System and method for phased array edge card

A system includes an ultrasound measurement probe. The ultrasound measurement probe includes a lower portion. The lower portion includes a delay block, an array of ultrasound transducers coupled to the delay block, and a first circuit board. The first circuit board further includes a first plurality of pins coupled to the array of ultrasound transducers. The ultrasound measurement probe also includes an upper portion removably coupled to the lower portion. The upper portion includes a second circuit board. The second circuit board further includes a second plurality of pins configured to couple with the first plurality of pins when the upper portion is removably coupled to the lower portion.

BACKGROUND

The subject matter disclosed herein relates generally to ultrasound measurement probes, and more particularly to phased array ultrasound measurement probes.

Ultrasound measurement probes are used to inspect test objects in order identify and/or characterize defects, flaws, and other anomalies in the test object. Phased array ultrasound measurement probes are particularly useful in measuring the thickness of materials subject to corrosion or other wear. Use of ultrasound measurement probes generally causes wear on the probe itself until the probe is worn down, resulting in the entire probe being replaced. A probe may be replaced if a probe with a longer cable length is desired, such as when scanning a larger area. A probe may also be replaced if a different test controller is used, as test controller manufacturers may use probe connectors with different configurations.

BRIEF DESCRIPTION

In a first embodiment, a system includes an ultrasound measurement probe. The ultrasound measurement probe includes a lower portion. The lower portion includes a delay block, an array of ultrasound transducers coupled to the delay block, and a first circuit board. The first circuit board further includes a first plurality of pins coupled to the array of ultrasound transducers. The ultrasound measurement probe also includes an upper portion removably coupled to the lower portion. The upper portion includes a second circuit board. The second circuit board further includes a second plurality of pins configured to couple with the first plurality of pins when the upper portion is removably coupled to the lower portion.

In a second embodiment, a method includes electrically connecting a first plurality of pins disposed on a first edge of a first circuit board of a first lower portion to a second plurality of pins of a second circuit board of a first upper portion. The first plurality of pins is configured to interface directly with the second plurality of pins. The method also includes removably coupling the first lower portion to the first upper portion to form a first ultrasound measurement probe. Each pin of the first plurality of pins is coupled to a first ultrasound transducer of a first array of ultrasound transducers of the first lower portion.

In a second embodiment, a method including an ultrasound measurement probe. The ultrasound measurement probe includes a lower portion. The lower portion includes a delay block and an array of ultrasound transducers coupled to the delay block. The array of ultrasound transducers includes a row of transmitter elements and a row of receiver elements. Each transmitter element is electrically connected to a first plurality of pins1-32. Each receiver element is electrically connected to a second plurality of pins1-32. The lower portion further includes a first housing disposed about the delay block and the array of ultrasound transducers. The first housing includes a plurality of indicators configured to indicate wear of the first housing a first circuit board. The first circuit board includes a third plurality of pins1-80at a first end portion of the first circuit board, where pins1-8and73-80are electrically connected to at least one grounding element; pins9,10,13,14,17,18,21,22,25,26,29,30,33,34,37,38,41,42,45,46,49,50,53,54,57,58,61,62,65,66,69, and70are each electrically connected to a respective pin of the first plurality of pins1-32; pins11,12,15,16,19,20,23,24,27,28,31,32,35,36,39,40,43,44,47,48,51,52,55,56,59,60,63,64,67,68,71, and72are each electrically connected to a respective pin of the second plurality of pins1-32; and the third plurality of pins is configured to electrically connect with a second circuit board of an upper portion of the ultrasound measurement probe at a second end portion of the first circuit board opposite the first end portion. The ultrasound measurement probe further includes an upper portion removably coupled to the lower portion. The upper portion includes a second circuit board, and the second circuit board comprises a fourth plurality of pins configured to couple with the third plurality of pins when the upper portion is removably coupled to the lower portion.

DETAILED DESCRIPTION

The disclosed embodiments relate to multi-component or multi-section probes, which include a plurality of probe portions that removably couple together. These probes may include ultrasound probes, eddy current probes, visual inspection probes (e.g., borescopes), x-ray fluorescence (XRF) probes, non-destructive testing probes, or any combination thereof. The following discussion focuses on ultrasound measurement probes, but is intended to be inclusive of any probes including the examples provided above. The following discussion also focuses on handheld probes that are connected to a test controller, where the controls to direct and instruct the probe are located on the test controller and a user guides the probe with his hand. However, the following discussion is intended to be inclusive of any probes, including those that are not handheld or those that includes controls on the probe itself. Similarly, the disclosed embodiments refer to probe portions as upper and lower portions. However, it is appreciated that what is referred to as the lower portion is the portion of the probe that is in contact with, applied to, or otherwise directed toward the object to be tested. It is also appreciated that what is referred to as the upper portion is the portion of the probe that connects to the lower portion and couples to a cable that further couples to a test controller. References to features of the lower portion of the probe in the disclosed embodiments are not meant to necessarily limit those features to a portion of the probe that is closest to a relative “bottom.” Likewise, references to features of the upper portion of the probe in the disclosed embodiments is not meant to necessarily limit those features to a portion of the probe that is closest to a relative “top.” As mentioned above, referencing probe portions as upper and lower portions in the disclosed embodiments is not meant to limit the portions of the probe to two portions.

Ultrasound testing is a type of non-destructive testing that is used to inspect test objects in order to identify and/or characterize defects, flaws, and other anomalies in the test object. Testing equipment that is used in ultrasound testing generally includes an ultrasound measurement probe that sends and receives signals, a test controller that operates the probe, and a cable that transmits information between the probe and the test controller. In certain embodiments, the ultrasound measurement probe may be used to inspect pipe, machinery, or other industrial equipment. For example, the machinery may include compressors, pumps, and turbines, such as gas turbines, steam turbines, wind turbines, or hydro turbines.

The ultrasound measurement probe may incorporate transducer elements that are constructed of piezoelectric materials that are responsive to certain stimuli in a manner conducive to non-destructive testing. The transducer elements generate acoustic waves in response to electrical waveform pulses that are applied to electrodes connected to the transducer elements. These transducer elements are also responsive to acoustic waves, such as those acoustic waves that are reflected from the test object. For purposes of ultrasound testing, transducer elements are used to transmit acoustic waves into the test object and capture the reflection of those acoustic waves, where the resultant voltage differences across electrodes connected to the transducer elements caused by the reflected waves may be processed in order to analyze the test object.

Generally, ultrasound measurement probes are formed with at least transducer elements, electrodes, and circuitry elements disposed in a single, unitary body. For example, a potted sensor may utilize a filler material to form a unitary sensor structure that substantially encapsulates the transducer elements, electrodes, and circuitry elements of the ultrasound measurement probe. Use of ultrasound measurement probes generally causes wear on the probe itself, thereby limiting the usable life of the probe. A probe may be replaced if a probe with a longer cable length is desired, such as when scanning a larger area. A probe may also be replaced if a new test controller is used that has a different probe connector than was previously used.

The present disclosure provides an ultrasound measurement probe that includes a plurality of probe portions, (e.g., upper and lower portions) that are capable of being removably coupled together. The present disclosure also provides circuit boards disposed in each of the upper and lower portions whose pins are configured to be electrically connected together, such that the ultrasound measurement probe can then be operated when the upper and lower portions are removably coupled together. The lower portion is applied to the test object to inspect the test object. The lower portion includes a delay block or acoustic layer made of a delay material, an array of ultrasound transducers that is coupled to the delay material, and a first circuit board that includes a first plurality of pins that may be coupled to the array of ultrasound transducers at a first end of the first circuit board. The first plurality of pins may be disposed on an edge of the first circuit board at a second end of the first circuit board opposite the array of ultrasound transducers. The upper portion includes a second circuit board that includes a second plurality of pins that are configured to electrically connect to the first plurality of pins when the upper portion is removably coupled to the lower portion. The upper portion may include a cable assembly that couples to both the second plurality of pins and a cable that transmits information between the probe and the test controller. Advantageously, the ability to removably couple the upper portion with the lower portion, and thus electrically connect and disconnect the second plurality of pins from the first plurality pins, enables only the lower portion of the probe to be replaced when the probe is worn with use rather than the entire probe. Additionally, the modularity of the presently disclosed upper and lower portions of a probe enables the use of different cable lengths for different applications to be alternatively used with a single, removable, lower probe portion. Furthermore, the modularity of having removably coupled upper and lower portions of a probe allows different instrument connector options to be alternatively used with a single lower probe portion. Again, although the present discussion focuses on ultrasound measurement probes as an example, the disclosed embodiments are equally applicable to other types of probes (e.g., ultrasound probes, eddy current probes, visual inspection probes (e.g., borescopes), X-ray fluorescence (XRF) probes, non-destructive testing probes, or any combination thereof).

FIG. 1is a perspective view of an embodiment of a system or application10of a non-destructive measurement system12(e.g., an ultrasound measurement system) having a non-destructive testing probe14(e.g., an ultrasound measurement probe14) placed on a scan surface16of a test object18. Again, as noted above, the system12and probe14may include any number of measurement techniques, such as ultrasound, eddy current, visual inspection, X-ray, or other non-destructive testing. Exemplary objects that can be interrogated by the ultrasound measurement system12as the test object18include, but are not limited to, pipes, ducts, plates, vessels, tanks, industrial equipment, compressors, pumps, turbines (e.g., wind, gas, hydro, and/or steam turbines), or any combination thereof. These test objects18may be susceptible to corrosion, thermal stress and cracking, mechanical stress and cracking, erosion, or other wear as shown by the recessed portion20. For example, the recessed portion20may be a result of exposure to materials that cause oxidation of an opposing surface22that is opposite of the scan surface16of the test object18.

In the present example, the ultrasound measurement probe14can have a lower portion28and an upper portion29that may be removably coupled. The lower portion28can have a scan area30that has a length40. The length40of the scan area30can vary in a manner that permits the ultrasound measurement probe14to measure a variety of characteristics of the test object18. These characteristics may include, but are not limited to, the material thickness23of the test object18and other defects, anomalies, and deviations (e.g., cracks, voids, and inclusions)20that may be located at different depths between the scan surface16and the opposing surface22of the test object18.

The ability of the ultrasound measurement probe14to measure a variety of characteristics of the test object18is beneficial because the test object18can be interrogated in a manner that would normally utilize separate devices (e.g., devices optimized for detecting recessed portions20near the scan surface16of the test object18as opposed to deeper in the test object18). It is likewise beneficial that the length40of the scan area30can be configured so as to substantially reduce both the interrogation time, as well as the likelihood that recessed portions20are missed during interrogation of the test object18.

In the present embodiment of the ultrasound measurement system12, a test controller24may be connected to the ultrasound measurement probe14by a cable26that exchanges information between the test controller24and the ultrasound measurement probe14. The cable26may include a connector72to connect the probe14to a test controller24through the test controller connector76of the test controller24. The test controller24may operate the probe14so as to activate, and collect data from, the scan area30. Exemplary devices that are suited for use as the test controller24can include, but are not limited to, computers, ultrasound instruments, ultrasound systems, and the like. Examples of ultrasound instruments include the Phasor XS Ultrasonic Flaw Detector available from General Electric Inspection Technologies of Lewiston, Pa. and the OmniScan MX2 Phased Array Flaw Detector available from Olympus Corporation of Waltham, Mass.

By way of non-limiting example, the test controller24includes an interface32that has a display34that displays information, which can be collected by the ultrasound measurement probe14. The interface32also includes one or more controls36(e.g., buttons, dials, switches, touch screen, etc.) that control the operation of the ultrasound measurement probe14.

In view of the foregoing, and discussing one implementation of the ultrasound measurement probe14and the ultrasound measurement system12in application10in more detail, a user (e.g., a field engineer) can position the ultrasound measurement probe14on the scan surface16of the test object18so that the acoustic signals from transmitter elements44(FIG. 2) of the ultrasound measurement probe14enter the test object18. The user can move the probe14along the scan surface16in a direction38that may be substantially perpendicular to the scan area30. In the case of cylindrical test objects18(e.g., pipes), the direction38may be substantially circumferential and/or axial. Moving the probe14in this direction38may move scan area30over the area of interest of the test object18. The term “area of interest” (or “AOI”) is used herein to describe the portion of the test object18where data is to be collected with the ultrasound measurement system12. An area of interest, for example, may include the test object18in its entirety, and/or a portion of the test object18. The area of interest may also include portions of the test object18that are subject to corrosion, stress, or other wear as shown by the recessed portion20. The area of interest may further include the scan surface16of the test object18in its entirety, and/or a portion of the scan surface16of the test object18.

In one embodiment of the ultrasound measurement probe14, the user can adjust the controls36of the test controller24so as to accommodate changes in the physical characteristics of the area of interest of the test object18, including changes in the thickness23of the material between the scan surface16and the opposing surface22of the test object18. For example, certain portions of the test object18may be subject to corrosion, stress, or other wear as shown by the recessed portion20such that the material thickness23of one portion of the test object18is different than the material thickness23of another portion of the test object118. The physical characteristics also include the depth of the recessed portion20from the scan surface16. For example, one recessed portion20may have a depth within the test object18that is different from other recessed portions20within the test object18, which are also detected with the ultrasound measurement system12. Additionally, or in the alternative, the physical characteristics may include a size or shape of the recessed portion20.

FIG. 2is an exploded perspective view of an embodiment of a non-destructive testing probe (e.g., an ultrasound measurement probe14) in accordance with the present disclosure. In the present example, the scan area30of the probe14includes a plurality of transducer elements (e.g., ultrasound transducer elements41) arranged in an array42. The array42of transducer elements41includes a plurality of transmitter elements44and a plurality of receiver elements46. The plurality of transmitter elements44and receiver elements46may each be arranged in a row. For example,FIG. 3is a schematic of electrical connections of an embodiment of a non-destructive testing probe in accordance with the present disclosure.FIG. 3shows a mapping of pins for a row37of 32 transmitter elements44(labeled EL1-EL32) and a row39of 32 receiver elements46(labeled EL33-EL64). Each transmitter element44(labeled EL1-EL32) is mapped to a respective pin (labeled1-32) of row37. Each receiver element46(labeled EL33-EL64) is mapped to a respective pin (labeled1-32) of row39. The user may define how many transmitter elements44of row37and receiver elements46of row39will be active at any time during operation. There may be any number of transmitter elements44in row37and receiver elements46in row39. For example, there may be 16 transmitter elements44in row37and 16 receiver elements46in row39. As another example, there may be 64 transmitter elements44in row37and 64 receiver elements46in row39.

The receiver elements46are configured to receive echo signals from the test object18. Exemplary echo signals include, but are not limited to, acoustic signals and/or acoustic waves that correspond to the acoustic signals transmitted by the transmitter elements44, and which are reflected back from the test object18toward the ultrasound measurement probe14. Each of the transmitter elements44and the receiver elements46can be constructed, in whole or in part, of a piezoelectric material, including, for example, piezoelectric ceramics, lead zirconate titanate, lead mataniobate, piezoelectric crystals, and any combinations thereof. In one example, one or more of the transmitter elements44and one or more of the receiver elements46may include a 1-3 type piezocomposite material. In some embodiments, the transmitter elements44may be used as receiver elements46, and vice versa.

The scan area30of the ultrasound measurement probe14may have one or more active groups50. The active groups50may include a plurality of transducer elements41, and more particularly the active groups50may include one or more of the transmitter elements44and one or more of the receiver elements46. By way of a non-limiting example, each of the active groups50has at least one transmitter element44and transducer elements one receiver element46, where the receiver element46receives the echo signals that correspond to the acoustic signals that originate from the transmitter element44. In other examples of the ultrasound measurement probe14, each of the active groups50includes any number of the transmitter elements44and the receiver elements46. In one embodiment, active group50includes one to twenty transmitter elements44and one to twenty receiver elements46. In another embodiment, active group50includes two to ten transmitter elements44and two to ten receiver elements46. In another embodiment, active group50includes two to ten transmitter elements44and three to five receiver elements46. The number of the transmitter elements44and the receiver elements46in the active groups50can be determined in accordance with the depth of the recessed portion20in the test Object18. Greater quantities of transmitter elements44and receiver elements46enable detection of deeper recessed portions20.

The test controller24that can be used in the present embodiment of the ultrasound measurement probe14can be configured to activate desired active groups50of the scan area30. Additionally, or in the alternative, the test controller24can be configured to activate desired transmitter elements44and receiver elements46. In some embodiments of the ultrasound measurement probe14, the controls36of the test controller24can be configured to select the length40of the scan area30, the number of active groups50, and/or the number of the transmitter elements44and the receiver elements46in each of the active groups50.

The lower portion28of the ultrasound measurement probe14includes a first circuit board52that has a first plurality of circuit board pins54(e.g., flat conductive contacts, pads, electrical contact points, etc.) coupled to the array42of ultrasound transducers elements41disposed at a first end47of the first circuit board52. For example,FIG. 3shows a mapping of circuit board pins54for the first circuit board52at the first end47. Circuit board pins labeled1-8and73-80are connected to at least one ground or electrical common ground. Circuit board pins labeled70,69,66,65,62,61,58,57,54,53,50,49,46,45,42,41,38,37,34,33,30,29,26,25,22,21,18,17,14,13,10, and9correspond to transmitter elements44(labeled EL1-EL32) of row37of array42, which connect to pins labeled1-32of row37as described above. Pins71,72,67,68,63,64,59,60,55,56,51,52,47,48,43,44,39,40,35,36,31,32,27,28,23,24,19,20,15,16,11, and12correspond to receiver elements46(labeled EL33-EL64) of row39of array42, which connect to pins1-32of row39as described above. Because there may be any number of transmitter elements44in row37and receiver elements46in row39, there may be a corresponding number of circuit board pins54of the first circuit board52. For example, if there are 16 transmitter elements44in row37and 16 receiver elements46in row39, there are at least 32 circuit board pins54for mapping to the transmitter elements44and receiver elements46of the first circuit board52. As another example, if there are 64 transmitter elements44in row37and 64 receiver elements46in row39, there are at least 128 circuit board pins54for mapping to the transmitter elements44and receiver elements46of the first circuit board52. Additionally, while it is disclosed that the first plurality of circuit board pins54are expressly mapped as described above and illustrated inFIG. 3, it is appreciated that each of the first plurality of circuit board pins54may be mapped differently to other transmitter elements44(labeled EL1-EL32) and receiver elements46(labeled EL33-EL64). The first plurality of circuit board pins54may be coupled to the array42of ultrasound transducer elements41through the use of wiring harnesses61. Embodiments of the probe14may include the first circuit board52oriented substantially perpendicular (between 85 and 95 degrees, or about 90 degrees) to the array42of ultrasound transducer elements41. The first plurality of circuit board pins54may be disposed on an edge56of the first circuit board52at a second end48of the first circuit board52opposite the array42of ultrasound transducer elements41. The first plurality of pins circuit board54may be disposed on one surface49of the first circuit board52and/or on the opposite surface51of the first circuit board52. The first circuit board52may include a notch57to ensure that the first circuit board52is connected to the circuit board connector63of the upper portion29in a desired orientation.

The lower portion28of the ultrasound measurement probe14may also include a delay block58or acoustic layer that is coupled to the array42of ultrasound transducer elements41between the test object18and the array42of ultrasound transducer elements41. The delay block58has a contact surface60. The delay block58may acoustically couple, via the contact surface60, the array42of ultrasound transducer elements41to the scan surface16of the test object18. The delay block58may have a transmitter support surface62(FIG. 4) on which may be placed a plurality of transmitter elements44. The delay block58may also have a receiver support surface64(FIG. 4) on which may be placed a plurality of receiver elements46. The delay block58provides a barrier between the transducer elements41and the scan surface16of the test object18and adds a time delay to the time interval required for the wave to traverse the scan surface16of the test object18to be inspected. The delay block58is made of a delay material generally selected based on its acoustic velocity, or the velocity of the particles in the material as the material transmits an acoustic wave. The acoustic velocity of the materials in the delay block58may be different from the acoustic velocity of the materials of the test object18. Exemplary delay materials for the delay block58include, but are not limited to, metals and plastics. In some embodiments of the ultrasound measurement probe14, the delay materials may include one or more of plastic, plexi-glass, and/or polystyrene.

The ultrasound measurement probe14includes a lower housing66for the lower portion28of the probe14that is disposed about the delay block58and the array42of ultrasound transducer elements41. The lower housing66may have a wear portion69that includes indicators68(e.g., slots, notches, grooves, markings, or ridges) to show wear. For example, the wear portion69may have a number of horizontal indicators68spaced vertically along the lower housing66. As the probe14is used, the part of the wear portion69that is in contact with the scan surface16of the test object18will wear. The space from the part of the wear portion69that is placed in contact with the scan surface16of the test object18to the closest indicator68, along with the number of remaining indicators, indicate how much wear the wear portion69has undergone. The wear portion69of the lower housing66may be made of an abradable material, such that the hardness of the abradable material is less than that of the hardness of the material of the scan surface16of test object18. Exemplary materials for use in the lower housing66include, but are not limited to, metals (e.g., aluminum, steel, brass, etc.), composites, and plastics, among many others.

The upper portion29of the ultrasound measurement probe14can include a second circuit board53that has a second plurality of pins55(e.g., flat conductive contacts, pads, electrical contact points, etc.) that may electrically connect to the first plurality of pins54located in the lower portion28. The first plurality of pins54may be configured to interface directly with the second plurality of pins55. For example, the first plurality of pins54and the second plurality of pins55may be configured such that they may be electrically connected using a male-female connector (e.g., first circuit board52of the lower portion28and a circuit board connector63and second circuit board53of the upper portion29). It should be appreciated that the first circuit board52could alternatively have male and/or female connectors or pins and the second circuit board53could have corresponding female and/or male connectors or pins. The upper portion29includes an upper housing67disposed about the second circuit board53. The upper portion29also includes a cable assembly70that couples to the second plurality of pins55. The upper portion29of the probe14may include internal connectors59that couple the second circuit board53to the cable assembly70. The cable assembly70includes a cable26that transmits information between the probe14and the test controller24. One or more connectors72may also be disposed on the cable assembly70. The one or more connectors72may couple the second circuit board53to a test controller connector76that corresponds to the test controller24. As such, the test controller connector76of the test controller24may have a different configuration (e.g., pin layout) based on the make and/or model of test controller24. For example, a Hypertronics model test controller connector76, such as one available from General Electric Inspection Technologies of Lewiston, Pa., may have a different configuration88(FIGS. 4 and 5) than that of another Hypertronics test controller connector76or a test controller connector76manufactured by Omniscan (e.g., for the Omniscan MX2 Phased Array Flaw Detector) or Phasor (e.g., for the XS Ultrasonic Flaw Detector). In one embodiment of the probe14, the one or more connectors72may couple the second circuit board53to a Hypertronics model test controller connector, an Omniscan model test controller connector, or a Phasor model test controller connector, or any combination thereof.

The upper portion29of the ultrasound measurement probe14may include a biasing element74coupled to the upper housing67and the second circuit board53. The biasing element74urges the second circuit board53into contact with the first circuit board52of the lower portion28when the upper portion29is removably coupled to the lower portion28. In some embodiments, the second plurality of pins55are biased pins configured to engage with the first plurality of pins54. Non-limiting examples of a biasing element74include a spring or group of springs, a resilient material (e.g., rubber, foam, or plastic), or a combination thereof.

The ultrasound measurement probe14may include at least one gasket78that can be disposed, for example, between the upper portion29and lower portion28of the ultrasound measurement probe14when the upper portion29and lower portion28are removably coupled. The lower portion28may include a sealing surface35that is configured to interface with the at least one of a gasket78. The at least one gasket78, with the upper portion29and lower portion28, helps to seal the enclosure31and at least the first circuit board52of the lower portion28from the external environment33(FIGS. 4 and 5). The seal created by the at least one gasket78and upper portion29and lower portion28may be watertight, airtight, or a combination thereof. The gasket78may be made of an elastomer, a plastic, a fabric, or any combination thereof.

Removably coupling the lower portion28and the upper portion29may also include coupling the lower housing66to the upper housing67. In some embodiments, first mating features80of the lower portion28and second mating features82of the upper portion29may be configured or disposed on the upper housing67and lower housing66such that the lower portion28and upper portion29can only interface in a desired orientation. For example, mating feature84(e.g., orientation guide) only allows the lower portion28and upper portion29of the probe14to be removably coupled in a desired orientation. The mating features80and82may include threaded fasteners (e.g., male and female threaded fasteners), snap-fit structures (e.g., male and female snap-fit structures), hooks and slots, latches, clamps, or any combination thereof.

FIG. 4is a cross-sectional side view of an embodiment of the assembled non-destructive testing probe (e.g., the ultrasound measurement probe) ofFIG. 2, taken along line3-3.FIG. 5is a cross-sectional side view of an embodiment of the assembled non-destructive testing probe (e.g., the ultrasound measurement probe) ofFIG. 2, taken along line4-4. Removably coupling the upper housing67to the lower housing66forms an enclosure31at least about the first circuit board52of the lower portion28. The second plurality of pins55on the second circuit board53of the upper portion29are also electrically connected with the first plurality of pins54of the first circuit board52of the lower portion28. The first circuit board52may be disposed such that it is substantially perpendicular (between 80 and 100 degrees) to the second circuit board53when the upper portion29is removably coupled to the lower portion28. The first plurality of pins54may be disposed on the edge56of the first circuit board53and may be electrically connected with the second plurality of pins55.

FIGS. 6-10show different embodiments of non-destructive testing probes (e.g., ultrasound measurement probes14) to illustrate how the upper portion29and lower portion28can be removably coupled and uncoupled to form different ultrasound measurement probes14. As shown in the non-limiting example inFIG. 6, a first non-destructive testing probe (e.g., an ultrasound measurement probe102) is formed by electrically connecting a first plurality of pins54of a first circuit board52of a first lower portion28with a second plurality of pins55on a second circuit board53of a first upper portion29and removably coupling the first lower portion28and the first upper portion29. The first upper portion29may include a first cable assembly70that couples to the second plurality of pins55. As discussed above, the first cable assembly70transmits information between the first ultrasound measurement probe102and a test controller24. The first cable assembly70has a first cable26that has a first cable length92between the first upper housing67and the first connector72. The first connector72may be used to couple the upper portion29of the first ultrasound measurement probe102to a test controller connector76that corresponds to the test controller24. As illustrated, the first connecter72is of a first configuration88.

As shown in the non-limiting example inFIG. 7, a second non-destructive testing probe (e.g., an ultrasound measurement probe104) is formed by electrically connecting the first plurality of pins54with a third plurality of pins55on a third circuit board53of a second upper portion29. In this example, a second cable assembly70of the second upper portion29includes a second cable70of a second cable length94that is different (e.g., greater) than the first cable length92as shown inFIG. 6. As may be appreciated, replacing the first upper portion29of the first ultrasound measurement probe102with the second upper portion29increases the overall range of the ultrasound measurement probe104due to a greater cable length94without replacing the entire probe102.

As shown in the non-limiting example inFIG. 8, a third non-destructive testing probe (e.g., an ultrasound measurement probe106) is formed by electrically connecting the first plurality of pins54with a fourth plurality of pins55on a fourth circuit board53of a third upper portion29. In this example, a third cable assembly70of the third upper portion29includes a second connector72that has a second configuration90that is different than that of the first connector72that has a first configuration88as shown inFIG. 6. The third ultrasound measurement probe106may then be used with a test controller24that has a test controller connector76that can be mated with the second connector72with second configuration90. As may be appreciated, replacing the first upper portion29of the first ultrasound measurement probe102with the second upper portion29enables the probe106to connect to a different test controller connecter76, and thus a different test controller24, without replacing the entire probe102.

FIG. 9illustrates a fourth non-destructive testing probe (e.g., an ultrasound measurement probe)108formed by electrically connecting a fifth plurality of pins54of a fifth circuit board52of a worn second lower portion112with a sixth plurality of pins55on a sixth circuit board53of a fourth upper portion29. In this example, the worn second lower portion112is worn from use, as can be seen by evaluating the indicators68on a wear portion69of a first lower housing66, such that the first lower housing66is of a first thickness116. The worn second lower portion112is replaced with a less worn (e.g., new) third lower portion114such that a fifth non-destructive testing probe (e.g., an ultrasound measurement probe110) is formed, as shown inFIG. 10. As may be appreciated, the less worn third lower portion114has a second thickness118greater than that of the worn second lower portion112with a first thickness of116.

FIG. 11is a flow chart illustrating the formation of an embodiment of a first non-destructive testing probe (e.g., an ultrasound measurement probe14) and subsequent formations of other embodiments of non-destructive testing probe (e.g., an ultrasound measurement probe14) from the lower portion28and upper portion29of the first probe14.

A first ultrasound measurement probe14is formed (block120) by connecting a first plurality of pins54of a first circuit board52of a first lower portion28to a second plurality of pins55of a second circuit board53of a first upper portion29(block122). Additionally, the first lower portion28and first upper portion29are removably coupled (block124) when the first ultrasound measurement probe14is formed. The first ultrasound measurement probe14may then be used (block126) to inspect test objects18in order identify and/or characterize defects, flaws, and other anomalies20in the test object18.

The first ultrasound measurement probe14may be disassembled (block128) to reduce and/or repurpose at least one of the first lower portion28and the first upper portion29. First, the first upper portion29is uncoupled from the first lower portion28(block130). Second, the first plurality of pins54is electrically disconnected from the second plurality of pins55(block132).

In some embodiments, a second ultrasound measurement probe14may be formed (block134) by electrically connecting the first plurality of pins54to a third plurality of pins55of a third circuit board53of a second upper portion29(block136). Additionally, the first lower portion28and second upper portion29may be removably coupled (block138) when the second ultrasound measurement probe14is formed. The first upper portion29includes a first cable assembly70coupled to the second circuit board53and the second upper portion29includes a second cable assembly70coupled to the third circuit board53. As may be appreciated and as discussed inFIGS. 6-10above, replacing the first upper portion29of the first ultrasound measurement probe14with the second upper portion29may increase the overall range of the probe14due to a greater cable length of the second upper portion29or enable the probe14to use other test controllers24without replacing the entire probe14. The second ultrasound measurement probe14may then be used (block140) to inspect test objects18in order identify and/or characterize defects, flaws, and other anomalies20in the test object18.

In some embodiments, a third ultrasound measurement probe14may be formed (block142) by electrically connecting a fourth plurality of pins54of a fourth circuit board52of a second lower portion28to the second plurality of pins55(block144). Additionally, the second lower portion28and first upper portion29may be removably coupled (block146). As may be appreciated, replacing the first lower portion28of the first ultrasound measurement probe14with the second lower portion28enables the user to replace the lower portion28of the probe14(e.g., due to wear of the lower portion's contact surface) extending the probe's lifetime without replacing the entire probe14. The third ultrasound measurement probe14may then be used (block148) to inspect test objects18in order identify and/or characterize defects, flaws, and other anomalies20in the test object18.

Technical effects of the subject matter disclosed herein include, but are not limited to, forming an ultrasound measurement probe with upper and lower portions that can be removably coupled together. Disposing the pins of the circuit board of the lower portion on the edge of the circuit board of the lower portion facilitates this modularity by conveniently ensuring that the pins of the circuit board of the lower portion and the pins of the circuit board of the upper portion are securely connected when the portions are removably coupled. Advantageously, the ability to removably couple the upper portion from the lower portion and thus electrically connect and disconnect the pins of the circuit board located in the upper portion from the pins of the circuit board located in the lower portion enables only the lower portion of the probe to be replaced when the probe is worn with use rather than the entire probe. Additionally, a probe that is capable of removably coupling its upper and lower portions enables the use of different cable lengths for different applications to be used with a single, removable lower probe portion, thereby eliminating the need to acquire an entirely new probe with a desired cable length. Furthermore, the ability to removably couple a probe's upper and lower portions enables different instrument connector options to be used with a single, removable lower probe portion, thereby eliminating the need to acquire an entirely new probe with a desired instrument connector.