Ultrasonic inspection device and method for calibrating an ultrasonic inspection device

专利摘要:
ULTRASONIC INSPECTION USING A FLEXIBLE TWO-DIMENSIONAL ARRANGEMENT APPLIED TO A SURFACE OF AN ARTICLE. The present invention relates to methods for ultrasonic inspection of a structure by arranging a flexible two-dimensional ultrasonic transducer array over a site of damage in the structure with minimal physical interaction with the array during setup and without additional movement of the array. during a data acquisition. In addition, the arrangement can remain in place on a hard-to-reach surface to allow easy periodic inspections over an extended period of time. In some embodiments, the array is interleaved between a flexible delay line substrate and a flexible display panel. In one wireless embodiment, a GPS receiver, a transceiver, a pulser/receiver circuit, and an electrical power source (e.g., a battery) are affixed to a portion of the flexible delay line substrate that extends beyond an edge of the array.
公开号:BR102016016653B1
申请号:R102016016653-5
申请日:2016-07-19
公开日:2022-02-01
发明作者:Tyler M. Holmes；Jeffrey R. Kollgaard；Gary E. Georgeson
申请人:The Boeing Company；
IPC主号:

专利说明:

BACKGROUND
[001] The present invention relates generally to systems and methods for ultrasonic inspection of manufactured articles and, in particular, to methods for ultrasonic inspection of a damaged structure underlying non-planar surfaces.
[002] A non-destructive inspection (NDI) of structures involves examining a structure without harming the structure or requiring significant disassembly. A non-destructive inspection is typically preferred to avoid the time and expense associated with removing a part for inspection and to avoid the potential for damage when an inspection is required. A non-destructive inspection is used in the aeronautical industry for the inspection of aircraft structures, such as composite structures and bonded panels. Inspections can identify defects such as cracks, discontinuities, detachments between layers, voids and areas having undesirable porosity. Preventive inspections can be performed during manufacture and at any time during the service life of an aircraft structure to validate the integrity and fit of the structure. Inspections can also be triggered by incidents such as collisions and ballistic impacts that are suspected or known to cause damage.
[003] Various types of ultrasonic methods are used to perform non-destructive inspections. For example, a structure can be inspected by a pulse echo method, where a sensing device sends ultrasonic pulses to a structure and receives echo pulses that reveal the condition of the structure. Data acquired by such a sensor device can be processed and presented to an operator. B-scan images can be produced which reveal depth features of an inspected structure. C-scan images can be produced to reveal a mapping of an inspected structure. These images can reveal features that are not easily perceived or characterized by a simple visual inspection of the exterior of a structure. Data collection for B-scan and C-scan images typically involves moving a sensor along a portion of a structure in order to collect data across an area of the inspected structure.
[004] Two-dimensional arrays of pulse ultrasonic echo sensors were developed and employed in NDI procedures. These arrays provide numerous sensors regularly distributed across an area, and each sensor can collect location-specific data. Thus, a mapping of a portion of the internal structure of a manufactured article can be obtained, without the movement of the sensors.
[005] When inspecting a structure, a viewer is typically needed in order to see the images of the structure being inspected. For example, an on-site inspection may require a computer or laptop having a screen for viewing displayed images and processing data associated with the displayed images. However, the information and image display must be accurately transferred to locations registered in the structure.
[006] Therefore, it would be advantageous to provide an ultrasonic inspection system that is capable of accurately transferring a displayed image to a structure. Furthermore, it would be advantageous to provide an ultrasonic inspection system that is portable, lightweight and capable of inspecting structures effectively and efficiently with the results displayed close to the inspection zone. Furthermore, it would be advantageous to provide an ultrasonic inspection system that is economical to manufacture and use. Furthermore, it would be advantageous to provide simple methods for ultrasonic inspection of a structure by arranging a flexible sensor array overlying a site of damage on the structure with minimal physical interaction with the array during setup and without further movement of the array. during data acquisition. Furthermore, it would be advantageous to provide simple single-sided ultrasonic inspection methods for the detection and characterization of damage under contoured surfaces of structures in cases where access to the damage site is limited. SUMMARY
[007] The subject exposed in detail below is directed to systems, methods and devices for ultrasonic inspection of a structure, which obtains the advantageous features mentioned above. In particular, a flexible ultrasonic transducer device can be placed against and acoustically coupled to a site of damage in the structure with minimal physical interaction with the device during a setup by a technician, and without additional movement of the device during an acquisition. of data. In addition, the flexible ultrasonic inspection device can remain in place on a hard-to-reach surface to allow for periodic inspections over a long period of time.
[008] In accordance with some embodiments, the ultrasonic transducer device comprises a flexible two-dimensional flexible ultrasonic transducer array having a flexible delay line substrate affixed to one side of the flexible ultrasonic transducer array. In other embodiments, the flexible ultrasonic transducer array is sandwiched between the flexible delay line substrate and a flexible display panel. In one wireless embodiment, a GPS receiver, a transceiver, a pulser/receiver circuit, and an electrical power source (e.g., a battery) are affixed to a portion of the flexible delay line substrate that extends plus an edge of the flexible ultrasonic transducer array.
[009] In addition, the inspection methods exposed here may include an automated process for calibrating the ultrasonic inspection device using data from a three-dimensional (3-D) model of the structure to be inspected. This will make it possible for technicians without NDI training to configure the inspection device at the inspection site. Automated calibration reduces waiting time as there is no need to wait for an off-site trained NDI inspector to arrive at the inspection site, and time is also saved by automating the calibration process. An automated calibration also reduces the potential for human error.
[0010] One aspect of the subject matter set out in detail below is an ultrasonic inspection device comprising: a flexible assembly comprising a flexible ultrasonic transducer array having first and second faces, and a flexible delay line substrate acoustically coupled to the first face of the first face of the flexible ultrasonic transducer array; a data acquisition module configured to control pulse and data acquisition by the flexible ultrasonic transducer array; a global positioning system receiver configured for determining a location of the global positioning system receiver; a transceiver configured for communication with the data acquisition module and the global positioning system receiver; and a battery electrically coupled to the data acquisition module, the global positioning system receiver and the transceiver for providing power thereto, wherein the data acquisition module, the global positioning system receiver, the transceiver and battery are physically affixed to the flexible assembly. The ultrasonic inspection device may further comprise an adhesive adhered to portions of a surface of the flexible delay line substrate that faces away from the flexible ultrasonic transducer array.
[0011] In accordance with some embodiments of the ultrasonic inspection device described in the preceding paragraph, the flexible assembly further comprises a flexible display panel overlying at least a portion of the second face of the flexible ultrasonic transducer array, and the acquisition module is further configured to receive ultrasonic data from the flexible ultrasonic transducer array in a first format, convert the ultrasonic data in the first format to ultrasonic data in a second format suitable for display, and send the ultrasonic data in the second format to the flexible display panel. The data acquisition module comprises: an electrically coupled pulser/receiver circuit for receiving the ultrasonic data in the first format from the flexible ultrasonic transducer array; and a processor programmed to convert the ultrasonic data in the first format to ultrasonic data in the second format and control the flexible display panel for displaying the ultrasonic data in the second format. The flexible display panel includes a polymeric substrate, a plurality of pixels arranged in rows and columns on or on the polymeric substrate, and a plurality of thin-film transistors arranged on or on the polymeric substrate and electrically coupled to the respective pixels of the multiplicity. of pixels. The pixels may comprise respective organic or liquid crystal light-emitting diodes.
[0012] In some embodiments of the ultrasonic inspection device, the data acquisition module, global positioning system receiver, transceiver, and battery are physically affixed to a portion of the flexible delay line substrate that extends beyond a perimeter of the flexible ultrasonic transducer array.
[0013] Another aspect of the subject discussed in detail below is a system comprising: a structural component (eg part of an aircraft) having a contoured surface; a flexible assembly affixed to the contoured surface of the structural member, the flexible assembly comprising a flexible ultrasonic transducer array having first and second faces, and a flexible delay line substrate having first and second faces, the first face of the line substrate delay device being affixed to the contoured surface of the structural member and the second face being acoustically coupled to the first face of the flexible ultrasonic transducer array; an external module comprising an electrical power source, a transceiver for transmitting and receiving data, and a data acquisition device configured for communication with the transceiver; and an electrical cable connecting the flexible ultrasonic transducer arrangement to the data acquisition device, the electrical cable having plugs at opposite ends thereof capable of being coupled to and decoupled from the flexible assembly and the external module, wherein the data acquisition device data is configured to communicate with the flexible ultrasonic transducer array via the electrical cable. This system may comprise a display panel, wherein the data acquisition device is further configured to control the display panel for displaying ultrasonic data acquired by the flexible ultrasonic transducer arrangement. The display panel can be part of the external module or part of the flexible assembly. In the first case, the display panel will be referred to as a “display monitor”; in the latter case, the display panel will be referred to here as a “flexible display panel”.
[0014] An additional aspect is a system comprising: a structural component (eg a part of an aircraft) that has a contoured surface; a flexible assembly affixed to a portion of the contoured surface of the structural member, the flexible assembly comprising a flexible ultrasonic transducer array having first and second faces, and a flexible delay line substrate having first and second faces, the first face of the flexible delay line substrate being affixed to the contoured surface of the structural member and the second face being acoustically coupled to the first face of the flexible ultrasonic transducer array; a data acquisition module configured for pulse control and data acquisition by the flexible ultrasonic transducer array; a global positioning system receiver configured for determining a location of the global positioning system receiver and output location data representing that location; a transceiver configured for communication with the data acquisition module and for receiving location data from the global positioning system receiver; and a computer system programmed to receive the location data from the transceiver, and then generate or retrieve a calibration file containing calibration data, which is a function of the material properties of a portion of the electrical cable below the contoured portion of the surface.
[0015] Yet another aspect is a method for calibrating an ultrasonic inspection device that comprises (a) storing structural model data representing material properties of a structure as a function of locating a coordinate system of the structure; (b) affixing a flexible ultrasonic inspection device to a surface of a portion of the structure, wherein the flexible ultrasonic inspection device comprises a flexible substrate, a flexible two-dimensional ultrasonic transducer array affixed to the flexible substrate, and a global positioning system affixed to the flexible substrate; (c) acquiring location data using the global positioning system receiver, said location data representing a location of the global positioning system receiver; (d) sending the acquired location data to a computer system at a remote location; (e) determining a location of the flexible ultrasonic inspection device in the structure's coordinate system; (f) retrieving structural model data representing the material properties of the structure in proximity to said location of the flexible ultrasonic inspection device in the structure's coordinate system; (g) generating or retrieving a calibration file containing calibration data which is a function of said retrieved structural model data representing material properties of the portion of the structure in proximity to the location of the flexible ultrasonic inspection device; (h) sending the calibration file to a data acquisition module that is configured to communicate with the flexible ultrasonic transducer array; and (i) calibrating the data acquisition module using the calibration data from the calibration file.
[0016] A further aspect is a method for ultrasonic inspection of multiple locations on a structure, comprising: (a) affixing a first flexible ultrasonic inspection device to a surface of a first portion of the structure, wherein the first inspection device flexible ultrasonic inspection comprises a first flexible substrate and a first flexible two-dimensional ultrasonic transducer array affixed to the first flexible substrate; (b) affixing a second flexible ultrasonic inspection device to a surface of a second orthogonal plane of the structure, wherein the second flexible ultrasonic inspection device comprises a second flexible substrate and a second flexible two-dimensional ultrasonic transducer array affixed to the second flexible substrate; (c) connecting a module of the first flexible ultrasonic inspection device via an electrical cable, which module comprises a pulser/receiver circuit, which is configured for interrogation control and data acquisition by the first flexible ultrasonic transducer arrangement during an inspection of the first portion of the structure and is further configured to control the interrogation and acquisition of data by the second flexible ultrasonic transducer arrangement during an inspection of the second portion of the structure; (d) controlling the first flexible ultrasonic transducer arrangement for interrogating and acquiring data from the first portion of the structure while the module is connected to the first flexible ultrasonic inspection device; (e) disconnecting the electrical cable from the first ultrasonic inspection device upon completion of step (d); (f) connecting the module to the second flexible ultrasonic inspection device via the electrical cable; and (g) controlling the second flexible ultrasonic transducer arrangement for interrogating and acquiring data from the second portion of the structure while the module is connected to the second ultrasonic inspection device. This method may further comprise: (h) disconnecting the electrical cable from the second ultrasonic inspection device upon completion of step (g); and (i) repeating steps (c) to (h) at a later time, where the first and second flexible ultrasonic inspection devices are not removed after steps (a) and (b), and before step ( i).
[0017] Other aspects of methods for ultrasonic inspection using flexible two-dimensional flexible ultrasonic transducer arrays are exposed and claimed below. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The features, functions, and benefits discussed in the previous section can be obtained independently in various modalities or can be combined in still other modalities. Various embodiments will be described hereinafter with reference to the drawings, which illustrate at least some of the aspects described above and other aspects in which similar elements having different drawings carry the same reference numerals.
[0019] Figure 1 is a diagram representing an isometric view of a flexible wireless ultrasonic inspection device according to an embodiment.
[0020] Figure 2A is a diagram representing a sectional view of a flexible wireless ultrasonic inspection device having a multiplicity of ultrasonic transducer arrays arranged in rows and columns.
[0021] Figure 2B is a diagram representing a sectional view of a flexible wireless ultrasonic inspection device having an ultrasonic transducer arrangement comprising mutually orthogonal strip-shaped transmit and receive transducer elements.
[0022] Figure 3 is a block diagram that identifies some components of a system that includes external servers and a flexible wireless ultrasonic inspection device that can communicate wirelessly with external servers to obtain calibration data and the C raster data storage.
[0023] Figure 4A is a simulated C-scan image of a portion of an inspected aircraft structure, the image showing simulated features including elongated damage.
[0024] Figure 4B is another Csimulated raster image of another portion of an inspected aircraft structure, the image showing simulated features including damage distributed across an area.
[0025] Figure 5 is a block diagram that identifies some components of a flexible wireless ultrasonic inspection device that can communicate wirelessly with a remotely located NDI expert.
[0026] Figure 6 is a block diagram that identifies some components of an ultrasonic inspection system, in which a data acquisition module can be calibrated based on information stored on a pluggable non-volatile memory card.
[0027] Figure 7 is a block diagram representing an architecture of a modular ultrasonic inspection system that employs at least some of the concepts described here.
[0028] Figure 8 is a block diagram depicting an architecture of a modular or ultrasonic inspection system that employs at least some of the concepts described here.
[0029] Figure 9 is a flowchart that identifies the steps of a method for an ultrasonic inspection of multiple locations on a structure in which the respective flexible ultrasonic inspection devices are affixed to the surface of each location and left in place to allow for periodic inspection. using an external module that can be connected to each of the flexible ultrasonic inspection devices in turn.
[0030] Figure 10 is a diagram representing an isometric view of a flexible ultrasonic inspection device that sits against and is acoustically coupled to a portion of an integrally stiffened wing box with a radiated surface.
[0031] Figure 11 is a flowchart that identifies the steps of a method for generating a calibration file at a target position on a surface of a test object (determined using a positioning system) and retrieved associated structural data from a server. DETAILED DESCRIPTION
[0032] According to a first embodiment described in figure 1, a flexible wireless ultrasonic inspection device 2 is designed to conform to a surface in an area where a structure (for example, an aircraft fuselage or wing, a hull of a boat or a portion of some other type of structure) is to be inspected. This area may contain damage or defects in the structure underlying the surface area of the inspection site. In particular, the ultrasonic inspection device 2 can be especially useful when the inspection site is difficult to access.
[0033] The ultrasonic inspection device 2 described in Figure 1 comprises a flexible ultrasonic transducer array 14 having first and second faces, a flexible delay line substrate 12 acoustically coupled to the first face of the flexible ultrasonic transducer array 14, and a flexible display panel 16 capable of overlapping at least a portion of the second face of the flexible ultrasonic transducer array 14. The periphery of the flexible delay line substrate 12 may define a gasket to contact an inspected structure and tentatively adhere the ultrasonic inspection device 2 to the frame when intervening air is removed by an optional vacuum system accessory. Alternatively, peripheral edge portions of the flexible delay line substrate 12 may be derivatized or tentatively adhered (e.g., using adhesive) to a structure inspected by an adhesive material. As an additional alternative, the ultrasonic inspection device 2 can be held in place by a clamp or a bracket.
[0034] According to some embodiments, the flexible ultrasonic transducer arrangement 14 comprises a multiplicity of ultrasonic transducer elements 15 arranged in rows and columns, as described in the sectional view of Figure 2A. The ultrasonic transducer elements 15 can be attached directly to the flexible delay line substrate 12 (as shown in Figure 2A). Alternatively, the ultrasonic transducer elements 15 may be affixed to, integrated with, printed on or embedded in a flexible substrate (not shown in Figure 2A), which is affixed to the flexible delay line substrate 12. For example, that substrate flexible could be a thin sheet of polymeric material, such as polyvinylidene fluoride ("PVDF"). The provision of a flexible sheet of material allows the flexible ultrasonic transducer array 14 to be manipulated to conform to a variety of surface contours during an inspection procedure, as well as maintain intimate contact with the underlying structure.
[0035] In some embodiments, the flexible display panel 16 comprises a polymeric substrate, a plurality of pixels arranged in rows and columns on or on the polymeric substrate, and a plurality of thin-film transistors arranged on or on the polymeric substrate and electrically coupled to respective pixels of the multiplicity of pixels. For example, the pixels may comprise respective organic or liquid crystal light-emitting diodes.
[0036] The ultrasonic inspection device 2 described in figure 1 is independent and self-powered in the sense that a battery 18, a module comprising a GPS receiver 20 and a transceiver 22, and a data acquisition module 24 are all affixed to an extension portion of the flexible delay line substrate 12. The data acquisition module 24 is configured to receive ultrasonic data from the flexible ultrasonic transducer array 14 in a first format, convert the ultrasonic data in the first format into data. in a second format suitable for display, and then send the ultrasonic data in the second format to the flexible display panel 16. The transceiver 22 is configured to communicate with the data acquisition module 24 and the system receiver. global positioning 20. Battery 18 is electrically coupled to data acquisition module 24, global positioning system receiver 20 and transceiver 22 for power supply to system components. As best seen in Figure 1, the data acquisition module 24, the global positioning system receiver 20, the transceiver 22 and the battery 18 are physically attached to the flexible assembly. These physical displays shall be designed to minimize any decrease in flexibility of the portion of the flexible delay line substrate 12 that extends beyond a perimeter of the flexible ultrasonic transducer array 14.
[0037] With reference to Figure 2A, the flexible ultrasonic transducer array 14 can be configured for use in a pulse echo mode. Thus, the ultrasonic transducer elements 15 would transmit and receive ultrasonic signals generally perpendicular to the surface of the structure being inspected. In the alternative, the flexible ultrasonic transducer array 14 may be configured for use in a step capture mode. For example, the ultrasonic transducer elements 15 could be arranged so that an ultrasonic transducer element transmits an ultrasonic signal to the structure at an acute angle and the return ultrasonic signal is captured by a receiving ultrasonic transducer element.
[0038] The ultrasonic transducer elements 15 can be arranged in a variety of configurations. As the distance between the ultrasonic transducer elements 15 decreases, the smaller the fault that can be detected. Therefore, the spacing of the ultrasonic transducer elements 15 can be varied depending on the size of the flaw to be detected and for obtaining a particular resolution of the inspection image.
[0039] In accordance with other embodiments, the flexible ultrasonic transducer array 14 comprises a plurality of mutually parallel strip-shaped transmit transducer elements 94 and a plurality of mutually parallel (orthogonal to the strip-shaped) receive transducer elements. transducer), which are acoustically coupled by a flexible substrate 96 (e.g., a thin layer, sheet, or spray film) of an acoustic coupling means, as depicted in the sectional view of Figure 2B .
[0040] In the alternative, a background example of the flexible ultrasonic transducer arrangement 14 described in Figure 2B can be found in the U.S. patent application. 2008/0309200. That ultrasonic transducer arrangement comprises a transmitter layer, a receiver layer and two ground planes. The transmitter layer comprises a set of elongated mutually parallel electrodes disposed on the upper surface of a first layer of piezoelectric material (e.g. a film made of polyvinylidene fluoride) and a first flat electrode disposed on the lower surface of the first layer of piezoelectric material. . Similarly, the receiver layer comprises a set of mutually parallel elongated receiving electrodes disposed on the lower surface of a second layer of piezoelectric material and a second flat electrode disposed on the upper surface of the second layer of piezoelectric material. These transmitter and receiver layers are in turn adhered to the upper and lower surfaces of a flexible substrate 96. The elongated transmitting elements 94 of the transmitter layer overlap and intersect the elongated receiving elements 92 of the receiver layer, thereby providing an array of overlapping intersections/pixels which constitute signal points of the flexible ultrasonic transducer array 14. The elongated electrodes of the transmitting elements 94 overlap the elongated receiving elements 92 to form an array of individual transducer elements. capable of transmitting and receiving ultrasonic waves at their respective locations in the matrix. The transmission and reception of ultrasonic waves must be done in separate operations using multiplexers (not shown), which connect the transmit electrodes to a signal source and connect the receive electrodes to a signal processor. The elongate transmit elements 94 transmit and the elongate receive elements 92 receive alternately, the elements in each set incrementing through the matrix. This arrangement uses less processing power and less cabling than an ultrasonic transducer arrangement comprising multiple rows of transducer elements, each row comprising a respective multiplicity of transducer elements.
[0041] The flexible ultrasonic transducer arrangement 14 is capable of detecting a failure in a structure and communicating acquired ultrasonic data indicative of the failure to the data acquisition device 24. According to one embodiment, the data acquisition module 24 comprises: a electrically coupled pulser/receiver circuit for receiving ultrasonic data in the first format from the flexible ultrasonic transducer array 14; and a processor programmed to convert the ultrasonic data in the first format to ultrasonic data in the second format and controlling the flexible display panel 16 for displaying the ultrasonic data in the second format. Flexible display panel 16 may be positioned adjacent to flexible ultrasonic transducer array 14 and is capable of generating multiple images of a portion of the underlying structure based on information generated by data acquisition device 24.
[0042] The ultrasonic inspection device 2 can be used to inspect various structures in a variety of industries where the detection of flaws or defects in the structure is required, such as in the aircraft, automotive, marine or construction industries. The ultrasonic transducer array is capable of detecting any number of flaws or defects within or on the surface of the structure, such as impact damage (e.g. delaminations and matrix cracking), detachments (e.g. airframe members/ reinforcement or honeycomb composites), discontinuities, voids or porosity, which could adversely affect the retaining element of the structure.
[0043] The term “structure” is not meant to be limiting, as the ultrasonic inspection device 2 could be used for the inspection of any number of parts or structures of different shapes and sizes, such as machined forgings, castings, tubes or composite panels or parts. The inspection could be performed on newly fabricated structures or on existing structures that are being inspected as part of a maintenance program. In addition, the framework could include several components. For example, the structure could include a substructure to provide additional support to a structure. Also, the structure could be any number of materials. For example, the structure could be a metallic material, such as aluminum, or a composite material, such as graphite-epoxy. Furthermore, the structure could be a portion of an aircraft made of a composite material (for example, a fuselage or a wing).
[0044] The data acquisition module 24 comprises a processor or similar computing device operating under software control, so that the data acquired by the flexible ultrasonic transducer array 14 can be converted into C-scan image data. Further, the data acquisition module 24 comprises a pulser/receiver circuit, or a similar device, such that the ultrasonic transducer elements are capable of transmitting ultrasonic waves to and receiving ultrasonic waves returned from the inspected structure. . Flexible ultrasonic transducer array 14 communicates with data acquisition module 24 via electrical conductors (not shown in drawings). The data acquisition module 24 in turn communicates with the flexible display panel 16 and the transceiver 22 via electrical conductors (not shown in the drawings).
[0045] The flexible display panel 16 is positioned adjacent to the flexible ultrasonic transducer array 14. Because the flexible display panel 16, like the flexible ultrasonic transducer array 14, is flexible or collapsible, the flexible display panel is also It is capable of conforming to a variety of surface contours of the structure under inspection. Flexible display panel 16 may extend to the outer perimeter of flexible ultrasonic transducer array 14 such that flexible display panel 16 is capable of displaying images resulting from data acquired through each of the ultrasonic transducer elements and , in particular, in a one-to-one full-size format. However, the flexible display panel 16 could be of various sizes and configurations for different inspection applications and structures.
[0046] The flexible display panel 16 is capable of displaying an indicative image of the structure being inspected by the flexible ultrasonic transducer arrangement 14. Thus, technicians are able to readily identify the location and characteristics of any fault, defect or the like without having to reference a remotely located display, such as a computer screen, and then attempting to transfer the location of the damaged area from the remotely located display to the structure. As a result, technicians can repair/replace the damaged area(s) on the structure or mark the damaged area(s) with a marking device such as a pen or ink. For example, the vacuum applied to the flexible delay line substrate 12 can be released so that the ultrasonic inspection device 2 can be partially or completely stripped from the structure, and the technician can mark the location of the area(s). ) damaged accordingly. Consequently, the technician can immediately repair or replace the damaged area(s).
[0047] The data acquisition module 24 generates information indicative of the underlying structure, including, for example, faults detected in the structure, based on data acquired by the flexible ultrasonic transducer array 14 and provides the flexible display panel 16 with the information for displaying an image, such as an ultrasonic C-scan.
[0048] Figure 3 is a block diagram identifying components of a system that includes a flexible wireless ultrasonic inspection system of the type shown in Figure 1, which communicates through a transceiver 22 with a calibration database server. 26 for obtaining calibration data and with a C-scan database server 28 for storing C-scan data.
[0049] More specifically, the GPS receiver 20 determines its location and sends location data representing that location to the transceiver 22. A GPS receiver is a stand-alone instrument that receives varying broadcast signals from a constellation of GPS satellites, and turns those varying signals into a GPS receiver location. The receiver's processor contains executable code for generating a pseudo-range or line-of-sight distance to each satellite. For computing the location of the GPS receiver (whose location establishes the location of the flexible ultrasonic transducer array 14), the GPS receiver determines the pseudorange for three or more GPS satellites. The location data that the GPS receiver 20 sends to the transceiver 22 can be used to generate or retrieve a calibration file adapted to correctly calibrate the ultrasonic inspection device with respect to the actual structure being inspected.
[0050] The transceiver 22 transmits the location data to a calibration database server 26. The calibration database server 26 may also receive location data from other GPS receivers affixed to different portions of the structure ( for example an aircraft) being inspected. In one embodiment, the calibration database server 26 may comprise a processor programmed to determine the location of the GPS receiver 20 in the coordinate system of the structure being inspected and then retrieve or generate a calibration file containing data. parameters, which are dependent on the structural features in the area being interrogated by the flexible ultrasonic transducer array 14. More specifically, the processor within the calibration database server 26 can be programmed with software that will pull the thickness and other data. material to the identified location from a CAD file and (a) generate an in-flight calibration file based on the 3-D model data; or (b) pull a calibration file from a calibration database. This calibration file is then sent to the transceiver 22, which forwards the calibration information to the data acquisition module 24. The data acquisition module 24 comprises a processor that is programmed to self-calibrate the flexible ultrasonic transducer array 14. , using the calibration data.
[0051] Following self-calibration, the pulser/receiver circuit of the data acquisition module 24 controls the ultrasonic arrangement for the acquisition of C-scan data. The processor of the data acquisition module 24 is additionally programmed to convert the C-scan data from the flexible ultrasonic transducer array 14 into a format required by the flexible display panel 16. The C-scan data from the flexible ultrasonic transducer array 14 can also be sent through the transceiver 22 for the C-scan database server 28 for storage.
[0052] According to one implementation, the ultrasonic transducer array 14 may comprise two hundred and fifty-six ultrasonic transducer elements 15 (see Figure 2A) arranged in rows and columns evenly spaced by 6.35 mm (one quarter of an inch). ) for defining a square net pattern that is 10.16 cm (four inches) wide on each side of the net. However, it should be understood that the concepts set forth herein can be applied with equal effect as when the ultrasonic transducer array 14 has other numbers of ultrasonic transducer elements, other array patterns, and other pattern spacings. In particular, the concepts set forth herein can be applied when the flexible ultrasonic transducer array 14 has any number of ultrasonic transducer elements arranged in any two-dimensional pattern.
[0053] Data acquisition module 24 can operate to energize each ultrasonic transducer element 15 (see Figure 2A) to send an ultrasonic pulse to an inspected structure and then receive an electrical signal generated by the sensor when a signal of ultrasonic echo return from the structure. Ultrasonic pulses traveling through a structure tend to reflect from surfaces, edges and other discontinuities such as damage to the structure. A returning ultrasonic echo signal may include multiple time-distributed echo pulses reflected from surfaces and edges that are expected and from damage that merits investigation and repair. The electrical signal generated by each ultrasonic transducer element 15 carries data and amplitude and time corresponding to the amplitudes and arrival times of echo pulses in the ultrasonic echo signal. Amplitude and time data can be used to discriminate damage-related echo pulses from echo pulses reflected from undamaged aspects of a structure. After the data acquisition module 24 energizes an ultrasonic transducer element 15 and collects amplitude and time data therefrom, a brief period of quiet then passes before the controller energizes another ultrasonic transducer element 15. By maintenance of pulse echo operations of each ultrasonic transducer element 15 separated in time from operations of other ultrasonic transducer elements, crosstalk between the ultrasonic transducer elements is avoided, and data collected from each ultrasonic transducer element 15 can be associated with the respective position of each ultrasonic transducer element. Thus, when the flexible ultrasonic transducer array 14 is disposed against a structure, data collected from the ultrasonic transducer elements 15 can be associated with localized properties of the structure at the respective positions of the ultrasonic transducer elements 15. data converts the acquired ultrasonic data into imaging data suitable for display on the flexible display panel 16. The flexible display panel 16 graphically displays the data for interpretation by a user to identify damage to an inspected structure.
[0054] For example, flexible display panel 16 may display a simulated echo amplitude C-scan image of a portion of an inspected structure of the type graphically depicted in Figures 4A and 4B. In Figure 4A , the simulated C-scan image 36 shows simulated features including an elongated damage 38A as distinguished by pixel colorations of an undamaged background area 40 corresponding to an undamaged portion of the structure being inspected. In Figure 4B, the simulated C-scan image 36 shows simulated features including damage 38B distributed across an area as distinguished by pixel colorations of the undamaged background area 40. The simulated data shown in the displays of Figures 4A and 4B represent actual data generated using a flexible ultrasonic transducer array 14 that has at least two hundred and fifty-six sensors arranged along sixteen rows and sixteen columns, as is evident from the regularly spaced two-dimensional rectangular array of pixels on the display panel flexible 16. Each particular pixel corresponds to a particular ultrasonic transducer element of the ultrasonic transducer array 14, in a one-to-one correspondence.
[0055] The flexible display panel 16 can display an echo amplitude C-scan image, in which the coloring of each pixel corresponds to an amplitude of a portion of an echo signal. In particular, the coloring of each pixel refers to the amplitudes of echo pulses present in a time gated portion of the waveform detected by a corresponding ultrasonic transducer element. Time gate control initiation and closing times are set by choice to follow closely and precede front surface and rear surface return pulses. On and off times can be set so that the ultrasonic inspection device instrument informs an operator of the likely presence or absence of return pulses from any chosen depth range. Any desired depth range, defined between a first depth and a second depth, can be chosen for inspection by the establishment or a predetermination of a door control start time corresponding to the first depth and a door control close time corresponding to the second depth.
[0056] The amplitude in the time gate control portion of the waveform can be derived from an attenuated and integrated function of the waveform according to known mathematical principles. The time gate control portion is selected according to considerations which will be discussed in more detail below.
[0057] The pixels in the C-scan images 36 of Figures 4A and 4B are each colored according to the summed amplitudes of echo pulses present in time gate control portions of corresponding waveforms. Thus, these images are C-scan echo amplitude images that represent the total ultrasonic echo energy reflected from discontinuities between the front and rear surfaces of an inspected structure. Pixels having colors that differ from the undamaged background area 40 generally correspond to damaged locations in the inspected structure. The damage revealed by the pixels in the damaged areas 38A and 38B in Figures 4A and 4B respectively resides between the front and rear surfaces of the inspected structure. Areas 38A and 38B graphically display damage products. The size, arrangement, and severity of damage are revealed by the sizes, arrangement, and coloring of areas 38A and 38B in the C-scan image 36.
[0058] The descriptions here refer to lines and columns of sensors and pixels distributed along horizontal and vertical axes as a convenient convention in describing two-dimensional arrays of ultrasonic transducer elements and pixels. It should be understood that the flexible ultrasonic transducer array 14 can be disposed across an area of a structure in almost any arbitrary orientation. Thus, the axes described need not correspond to any vertical axis demonstrated by a plumb line or any horizontal axis, such as those along the floor of a hangar in which aircraft are inspected.
[0059] Furthermore, the C-scan images depicted in Figures 4A and 4B generally refer to larger echo pulse amplitudes for darker pixel colorations as another convenient convention for purposes of illustrating the subjects of these descriptions. Lighter pixel colorations could just be related in the same way to larger echo pulse amplitudes in an alternative convention. In fact, the correlation of the amplitude of an echo pulse with the coloring of a corresponding pixel can be selected according to any desired function or mapping and a color legend can be provided. Although the figures described herein generally provide black and white images, these descriptions likewise refer to images comprising pixels having any number of colors, such as blue, green, yellow and red. These descriptions refer to almost any pixel coloring convention, shading convention, or pixel character convention by which an operator can discern information provided by graphically displayed pixels.
[0060] The embodiment described in Figure 1 provides several advantages. For example, the flexible ultrasonic transducer arrangement 14 and flexible display panel 16 allow the wireless flexible ultrasonic inspection device 2 to conform to a variety of surface contours. , so the inspection system is suitable for field level inspections of any number of structures. In addition, the Wireless Flexible Ultrasonic Inspection Device 2 is lightweight, portable and adaptable to a variety of structures, including an aircraft. Because the flexible display panel 16 is positioned directly on the structure and can display an image while positioned there, the potential for error in transferring the location of the fault in the structure is reduced. The wireless flexible ultrasonic inspection device 2 can also be configured quickly and display images on the flexible display panel 16 in a relatively short period of time after configuration. The Wireless Flexible Ultrasonic Inspection Device 2 also provides quantitative image-based data that a conventional handheld ultrasonic flaw detector test cannot provide.
[0061] In some situations, it may be desirable to involve a remotely located (ie off-site) NDI expert in the configuration and/or inspection procedures performed at the inspection site. According to an alternative embodiment described in Figure 5, the location data acquired by the GPS receiver 20 can be transmitted by the transceiver 22 of a wireless flexible ultrasonic inspection device to a remote expert 30. The remote expert 30 can also receive data. additional location data from other GPS receivers affixed to other portions of the structure to be inspected. In alternative embodiments, the remote expert 30 may receive a message identifying the location of the flexible ultrasonic inspection device in the coordinate system of the structure being inspected from an on-site technician, or may send the location prior to replacement of an inspection device. flexible ultrasonic by on-site technician.
[0062] Regardless of the method or means by which the remote expert 30 acquires location data representing the locations of the structure (e.g. an aircraft) to be inspected and the location of the flexible ultrasonic inspection device, the remote expert 30 can initiate a computer program that determines the location of the wireless flexible ultrasonic inspection device in the structure's coordinate system using the location data. This allows the remote specialist 30 to generate an ongoing calibration file based on the 3-D model data for the inspected structure or pull a calibration file from a calibration database. The calibration data is then sent to the transceiver 22, which forwards the calibration data to the data acquisition module 24, as previously described. The calibrated data acquisition module 24 can then control the flexible ultrasonic transducer array 14 and the flexible display panel 16, as previously described. The remote specialist 30 can provide real-time guidance to the on-site technician during the ultrasonic inspection to avoid errors. During the inspection procedure, the transceiver 22 may transmit the C-scan data to the remote expert 30 for review. Optionally, the data acquisition module could be programmed to control the flexible ultrasonic transducer array such that a predetermined number of locations on the flexible ultrasonic transducer array accumulate A-scan data that can be provided to a remote specialist at a saved/transmitted data file.
[0063] According to alternative embodiments, the remote expert 30 may deliver the calibration file to the inspection site in the form of a non-volatile memory card 32, as shown in Figure 6. The calibration file is stored on the memory card non-volatile 32 by the remote specialist 30, and then the non-volatile memory card 32 is plugged into a socket on the data acquisition module 24. The data acquisition module 24 is then self-calibrated using the calibration data in the file of calibration. The ultrasonic data acquired by the calibrated data acquisition module 24 may be displayed on a flexible display panel or display monitor 34 in a manner consistent with that calibration file. In that case, the remote specialist 30 can learn the location of the flexible ultrasonic transducer array by communicating with the on-site technician or via a procedure call or an airline consultation. The non-volatile memory card 32 could also be filled with pre-made calibrations for various areas on the structure.
[0064] Figure 7 is a block diagram representing an architecture of a modular ultrasonic inspection system that employs at least some of the concepts proposed here. The system described in figure 7 comprises a flexible ultrasonic inspection device 4 which is electrically connected via an electrical cable 5 to a separate external module 8. The electrical cable has plugs (not shown in the drawings) at opposite ends thereof capable of being coupled to and decoupled from the flexible ultrasonic inspection device 4 and the external module 8. The flexible ultrasonic inspection device 4 comprises a flexible ultrasonic transducer array sandwiched between a flexible delay line substrate and a flexible display panel. The external module 8 comprises an electrical power source, a data transmission means (such as the transceiver described previously), and a data acquisition means (such as a processor that performs the same functions as those performed by the acquisition module). described above, allowing the flexible display panel to display images simulating the structure that has been interrogated by the flexible ultrasonic transducer arrangement. The data acquisition means are configured to communicate with the flexible ultrasonic inspection device 4 via the electrical cable 5 A GPS receiver (not shown) can be attached to the flexible ultrasonic inspection device 4 (as previously described). Alternatively, the GPS receiver can be part of the external module 8, if the distance between the flexible ultrasonic inspection device 4 and external module 8 is known or minimal, and, depending on the resolution of the positioning system, negligible.
[0065] Figure 8 is a block diagram representing an alternative architecture of a modular ultrasonic inspection system that employs at least some of the concepts proposed here. The system described in Figure 8 comprises a flexible ultrasonic inspection device 6 which is electrically connected (via an electrical cable 5) to a separate external module 10. The flexible ultrasonic inspection device 6 comprises a flexible ultrasonic transducer arrangement affixed to a substrate of flexible delay line. The external module 10 comprises an electrical power source, a performance monitor, data transmission means (such as the transceiver previously described) and data acquisition means (such as a processor that performs the same function as those performed by the module. data acquisition method described previously, allowing the run monitor to display images simulating the structure that was interrogated by the flexible ultrasonic transducer arrangement. A GPS receiver (not shown) can be attached to the flexible ultrasonic inspection device 6. Alternatively, GPS receiver can be part of external module 10.
[0066] According to any of the architectures described in figures 7 and 8, the external module can be connected in turn to respective flexible ultrasonic inspection devices affixed at multiple locations on the structure to be inspected. Figure 9 is a flowchart identifying the steps of a method 70 for ultrasonic inspection of multiple locations on a structure, wherein the respective flexible ultrasonic inspection devices are affixed to the surface at each location and left in place to allow periodic inspection using An external module can be connected to each of the flexible ultrasonic inspection devices in turn.
[0067] According to the embodiment described in Figure 9, the method70 comprises the following steps: affixing a first flexible ultrasonic inspection device to a surface of a first portion of the structure (step 72), wherein the first inspection device flexible ultrasonic inspection comprises a first flexible substrate and a first flexible two-dimensional ultrasonic transducer array affixed to the first flexible substrate; affixing a second flexible ultrasonic inspection device to a surface of a second portion of the structure (step 74), wherein the second flexible ultrasonic inspection device comprises a second flexible substrate and a second flexible ultrasonic transducer array affixed to the second substrate flexible; connecting a module to the first flexible ultrasonic inspection device via a structural component (step 76), which module comprises a pulser/receiver circuit, which is configured for interrogation control and data acquisition by the first ultrasonic transducer array flexible during an inspection of the first portion of the structure and is further configured to control interrogation and data acquisition by the second flexible ultrasonic transducer arrangement during an inspection of the second portion of the structure; controlling the first flexible ultrasonic transducer array to interrogate and acquire data from the first portion of the structure while the module is connected to the first flexible ultrasonic inspection device (step 78); disconnecting the electrical cable from the first flexible ultrasonic inspection device after completing step 78 (step 80); connecting the module to the second flexible ultrasonic inspection device via the electrical cable (step 82); controlling the second flexible ultrasonic transducer arrangement for interrogating and acquiring data from the second portion of the structure, while the module is connected to the second flexible ultrasonic inspection device (step 84); disconnecting the electrical cable from the second flexible ultrasonic inspection device after completing step 84 (step 86); and determining whether the first and second portions of the structure should be re-inspected (eg, at a later date) or not (step 88). If the result of step 88 is a determination that the first and second portions of the structure must be inspected again, then the method will return to step 76 and the process will be repeated. If the result of step 88 is a determination that the first and second portions of the structure should not be re-inspected, then the method will not return to step 76 or repeat the process (step 90). At that time, the attached flexible ultrasonic inspection devices could be removed from the structure.
[0068] The method shown in Figure 9 can be used in situations where a multitude of potential damage sites in a structure are scheduled to be inspected periodically. This method is especially useful when damage locations are located in spaces that are difficult to get through. A single external module having a display monitor could be placed in an accessible location and then connected to each ultrasonic inspection device in turn via an electrical cable. The onsite technician can view the C-scan images in turn and take appropriate action based on what those images indicate about the structural integrity at potential damage sites.
[0069] In accordance with other embodiments, a flexible ultrasonic inspection device can be designed to handle radius surfaces. One embodiment would be the “L-shape” with a short radius that is flexible enough to fit on radii surfaces having a range of radii. The system configuration would be similar to that shown in Figure 8, in order to minimize the number of flexible layers (eg, by not including a flexible display panel), to allow for more flexibility. In the scenario shown in Figure 10, a flexible ultrasonic inspection device 6 (consisting of a flexible delay line substrate sits against and acoustically coupled to a portion 44 of an integrally generalized stiffened wing box (made of a composite material) The described portion 44 of the integrally stiffened wing box comprises a skin 48 connected to a spar web 46 via a radiused surface 47, which is a fillet joint region, which connects the web from stringer 46 to casing 48. As in the embodiment described in Figures 1 and 2, a power supply, a GPS receiver, data transmission means and data acquisition means can be mounted on the flexible delay line substrate in areas for the purpose of covering flat sections of the part being inspected. For radius surfaces that have larger radii, it may be possible to keep a flexible display panel mounted in the flexible ultrasonic transducer arrangement, rather than using an external module. Another embodiment would be a flat area arrangement, but with a marginal region made of flexible material to allow the marginal region to conform to the curvature of the radius surface being inspected. Arrangements having curved marginal regions of different radii could be fabricated, depending on the curvature of the radii surface that needs to be adapted.
[0070] The ultrasonic inspection systems discussed above can be used for measuring thickness, depth or distance by synchronism echoes. In order to convert these time measurements into distance measurements, the ultrasonic inspection device can be calibrated to the sound velocity of the inspected structure, as well as any necessary zero displacement. This process is commonly referred to as speed/zero calibration. The accuracy of any ultrasonic measurement of thickness, depth or distance is dependent on the accuracy of the calibration. Calibrations for different materials and transducers can be stored and retrieved as previously described.
[0071] The automated calibration method may involve, for example, establishing the propagation velocity of ultrasonic pulses in the inspected material, in order to correlate the time-of-flight (TOF) measurements with material depths, and the selection of ranges depth and time axes and time gate control settings for the display of C-scan images. Depth is derived from the TOF measured between the dispatch of an ultrasonic pulse in a structure and the return of an ultrasonic pulse. echo. If the propagation velocity of ultrasonic pulses is known for a particular inspected material, the vertical axis in the scanning window can be calibrated towards particular linear depth dimensions according to the TOF of each echo pulse.
[0072] The methodology exposed here automates the calibration of ultrasonic inspection systems through the use of three-dimensional (3-D) CAD data representing a 3-D model of the structure to be inspected. By basing the calibration on a CAD model, it is possible to pull in more data for location-specific inspections. The CAD model data (i.e., also referred to herein as “structural data”) may comprise information concerning one or more of the following structural features of the test object in or within the area containing the target position: physical dimensions, material characteristics, fastener locations, structural anomalies, a test object alteration or repair, average paint thickness, concealed longitudinal reinforcement spars, electromagnetic effects (EME) protection layers, and other features that may not be accounted for in a general inspection.
[0073] The CAD model database also includes information concerning the structure being inspected, which information can be used to automatically calibrate the ultrasonic inspection system that will be used to inspect that area. The CAD model contains data about the structure of the aircraft in the area of the inspection site, including information concerning one or more of the following: (a) material type (average attenuation, which will be determined by testing many standards involved composite); (b) material thickness; (c) underlying structure (can be displayed on the inspection instrument to help with the quality of odd signals); (d) presence of seal (a gain can be adjusted to account for a reduced back wall signal); (e) presence of an EME layer; (f) average ink thickness; (g) fastener location (user may be alerted to odd signals if they are positioned directly over a fastener); and (h) the presence of repairs in the inspection area (if the CAD file has been kept current by the airline or another user). This CAD model data can be used to generate a calibration file for the structure and provide the inspector with the necessary situational science to make informed inspection decisions.
[0074] Figure 11 is a flowchart that identifies the steps of a method 50 for generating a calibration file using a positioning system. First, a target position (ie the location on the surface of the test object where the underlying structure is to be inspected) is determined using the positioning system (step 52). Then, the structural data associated with that target position is pulled from a CAD model database server (step 54). A simplified modality would involve pre-made procedures being assigned to certain areas on the plane which are then loaded based on an initial target position at the start of the inspection.
[0075] Still referring to figure 11, it can be seen that the structural data can be used to perform a basic calibration or an advanced calibration (which may include the basic calibration and an additional calibration). In basic calibration, calibration parameters such as material, part thickness, coating thickness, probe frequency, and flexible delay line are selected based on the relevant structural data (step 55). The material type sets the sound velocity reference from a material velocity table (step 56). The slice thickness determines the screen range (step 58). The coating thickness and flexible delay line determine the screen delay (step 60). In addition, the gain can be adjusted to account for the back wall signal (step 62).
[0076] According to an advanced calibration methodology, additional calibration parameters, such as focal laws, gate control, distance-amplitude correction (DAC) and time compensated gain (TCG), can be determined by a computer, which is programmed with calibration software to process the structural data (step 64). Optionally, reference standard alerts can be automatically generated for more advanced calibration operations (step 66). The inspector could be automatically alerted to a reference standard and instructions given at those times.
[0077] Finally, all calibration parameters are organized according to a specific format to complete the calibration file (step 68). That calibration file is then used for the calibration of the ultrasonic inspection system.
[0078] The use of CAD model data allows automation of a process that usually requires an inspector trained in non-destructive testing (NDT). As a result, it removes a degree of human error from the calibration process. This cuts training costs and reduces inspection times by not requiring an NDT-trained inspector to perform each and every inspection.
[0079] Also, the exposure comprises modalities according to the following clauses:
[0080] Clause 1: An ultrasonic inspection device comprising: a flexible assembly comprising a flexible ultrasonic transducer array having first and second faces, and a flexible delay line substrate acoustically coupled to said first face of said array of flexible ultrasonic transducer; a data acquisition module configured for pulse control and data acquisition by said flexible ultrasonic transducer arrangement; a global positioning system receiver configured for determining a location of the global positioning system receiver; a transceiver configured for communication with said data acquisition module and said global positioning system receiver; and a battery electrically coupled to said data acquisition module, said global positioning system receiver and said transceiver for providing power thereto, wherein said data acquisition module, said global positioning system receiver , said transceiver and said battery are physically affixed to said flexible assembly.
[0081] Clause 2: the ultrasonic inspection device, as recited in clause 1, further comprising an adhesive adhered to portions of a surface of said flexible delay line substrate that faces away from said flexible ultrasonic transducer arrangement.
[0082] Clause 3: the ultrasonic inspection device, as recited in clause 1, wherein said flexible assembly further comprises a flexible display panel overlying at least a portion of said second face of said flexible ultrasonic transducer arrangement , and said data acquisition module is further configured to receive ultrasonic data from said flexible ultrasonic transducer array in a first format, converting said ultrasonic data in said first format to ultrasonic data in a second format suitable for display, and sending said ultrasonic data in said second format to said flexible display panel.
[0083] Clause 4: the ultrasonic inspection device, as recited in clause 3, wherein said data acquisition module comprises: an electrically coupled pulser/receiver circuit for receiving said ultrasonic data in said first format from said flexible ultrasonic transducer arrangement; and a processor programmed to convert said ultrasonic data in said first format to ultrasonic data in said second format and control said flexible display panel for displaying the ultrasonic data in said second format.
[0084] Clause 5: the ultrasonic inspection device, as recited in clause 3, wherein said flexible display panel includes a polymeric substrate, a plurality of pixels arranged in rows and columns on or on said polymeric substrate, and a plurality of thin film transistors disposed on or on said polymeric substrate and electrically coupled to respective pixels of said plurality of pixels.
[0085] Clause 6: the ultrasonic inspection device, as recited in clause 5, wherein said pixels comprise respective organic light-emitting diodes.
[0086] Clause 7: the ultrasonic inspection device, as recited in clause 5, wherein said pixels comprise liquid crystal.
[0087] Clause 8: the ultrasonic inspection device, as recited in clause 1, wherein said data acquisition module, said global positioning system receiver, said transceiver and said battery are physically affixed to a portion of said flexible delay line substrate extending beyond a perimeter of said flexible ultrasonic transducer array.
[0088] Clause 9: the ultrasonic inspection device, as recited in clause 1, wherein said flexible ultrasonic transducer arrangement comprises a multiplicity of ultrasonic transducer elements arranged in rows and columns.
[0089] Clause 10: the ultrasonic inspection device as recited in clause 1, wherein said flexible ultrasonic transducer arrangement comprises a plurality of mutually parallel transmitting electrodes and a plurality of parallel receiving electrodes which overlap, but are not parallel to said transmission electrodes.
[0090] Clause 11: a system comprising: a structural component having a contoured surface; a flexible assembly affixed to the contoured surface of the structural member, said flexible assembly comprising a flexible ultrasonic transducer array having first and second faces, and a flexible delay line substrate having first and second faces, said first face of said flexible delay line substrate being affixed to said contoured surface of said structural member and said second face of said flexible delay line substrate being acoustically coupled to said first face of said flexible ultrasonic transducer array; an external module comprising an electrical power source, a transceiver for transmitting and receiving data, and a data acquisition device configured for communication with said transceiver; and an electrical cable connecting said flexible ultrasonic transducer arrangement to said data acquisition device, said electrical cable having plugs at opposite ends thereof capable of being coupled to and decoupled from said flexible assembly and said external module, wherein said data acquisition device is configured for communication with said flexible ultrasonic transducer arrangement via said electrical cable.
[0091] Clause 12: the system, as recited in clause 11, wherein it further comprises a display panel, wherein said data acquisition device is additionally configured to control said display panel for displaying ultrasonic data acquired by the said flexible ultrasonic transducer arrangement.
[0092] Clause 13: the system, as recited in clause 12, wherein said display panel is part of said external module.
[0093] Clause 14: the system, as recited in clause 12, wherein said display panel is part of said flexible assembly, said display panel comprising a flexible display panel adjacent said second face of said transducer arrangement flexible ultrasonic.
[0094] Clause 15: the system, as recited in clause 11, wherein said structural component is part of an aircraft.
[0095] Clause 16: a system comprising: a structural component having a contoured surface; a flexible assembly affixed to a portion of said contoured surface of said structural member, said flexible assembly comprising a flexible ultrasonic transducer array having first and second faces, and a flexible delay line substrate having first and second faces, the said first face of said flexible delay line substrate being affixed to said contoured surface of said structural member and said second face being acoustically coupled to said first face of the flexible ultrasonic transducer array; a data acquisition module configured for pulse control and data acquisition by said flexible ultrasonic transducer arrangement; a global positioning system receiver configured for determining a location of said global positioning system receiver and output location data representing that location; a transceiver configured for communication with said data acquisition module and for receiving location data from said global positioning system receiver; and a computer system programmed to receive said location data from said transceiver, and then generate or retrieve a calibration file containing calibration data, which is a function of the material properties of a portion of said component. structure below said portion of the contoured surface.
[0096] Clause 17: the system, as recited in clause 16, wherein said flexible assembly further comprises a flexible display panel disposed adjacent said second face of said flexible ultrasonic transducer arrangement.
[0097] Clause 18: the system, as recited in clause 16, wherein said structural component is part of an aircraft.
[0098] Clause 19: a method for calibrating an ultrasonic inspection device comprising: (a) storing structural model data representing material properties of a structure as a location function of a coordinate system of the structure; (b) affixing a flexible ultrasonic inspection device to a surface of a portion of the structure, wherein the flexible ultrasonic inspection device comprises a flexible substrate, a flexible two-dimensional ultrasonic transducer array affixed to the flexible substrate, and a global positioning system affixed to the flexible substrate; (c) acquiring location data using the global positioning system receiver, said location data representing a location of the global positioning system receiver; (d) sending the acquired location data to a computer system at a remote location; (e) determining a location of the flexible ultrasonic inspection device in the structure's coordinate system; (f) retrieving structural model data representing the material properties of the structure in proximity to said location of the flexible ultrasonic inspection device in the structure's coordinate system; (g) generating or retrieving a calibration file containing calibration data which is a function of said retrieved structural model data representing material properties of the portion of the structure in proximity to the location of the flexible ultrasonic inspection device; (h) sending the calibration file to a data acquisition module that is configured to communicate with the flexible ultrasonic transducer array; and (i) calibrating the data acquisition module using the calibration data from the calibration file.
[0099] Clause 20: A method for ultrasonic inspection of multiple locations on a structure, comprising: (a) affixing a first flexible ultrasonic inspection device to a surface of a first portion of the structure, wherein the first inspection device flexible ultrasonic comprises a first flexible substrate and a first flexible two-dimensional ultrasonic transducer array affixed to the first flexible substrate; (b) affixing a second flexible ultrasonic inspection device to a surface of a second orthogonal plane of the structure, wherein the second flexible ultrasonic inspection device comprises a second flexible substrate and a second flexible two-dimensional ultrasonic transducer array affixed to the second flexible substrate; (c) connecting a module of the first flexible ultrasonic inspection device via an electrical cable, which module comprises a pulser/receiver circuit, which is configured for interrogation control and data acquisition by the first flexible ultrasonic transducer arrangement during an inspection of the first portion of the structure and is further configured to control the interrogation and acquisition of data by the second flexible ultrasonic transducer arrangement during an inspection of the second portion of the structure; (d) controlling the first flexible ultrasonic transducer arrangement for interrogating and acquiring data from the first portion of the structure while the module is connected to the first flexible ultrasonic inspection device; (e) disconnecting the electrical cable from the first ultrasonic inspection device upon completion of step (d); (f) connecting the module to the second flexible ultrasonic inspection device via the electrical cable; and (g) controlling the second flexible ultrasonic transducer arrangement for interrogating and acquiring data from the second portion of the structure while the module is connected to the second ultrasonic inspection device.
[00100] Clause 21: the method, as recited in clause 20, which further comprises: (h) disconnecting the structural component of the second ultrasonic inspection device upon completion of step (g); and (i) repeating steps (c) to (h) at a later time, where the first and second flexible ultrasonic inspection devices are not removed prior to step (i).
[00101] While the apparatus and methods have been described with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof, without departing from the teachings herein. In addition, many modifications can be made to adapt the concepts and reductions to practice exposed here to a particular situation. Therefore, it is intended that the subject matter covered by the claims is not limited to the foregoing embodiments.
[00102] As used in the claims, the term "computer system" is to be construed broadly to encompass a system having at least one computer or processor, and which may have multiple computers or processors that communicate over a network or a bus. As used in the preceding sentence, the terms "computer" and "processor" refer to devices comprising at least one processing unit (eg, a central processing unit, an integrated circuit, or an arithmetic logic unit).
[00103] The method claims set forth herein below shall not be construed to require that the steps recited herein be performed in alphabetical order (any alphabetical ordering in the claims is used solely for purposes of referring to previously recited steps) or in the order in which they are are recited. Nor should they be constructed to exclude any portions of two or more steps being performed concurrently or alternately.

权利要求:
Claims (10)
[0001]
1. An ultrasonic inspection device (2, 4, 6) for inspecting a structure, comprising: a flexible assembly (96) comprising a flexible ultrasonic transducer array (14) having first and second faces, and a flexible delay (12) acoustically coupled to said first face of said flexible ultrasonic transducer array (14); a data acquisition module (24) configured to control pulse and data acquisition by said flexible ultrasonic transducer array (14); a global positioning system receiver (20) configured for determining a location of the global positioning system receiver (20); a transceiver (22) configured for communication with said data acquisition module (24); ) and said global positioning system receiver (20); a battery (18) electrically coupled to said data acquisition module (24), to said positioning system receiver global (20) and said transceiver (22) for providing power thereto, and a calibration database server (26) configured to store structural model data representing the material properties of a structure as a function of location of a structure coordinate system, characterized by the fact that said data acquisition module (24), said global positioning system receiver (20), said transceiver (22) and said battery (18) are physically affixed to said flexible assembly (96), wherein said transceiver (22) is configured to: - receive location data from the global positioning system receiver (20) and transmit said location data to the database server of calibration (26); - receiving calibration data from the calibration database server (26), the calibration data being a function of said structural model data representing the properties s of material from part of the structure in proximity to the location of the flexible ultrasonic inspection device (2, 4, 6); e- sending said calibration data to the data acquisition module (24); and- said data acquisition module (24) is configured to auto-calibrate the flexible ultrasonic transducer array (14) using said calibration data.
[0002]
2. Ultrasonic inspection device (2, 4, 6), according to claim 1, characterized in that it further comprises an adhesive adhered to portions of a surface of said flexible delay line substrate (12) that turns away from said flexible ultrasonic transducer arrangement (14).
[0003]
3. Ultrasonic inspection device (2, 4, 6), according to claim 1 or 2, characterized in that said flexible assembly (96) further comprises a flexible display panel (16, 34) overlapping to at least a portion of said second face of said flexible ultrasonic transducer array (14), and said data acquisition module (24) is further configured to receive ultrasonic data from said flexible ultrasonic transducer array (14) in a first format, converting said ultrasonic data in said first format to ultrasonic data in a second format suitable for display, and sending said ultrasonic data in said second format to said flexible display panel (16, 34).
[0004]
4. Ultrasonic inspection device (2, 4, 6), according to claim 3, characterized in that said flexible display panel (16, 34) comprises a polymeric substrate, a multitude of pixels arranged in lines and columns on or on said polymeric substrate, and a plurality of thin film transistors disposed on or on said polymeric substrate and electrically coupled to respective pixels of said plurality of pixels.
[0005]
5. Ultrasonic inspection device (2, 4, 6), according to claim 4, characterized in that said pixels comprise organic light-emitting diodes.
[0006]
6. Ultrasonic inspection device (2, 4, 6), according to claim 4, characterized in that said pixels comprise liquid crystal diodes.
[0007]
7. Ultrasonic inspection device (2, 4, 6), according to any one of the preceding claims, characterized in that said data acquisition module (24), said global positioning system receiver (20) , said transceiver (22) and said battery (18) are physically affixed to a portion of said flexible delay line substrate (12) that extends beyond a perimeter of said flexible ultrasonic transducer array (14).
[0008]
8. Ultrasonic inspection device, according to claim 1, characterized in that said flexible ultrasonic transducer arrangement (14) comprises a multiplicity of ultrasonic transducer elements arranged in rows and columns.
[0009]
9. Ultrasonic inspection device (2, 4, 6) according to any one of claims 1 to 7, characterized in that said flexible ultrasonic transducer arrangement (14) comprises a plurality of mutually parallel transmission electrodes ( 94) and a plurality of parallel receiving electrodes (92) which overlap, but are not parallel to, said transmit electrodes.
[0010]
10. Method for calibrating an ultrasonic inspection device (2, 4, 6), characterized in that it comprises: (a) storing structural model data representing material properties of a structure as a function of location in a system of coordinates of the structure; (b) affixing a flexible ultrasonic inspection device (2, 4, 6) to a surface of a portion of the structure, wherein the flexible ultrasonic inspection device (2, 4, 6) comprises a flexible substrate (12 ), a two-dimensional flexible ultrasonic transducer array (14) (14) affixed to the flexible substrate, and a global positioning system receiver (20) affixed to the flexible substrate; (c) acquiring location data using the positioning system receiver global (20), said location data representing a location of the global positioning system receiver (20); (d) sending the acquired location data to a computer system (30) at a location remote location; (e) determining a location of the flexible ultrasonic inspection device (2, 4, 6) in the structure's coordinate system; (f) retrieving structural model data representing the material properties of the structure in the vicinity of said location of the flexible ultrasonic inspection device (2, 4, 6) in the structure's coordinate system; (g) generate or retrieve a calibration file containing calibration data, which is a function of said retrieved structural model data representing properties of material from the portion of the frame in the vicinity of the location of the flexible ultrasonic inspection device (2, 4, 6); (h) sending the calibration file to a data acquisition module (24) that is configured to communicate with the array of flexible ultrasonic transducer (14); and (i) calibrating the data acquisition module (24) using the calibration data from the calibration file.

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法律状态:
2017-01-31| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|

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2020-05-19| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-12-15| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2021-11-16| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2022-02-01| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 19/07/2016, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US14/809,522|US9689844B2|2015-07-27|2015-07-27|Ultrasonic inspection using flexible two-dimensional array applied on surface of article|

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US14/809,522|2015-07-27|

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