Methods and devices for ultrasonic nondestructive testing devices

A non-destructive testing system includes a probe positioning assembly, a matrix array ultrasonic probe arranged on the probe positioning assembly configured to position the matrix array ultrasonic probe adjacent to a mating axial surface of a wheel for ultrasonic communication with the wheel. The matrix array ultrasonic probe is configured to emit a validation ultrasonic signal directed towards a coupling validation section within the wheel, measure the emitted validation ultrasonic signal after reflection from the coupling validation section, emit a plurality of ultrasonic inspection signals directed towards at least one inspection section of the wheel, and measure each of the plurality of ultrasonic inspection signals reflected from a defect positioned within the inspection section of the wheel.

BACKGROUND

Non-destructive testing (NDT) is a class of analytical techniques that can be used to inspect a target, without causing damage, to ensure that the inspected target meets required specifications. For this reason, NDT has found wide acceptance in industries such as aerospace, power generation, oil and gas transport or refining, and transportation, which employ structures that are not easily removed from their surroundings. Certain inspection techniques, such as non-destructive inspection techniques or non-destructive testing (NDT) techniques, can be used to detect undesired equipment conditions.

As an example, global railroad standards can require train wheels to be ultrasonically inspected after manufacture and during maintenance on a regular basis. In ultrasonic testing, acoustic (sound) energy in the form, of waves can be directed towards the train wheel. As the ultrasonic waves contact and penetrate the train wheel, they can reflect from features such as outer surfaces and interior defects (e.g., cracks, porosity, etc.). An ultrasonic sensor can acquire ultrasonic measurements of acoustic strength as a function of time. Subsequently, these ultrasonic measurements can be analyzed to provide testing results that characterize defects present within a train wheel, such as their presence or absence, location, and/or size.

SUMMARY

Certain NDT devices can be used to observe structure of solid objects, such as train wheels. Ultrasonic NDT devices can be arranged adjacent to through these solid objects to perform maintenance checks to determine corrosion or internal defects. Such ultrasonic NDT devices require the ability to be validate a probe's location with respect to a solid object, and to determine surface and internal defects in multiple inspection section of the solid object. Therefore, it is beneficial to increase the functionality of an ultrasonic NDT device to both validate and measure using ultrasonic waves.

In general, systems and methods are provided for ultrasonic non-destructive testing devices.

In one embodiment, non-destructive testing system can include a probe positioning assembly and a matrix array ultrasonic probe arranged on the probe positioning assembly configured to position the matrix array ultrasonic probe adjacent to a mating axial surface of a wheel for ultrasonic communication with the wheel. The matrix array ultrasonic probe is configured to emit a validation ultrasonic signal directed towards a coupling validation section within the wheel, measure the emitted validation ultrasonic signal after reflection from the coupling validation section, emit a plurality of ultrasonic inspection signals directed towards at least one inspection section of the wheel, and measure each of the plurality of ultrasonic inspection signals reflected from a defect positioned within the inspection section of the wheel.

In another embodiment, the inspection section can further comprise a first inspection section and a second inspection section.

In another embodiment, the first inspection section can be an outer surface of the wheel and the second inspection section can be a flange of the wheel.

In another embodiment, the coupling validation section can be an outer axial surface opposite the mating axial surface of the wheel.

In another embodiment, the validation ultrasonic signal can be a back-wall echo of a single ultrasonic inspection signal from the plurality of ultrasonic inspection signals directed at the outer axial surface.

In another embodiment, an ultrasonic complaint fluid can be arranged between the matrix array ultrasonic probe and the mating axial surface of the wheel.

In another embodiment, the non-destructive testing system can further comprise a control unit comprising: at least one data processor; and a memory storing instructions, which when executed by at the least one data processor causes the at least one data processor to perform operations comprising: receiving the measured validation ultrasonic signal and the plurality of measured inspection ultrasonic signals; determining a correction ratio between the measured validation ultrasonic signal and a reference validation signal; and computing a plurality of corrected measured inspection ultrasonic signals based on the correction ratio.

In another embodiment, the matrix array ultrasonic probe emitting the plurality of inspection ultrasonic signals can be configured to sweep the plurality of inspection ultrasonic signals through an arc of predetermined directions.

In another embodiment, the matrix array ultrasonic probe measuring the plurality of reflected inspection ultrasonic beams can be configured to measure a plurality of inspection ultrasonic signals after reflection from a plurality of respective defects.

In another embodiment, the probe positioning assembly can be configured to reversibly lift the wheel above an underlying surface and to rotate the wheel while lifted.

Methods for controlling a non-destructive testing device are also provided. In one embodiment, a method can include positioning a matrix array ultrasonic probe adjacent to a mating axial surface of a wheel for ultrasonic communication with the wheel, the wheel including a coupling validation section and an inspection section; emitting, via the matrix array ultrasonic probe, a validation ultrasonic signal directed towards the coupling validation section of the wheel; measuring, via the matrix array ultrasonic probe, the emitted validation ultrasonic signal after reflection from the coupling validation section; emitting, via the matrix array ultrasonic probe, a plurality of ultrasonic inspection signals toward the inspection area of the wheel; measuring, via the matrix array ultrasonic probe, each of the plurality of the inspection ultrasonic signals after reflection from a defect positioned within the inspection area; and receiving, via a control unit in communication with the matrix array ultrasonic probe, the measured validation ultrasonic signal and the plurality of measured inspection ultrasonic signals, wherein the control unit comprises at least one data processor and a memory storing instructions.

In another embodiment, the method further comprises determining, via the control unit, a correction ratio between the measured validation ultrasonic signal and a reference validation signal, and computing, via the control unit, a plurality of corrected measured inspection ultrasonic signals based on the correction ratio.

In another embodiment, the inspection section can further comprise a first inspection section and a second inspection section.

In another embodiment, the first inspection section can be an outer surface of the wheel and the second inspection section can be a flange of the wheel.

In another embodiment, the coupling validation section can be an outer axial surface opposite the mating axial surface of the wheel.

In another embodiment, the validation ultrasonic signal can be a back-wall echo of a single ultrasonic inspection signal from the plurality of ultrasonic inspection signals directed at the outer axial surface.

In another embodiment, an ultrasonic complaint fluid can be arranged between the matrix array ultrasonic probe and the mating axial surface of the wheel.

In another embodiment, the matrix array ultrasonic probe emitting the plurality of inspection ultrasonic signals can be configured to sweep the plurality of inspection ultrasonic signals through an arc of predetermined directions.

In another embodiment, the matrix array ultrasonic probe measuring the plurality of reflected inspection ultrasonic beams can be configured to measure a plurality of inspection ultrasonic signals after reflection from a plurality of respective defects.

In another embodiment, the probe positioning assembly can be configured to reversibly lift the wheel above an underlying surface and to rotate the wheel while lifted.

DETAILED DESCRIPTION

Wheels, for example train wheels, can develop damage, such as cracks, over time during use. If this damage becomes too severe, it can cause the wheel to break. To avoid failure of wheels during service, they can be inspected periodically. In some cases, because damage is not visible on the surface of the wheel, inspection can include techniques that allow the interior of the wheel to be investigated, such as ultrasonic testing. In ultrasonic testing, ultrasonic probes can be positioned on the wheel and they can send and receive ultrasonic waves (high frequency sound waves) to detect defects beneath the surface of the wheel.

When ultrasonic testing is performed correctly, ultrasonic waves can easily travel between the ultrasonic probes and the wheel. This condition, referred to as coupling, and can ensure that defects are accurately measured. Existing ultrasonic testing systems can use one or more first ultrasonic probes to measure defects and one or more second ultrasonic probes, different from the first ultrasonic probes, to make measurements that validate the ultrasonic coupling of the first ultrasonic probes. However, this technique assumes that coupling validation measurements acquired by the second probe(s) are applicable to the first ultrasonic probe(s). However, in some cases, this assumption can be false, and the defect measurements acquired by the first set of ultrasonic probes can be erroneous due to poor coupling.

Accordingly, improved ultrasonic testing systems and corresponding methods are provided in which each ultrasonic probe is configured to measure defects within a target, such as a wheel, and to validate its coupling to the wheel. Because an ultrasonic probe can independently validate its coupling to the wheel, as long as its coupling remains validated, its defect measurements are ensured to be accurate.

Embodiments of ultrasonic testing systems and corresponding methods for validating ultrasonic measurements acquired for train wheels are discussed herein. However, embodiments of the disclosure can be employed for ultrasonic testing of other target objects without limit.

Referring now toFIGS. 1A and 1B, a schematic illustration of a train wheel10is generally depicted. The train wheel10can include a wheel disk11, an inner axial surface12, an outer axial surface13, a running tread14, a body15, and a wheel flange16. The wheel disk11can form a center of the train wheel10and the running tread14can form a circumferential outer surface of the train wheel10. The wheel flange16can be formed on one side of the train wheel10(e.g., an interior side) and extend radially outward from the running tread14.

The wheel disk11can include one or more holes arranged therein. As depicted, a primary hole18can be positioned at a center of the wheel disk11and be configured for receipt of an axle19, wherein the axle is concentric with an axial axis AA. One or more secondary holes can be formed radially outward from the primary hole18and configured for coupling other components to the train wheel10, such as brake disks (not shown).

Referring now toFIGS. 2A and 2B, a cross-sectional schematic view of the train wheel10is depicted. In an exemplary implementation, the train wheel10can include inspection sections20,22, and24. The inspection section20can be arranged on the outer axial surface13to detect surface defects26forming on the outer axial surface13. The inspection section22can be arranged on the wheel flange16to detect defects28forming on the wheel flange16. The inspection section24can be arranged within the body15to detect internal defects30within the body15of the train wheel10. The inspection sections20and22can extend inward from the outer surfaces to the body15of the train wheel10. As depicted, as an ultrasonic probe is arranged on the inner axial surface12and mated to the train wheel10, the inspection sections20,22, and24are at varying angles with respect to the inner axial surface12.

In general, when ultrasonic beams pass through a material, they can reflect from surfaces of the material, such as interior defects (e.g., cracks, pores, etc.) and outer surfaces. Material features, such as geometric boundaries and defects, can reflect ultrasonic beams in different ways. Some material features can reflect ultrasonic beams better than others, and the strength of the reflected ultrasonic beams can vary. Material features can also be at different distances from the ultrasonic probes and the time at which reflected ultrasonic beams reach the ultrasonic probes can vary. Measurements of the strength and time behavior of ultrasonic beams reflected from the train wheel10can be analyzed to determine the position and size of surface defects within the inspection sections20and22, and internal defects within the inspection section24.

Referring now toFIGS. 3A and 3B, an ultrasonic probe assembly100can include a matrix array ultrasonic probe102, a housing104, apertures106, and spacers108. In an exemplary embodiment, the matrix array ultrasonic probe102is arranged within the housing104so that the matrix array ultrasonic probe102is arranged facing outward in order to mate with the inner axial surface12of the train wheel10. The apertures106can also be arranged on the housing104in order to provide an ultrasonic compliant fluid (i.e., water) to the matrix array ultrasonic probe102so that ultrasonic waves can pass through the fluid to the train wheel10when an ultrasonic measurement is being taken. In an exemplary implementation, the spacers108can be arranged in order to provide a small gap between the inner axial surface12and the matrix array ultrasonic probe102in order to protect the surface of the matrix array ultrasonic probe102. The spacers108can be made from ceramic particles. The matrix array ultrasonic probe102can be communicatively coupled to the control unit via the cable110.

Referring still toFIGS. 3A and 3B, a matrix array ultrasonic probe102, also referred to as phased array ultrasonic probes, can include two or more ultrasonic active elements. These ultrasonic active elements can be configured to generate and measure ultrasonic beams and can be arranged in a predetermined pattern with respect to one another (e.g., a line, a circle, a grid, etc.). Each of the ultrasonic active elements can also be configured to generate ultrasonic beams that are varied in strength and/or time with respect to ultrasonic beams generated by the other ultrasonic active elements. The various ultrasonic beams can interfere with each other to produce a net ultrasonic beam112in a predetermined direction. This process can be repeated as necessary to sweep the ultrasonic beam112through an arc A of different predetermined directions.

Referring now toFIG. 4, the ultrasonic NDT device assembly200can include the ultrasonic probe assembly100ofFIG. 3A, a probe holder204, a probe holder mount206, a positioning unit210, and a control unit300. As shown, matrix array ultrasonic probe102can be positioned on or adjacent to the train wheel10(e.g., an inner axial surface12of the body15) for ultrasonic testing. A single matrix array ultrasonic probe102is illustrated. However, any number of matrix array probes can be employed in various positions about the train wheel10without limit. Under circumstances where the system is employed with wheels other than train wheels10, the matrix array ultrasonic probe102can be positioned on or adjacent to the wheel at a suitable location, such as an outer axial surface of the wheel.

Still referring toFIG. 4, the matrix array ultrasonic probe102can be mechanically coupled to the probe holder204and oriented with respect to the train wheel10. The probe holder204in turn can be coupled to the probe holder mount206. The probe holder mount206can be secured to a positioning unit210, which can position the matrix array ultrasonic probe102on or adjacent to the train wheel10. The probe holder mount206can be coupled to the probe holder204and it can be configured to position the matrix array ultrasonic probe102adjacent to or in contact with the inner axial surface12for ultrasonic communication with the inspection sections20,22, and24of the train wheel10. While the matrix array ultrasonic probe102is positioned adjacent to the train wheel10, an ultrasonic compliant fluid (i.e., water) can be provided between the matrix array ultrasonic probe102and the train wheel10via the apertures106(shown inFIG. 3A) to facilitate ultrasonic communication.

In an exemplary implementation, the matrix array ultrasonic probe102can be configured to acquire measurements for detection of defects26,28, and30within inspection sections20,22, and24. Additionally, validation of the ultrasonic coupling with respect to the train wheel10can be determined through a back-wall echo of an ultrasonic beam112contacting the outer axial surface13. A validation ultrasonic signal113can be emitted from the matrix array ultrasonic probe102at a 0° angle in order to contact the outer axial surface13to verify the coupling between the matrix array ultrasonic probe102and the train wheel10. A plurality of inspection ultrasonic signals114can also be emitted from the matrix array ultrasonic probe102in a sweeping arc A (shown inFIG. 3B). In an exemplary implementation, the validation ultrasonic signal113can be an ultrasonic beam112emitted prior to the plurality of inspection ultrasonic signals114. In another exemplary implementation, the validation ultrasonic signal113can be one of the plurality of inspection ultrasonic signals114, emitted during the sweeping arc A of the train wheel10. The ultrasonic beams112, validation ultrasonic signal113, and plurality of inspection ultrasonic signals114can be emitted at a 2 kHz frequency.

In some exemplary embodiments, when using the ultrasonic NDT device assembly200for inspection of train wheel10, a lift and rotation unit (not shown) can be configured to lift the train wheel10in the vertical direction (+Y) above an underlying rail (not shown). The lifted train wheel can then be examined by the ultrasonic NDT device assembly200at varying circumferential locations on the train wheel10. After a measurement is completed, the train wheel10can be rotated about the axle19to an adjacent circumferential location.

Still referring toFIG. 4, the train wheel10can be lifted from an underlying surface (e.g., a rail) while the validation ultrasonic signal113and the plurality of inspection ultrasonic signals114are emitted and reflected within the train wheel10. The train wheel10can also be rotated while lifted to facilitate inspection of substantially the entire volume of the train wheel10. In one aspect, rotation can be performed after measurement of reflected inspection ultrasonic signals114and the validation ultrasonic signal113. In some exemplary embodiments, the train wheel10is rotated 370° at 0.5 mm circumferential lengths. In another aspect, rotation can be performed at a selected speed during emission of the plurality of inspection ultrasonic signals114and the validation ultrasonic signal113, reflection of reflected inspection ultrasonic signals114and the validation ultrasonic signal113, and/or measurement of reflected inspection ultrasonic signals114and the validation ultrasonic signal113.

Still referring toFIG. 4, the control unit300of the can be configured for electronic communication with the matrix array ultrasonic probe102and positioning unit210. The control unit300can include any computing device employing a general purpose or application specific processor (e.g., processor302) and can also include a memory304. The processor302can include one or more processing devices, and the memory304can include one or more tangible, non-transitory, machine-readable media collectively storing instructions executable by the processor302to perform the methods and control actions described herein.

In one exemplary implementation, the memory304can store a reference validation signal for each coupling validation section32. The reference validation signal can represent a validation ultrasonic signal113measured under conditions of good coupling. The memory304can further store instructions and/or algorithms for determining whether the measured validation ultrasonic signal113reflected from a coupling validation section32matches a corresponding reference ultrasonic signal for that coupling validation section32. As an example, a match can be determined when the strength of the measured validation ultrasonic signal113and the reference validation ultrasonic signal vary from one another by less than a predetermined threshold amount as a function of time. Conversely, a match may not be determined when the strength of the measured validation ultrasonic signal113and the reference validation ultrasonic signal vary from one another by greater than the predetermined threshold amount as a function of time.

In an exemplary implementation, the memory304can store a reference validation signal strength for each coupling validation section32. The reference validation signal strength can represent a threshold strength above which a validation ultrasonic signal113can be considered to represent good coupling between the matrix array ultrasonic probe102and the train wheel10. The memory304can further store instructions and/or algorithms for determining whether the measured validation ultrasonic signal113reflected from a coupling validation section32exhibits a strength greater than or equal to the reference validation signal strength for that coupling validation section32. A measured validation ultrasonic signal113having a strength greater than or equal to the reference validation signal strength can be considered to possess good coupling. Conversely, a measured validation ultrasonic signal113determined having a strength less than the reference validation signal strength can be considered to possess poor coupling. Additionally, a measured validation ultrasonic signal113can be compared to the reference validation signal strength in order to determine a ratio which is representative of the coupling. Once the ratio is determined, each of the plurality of inspection ultrasonic signals114can be corrected using a stored algorithm within the memory304to determine if defects exist within the train wheel10.

Referring now toFIG. 5, a flow diagram illustrating an exemplary embodiment of a method400for ultrasonic inspection in which the matrix array ultrasonic probe102can be configured to both perform ultrasonic inspection of the train wheel10and validate its ultrasonic coupling with the train wheel10. The method400is described below in connection with the ultrasonic NDT device assembly200ofFIGS. 3A-4. As illustrated, the method400includes operations402-416. However, alternative embodiments of the method can include greater or fewer operations than illustrated inFIG. 5, and the operations can be performed in a different order than illustrated inFIG. 5.

In operation402, the matrix array ultrasonic probe102can be positioned for ultrasonic communication with the train wheel10. In an exemplary implementation, the matrix array ultrasonic probe102can be positioned using the positioning unit210. As an example, the matrix array ultrasonic probe102can be positioned on or adjacent to the inner axial surface12of the train wheel10. In operations404-406, the matrix array ultrasonic probe102can emit the validation ultrasonic signal113towards a coupling validation section32within the train wheel10and measure the corresponding reflected validation ultrasonic signal113. As illustrated inFIGS. 2A and 2B, the train wheel10can include a coupling validation section32arranged on the outer axial surface13of the body15. It should be appreciated that multiple coupling validation sections32can be arranged on the train wheel10. Furthermore, the matrix array ultrasonic probe102can be configured to sweep the emitted validation ultrasonic signal113through an arc of predetermined directions and measure a plurality of validation ultrasonic signals113after reflection from a plurality of coupling validation sections.

In operation408, the matrix array ultrasonic probe102can emit a plurality of ultrasonic inspection signals114towards the inspection sections20,22, and24of the train wheel10. Similar to the validation ultrasonic signals113, the emitted inspection ultrasonic signals114can be swept through an arc of predetermined directions. In operation410, the matrix array ultrasonic probe102can measure the emitted inspection ultrasonic signals114after reflection from a defect within the inspection sections20,22, and/or24(e.g., defects26,28, and/or30). Thus, the matrix array ultrasonic probe102that emits inspection ultrasonic signals114can be configured to sweep the inspection ultrasonic signals114through an arc of predetermined directions, and the matrix array ultrasonic probe102that measures the reflected inspection ultrasonic signals114can be configured to measure the plurality of inspection ultrasonic signals114after reflection from a plurality of respective defects26,28, and/or30.

The manner in which the validation ultrasonic signal113and the plurality of inspection ultrasonic signals114are generated can be chosen based upon the train wheel10under inspection. In general, a predefined number of inspection ultrasonic beams can be generated, followed by a validation ultrasonic signal, or vice versa. In one aspect, the inspection ultrasonic signals and validation ultrasonic signals can be alternatingly generated. In another aspect, a predetermined number of inspection ultrasonic signals can be generated (e.g., approximately 100,) followed by one or more validation ultrasonic signal. This cycle can be repeated or varied as necessary for the duration of ultrasonic testing.

In operations412-416, the control unit300can validate the ultrasonic coupling of the matrix array ultrasonic probe102with the train wheel10. In operation412, the control unit300can receive a measured validation ultrasonic signal113and a plurality of measured inspection ultrasonic signals114(e.g., from the matrix array ultrasonic probe102). In operation414, the control unit can determine that the measured validation ultrasonic signal113matches a reference validation ultrasonic signal. The reference validation ultrasonic signal can be maintained by the memory304and the processor302can conduct a comparison of the two to determine a match or determine a ratio between the values. As an example, a ratio can be identified when the measured validation ultrasonic signal113and the reference validation ultrasonic signal differ by greater than a threshold amount (e.g., on the basis of strength as a function of time). Under this circumstance, the control unit can be configured to use the ratio in order to correct the plurality of inspection ultrasonic signals114in operation416.

Exemplary technical effects of the methods, systems, and devices described herein include, by way of non-limiting example, integrated ultrasonic testing and ultrasonic coupling validation, in one aspect, ultrasonic coupling validation can be provided for the matrix array ultrasonic probe. That is, unlike existing ultrasonic testing system, ultrasonic coupling between the matrix ultrasonic probe and a train wheel can be measured directly, rather than assumed based upon measurements from other ultrasonic probes. This direct validation can ensure that ultrasonic testing results are properly interpreted. In another aspect, the use of matrix array ultrasonic probe in an ultrasonic testing system can substantially minimize the risk that defects are missed due to erroneous interpretations of ultrasonic testing results. In a further aspect, improved ultrasonic testing systems can be provided in which all ultrasonic probes are employed for detection of defects. That is in contrast to existing ultrasonic testing systems where some probes (e.g., validation ultrasonic probes) are employed solely for coupling validation and not defect detection. The absence of probes configured for different functions can reduce the complexity and cost of ultrasonic testing.

The present disclosure is not limited to the exemplary embodiments described herein and can be embodied in variations and modifications. The exemplary embodiments are provided merely to allow one of ordinary skill in the art to understand the scope of the present disclosure, which will be defined by the scope of the claims. Accordingly, in some embodiments, well-known operations of a process, well-known structures, and well-known technologies are not be described in detail to avoid obscure understanding of the present disclosure. Throughout the specification, same reference numerals refer to same elements.

Hereinabove, although the present disclosure is described by specific matters such as concrete components, and the like, the exemplary embodiments, and drawings, they are provided merely for assisting in the entire understanding of the present disclosure. Therefore, the present disclosure is not limited to the exemplary embodiments. Various modifications and changes can be made by those skilled in the art to which the disclosure pertains from this description. Therefore, the spirit of the present disclosure should not be limited to the above-described exemplary embodiments, and the following claims as well as all technical spirits modified equally or equivalently to the claims should be interpreted to fall within the scope and spirit of the disclosure.