
[0029] In the exemplary embodiment shown in
[0030] In certain embodiments an ultrasound pulse is directed into the object to be measured, and a pulse reflected from the surfaces of internal discontinuities in the object is received by transceiver 180. In these embodiments, at least a portion of the reflected energy propagates back into probe 140 where piezoelectric element 181 converts the received reflected energy into electrical energy that is converted into a digital signal through an analog-to-digital converter (not shown). Inspection is performed by scanning probe 140 over the surface of the object to be measured and capturing these digital signals into a computer memory. In certain exemplary embodiments, position indicator 131 records a position of probe 140 and correlates the probe position on the object to be measured with at least one received reflected pulse. In certain exemplary embodiments this is done by mounting providing encoded position data to a computer memory (not shown). In certain embodiments the stored signal and position data are used to create data images that show position correlations used to discriminate flawed components from normal components. In other embodiments, assessment (discrimination) is done though operator interpretation of the data image for abnormalities utilizing computers and software. Operators are trained to make this interpretation through training on equivalent data images obtained from intentionally flawed components though the development phase of an inspection program.
[0031]
[0032] The exemplary embodiment shown further includes a probe 140 in operable connection with carriage 120, with probe 140 having a first probe side 140a and a second probe side 140b. Probe 140 transmits an ultrasonic sound pulse into the object to be measured 300 at a specific transmission frequency and angle. In certain embodiments, the probe 140 includes a piezoelectric element 181 and a position indicator 131. In certain embodiments, the piezoelectric element 181 is custom shaped to conform to the shape of the object to be measured 300.
[0033] The exemplary embodiment further includes an actuator assembly 160 having an actuator 161 and a housing 162 having a first housing side 162a and a second housing side 162b, wherein the first housing side 162a is connected to actuator 161 and the second housing side 162b is connected to carriage 120. The embodiment shown further includes an adjustable mount 170 having an extension arm 171 connecting housing second side 162b and mount 170, with mount first side 170a and a mount second side 170b (see
[0034] In the exemplary scanning system of
[0035] The second exemplary embodiment includes a parallelpiped actuator assembly 160. Compared with actuator embodiments using springs to maintain pressure on probe 140, parallelepiped embodiments have a greater effective measurement length. In the exemplary embodiments shown, pressure applied to actuator 161 moves mechanism base 110b toward the surface of the object 300. Traversal direction of motion of carriage 120 is controlled by guides 169 in mechanism base 110. As carriage 120 and mechanism base 110 moves, probe 140 moves to contact the surface of the object to be measured. In the embodiment shown, probe 140 contact force is proportional to the pressure applied to pressure regulator 163. When the pressure is released, internal actuator return springs retract probe 140 from the surface of the object to be measured 300. In certain embodiments, actuator range of motion is limited to approximately 0.5 inches for inspection applications. In other exemplary embodiments with greater ranges of motion, actuator assembly 160 optionally includes stops (not shown) in carriage 120 and/or mechanism base 110 to prevent vertical ejection of carriage 120.
[0036] As shown in
[0037] In the exemplary embodiment shown, parallelepiped actuator assembly 160 acts through the diagonals 164a/164b, which can be made of the linked section(s), to exert a downward contact force on probe 140 relative to a surface of the object 300. The parallelpiped configuration enables a longer range of motion of the carriage 120 and mechanism base second side 110b and attached probe 140 (as compared with a vertical actuator of similar comparable size). The parallelpiped configuration creates more linear space for longer arms (diagonals), which allows for longer actuators with more travel and a greater range of vertical motion. Having a greater range vertical motion increases the ability to compensate for greater vertical changes (variations) in the surface of the component to be measured, which facilitates the ability to apply a continuous pressure on the probe so that coupling of sound into the part can be maintained despite vertical variations in the surface of the measured component. In certain exemplary embodiments the magnitude of the force applied to probe 140 is adjusted via pressure regulator 163 to maintain a constant contact force on a surface of the object to be measured, even when probe 140 encounters variations in the surface contour of the object to be measured.
[0038] Certain exemplary parallelpiped embodiments lose a portion of the vertical probe contact force to a horizontal force component due to the angle of actuator 161 with respect to the vertical (as referenced from a surface of object 300). As one way of compensating for less vertical force translation being applied to the probe 140, the embodiment shown includes at least one additional actuator 161 to compensate for some the force translated horizontally rather than vertically. Other ways of making up for this loss can be used, such as by using a higher pressure source and/or applying a greater initial pressure to the actuator 161 to account for this loss in vertical pressure applied to the surface of the object 300.
[0039] In the exemplary embodiment shown, the adjustable mount includes extension arm 171 and a fork 172 with mount first side 170a and mount first side 170b. In the exemplary embodiment shown, a transceiver 180 is connected to fork 172. Transceiver 180 is configured to emit a pulse (not shown) into the object to be measured 300 and is also configured to receive a pulse reflected from the object to be measured 300. Certain exemplary embodiments may also include a position indicator 131 configured to record a position of the transceiver 180. In the exemplary embodiment shown, transceiver 180 includes a piezoelectric element 181, with transceiver 180 configured to convert at least one received reflected pulse into a digital signal.
[0040] In certain embodiments an ultrasound pulse is directed into the object to be measured 300, and a pulse reflected from the surfaces of internal discontinuities in the object is received by transceiver 180. In these embodiments, at least a portion of the reflected energy propagates back into probe 140 where piezoelectric element 181 converts the received reflected energy into electrical energy that is converted into a digital signal through an analog-to-digital converter (not shown). Inspection is performed by probe 140 over the surface of the object to be measured 300 and the digital signals are stored in a computer memory (not shown). In certain exemplary embodiments, position indicator 131 records a position of probe 140 and correlates the probe 140 position on the object to be measured 300 with at least one received reflected pulse (not shown). In certain exemplary embodiments this is done by providing encoded position data to the computer memory. In certain embodiments the stored signal and position data are used to create data images that show position correlations used to discriminate flawed components from normal components. In other embodiments, assessment (discrimination) is done though operator interpretation of the data image for abnormalities utilizing computers and software. Operators are trained to make this interpretation through training on equivalent data images obtained from intentionally flawed components though the development phase of an inspection program.
[0041]
[0042] Utilizing one or more of the steps illustrated in
CONCLUSION
[0043] It will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated to explain the nature of the subject matter, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. The steps of the methods described above may be performed in any order unless the order is restricted in the discussion. Any element of any embodiment may be used in any other embodiment and/or substituted for an element of any other embodiment unless specifically restricted in the discussion.