Portable scanner device for metallurgical, nondestructive testing

A portable, self-contained scanner device for metallurgical, nondestructive testing is provided. The portable, self-contained scanner device includes a chassis having wheels extending beneath a lower surface thereof, a nondestructive testing probe detachably fixed to the chassis, and a computer processor device coupled to the chassis. The computer processor device includes applications executable by the computer processor device for performing the metallurgical, nondestructive testing on a test subject. The scanner device also includes a display device that displays images in response to the metallurgical, nondestructive testing. The chassis, computer processor device, and display device move along the test subject as a single unit.

TECHNICAL FIELD

The present disclosure relates generally to a scanner device, and more particularly, to a portable, self-contained scanner device for metallurgical, nondestructive testing.

BACKGROUND

Testing of pressure parts and large diameter tubes or piping (e.g., where the diameter is greater than 300 mm) using nondestructive testing techniques is an arduous task, particularly when testing girth and seam welds. For example, the parts to be measured are oftentimes installed in areas that require compact handheld equipment that the testing personnel operate by hand. Fully automated or semi-automated testing equipment can be bulky and too cumbersome for installation in these inaccessible areas. Further, using advanced handheld equipment (e.g., hand-guided scanners), the sensors (e.g., time of flight diffraction sensors, phased array, electromagnetic acoustic transducers, etc.) are mounted on the scanner and the data acquisition units, as well as the display unit, are both physically separate from the scanner and linked together via cabling. As a result, oftentimes two operators are needed to conduct the testing: one tester that guides the scanner, and another tester that observes the data acquisition process. If using only one operator, the data acquisition component and data display unit would need to be in the same location for simultaneous scanning and observation of the data. However, when testing in a confined space, e.g., boiler equipment, this may not be possible.

What is needed, therefore, is a compact, self-contained scanning device that enables a single operator to conduct both the testing and the data acquisition and observation activities with respect to a metallurgical, nondestructive test.

SUMMARY

According to the aspects illustrated herein, there is provided a portable, self-contained scanner device for metallurgical, nondestructive testing. The portable, self-contained scanner device includes a chassis having wheels extending beneath a lower surface thereof, a non-destructive testing probe detachably fixed to the chassis, and a computer processor device coupled to the chassis. The computer processor device includes applications executable by the computer processor device for performing the metallurgical, nondestructive testing on a test subject. The scanner device also includes a display device that displays images in response to the metallurgical, nondestructive testing. The chassis, computer processor device, and display device move along the test subject as a single unit.

According to the other aspects illustrated herein, a chassis for a metallurgical nondestructive scanner device is provided. The chassis includes a base, sidewalls extending upward from the base, and an opening formed by the base and the sidewalls for receiving a computer processor device. The chassis also includes wheels extending beneath the base of the chassis, at least one nondestructive testing probe fixed to the chassis, and an interface connector attached to the chassis. The interface connector is communicatively coupled to the at least one probe. The interface connector is configured to connect to a communications port of the computer processor device.

DETAILED DESCRIPTION

A portable, self-contained scanner device for metallurgical, nondestructive testing is provided in accordance with exemplary embodiments. The self-contained scanner device is compact and usable in conjunction with various sensors. The scanner device is self-contained, such that its collective components move along a test subject as a single unit. As a result of its self-contained configuration, one tester alone may bring the scanner device into confined spaces and simultaneously guide the scanner device and collect and observe test data via a display mounted thereon.

Turning now toFIGS. 1-3, a portable, self-contained scanner device for metallurgical, nondestructive testing will now be described in accordance with exemplary embodiments. The portable, self-contained scanner device100includes a chassis102and a computer processor device200coupled to the chassis102. In one exemplary embodiment, the chassis102includes a base104, sidewalls106extending upward from the edges of the base104, and an opening formed by the base and the sidewalls. The computer processor device200is then disposed in the opening of the chassis102. It will be understood, however, that other configurations may be employed for the chassis102in order to realize the advantages of the invention.

The chassis102also includes at least one probe118detachably fixed to a lower surface of the chassis102(e.g., at the base104thereof). It is also contemplated that the probe118is detachably fixed to a sidewall106of the chassis and arranged such that the probe118extends beneath the lower surface of the chassis102. The probe118may be an ultrasonic transducer, electromagnetic acoustic transducer, or any other probe useful for metallurgical, nondestructive testing. The chassis102also includes an interface connector114attached to the chassis102. The interface connector114is communicatively coupled to the probe118by wiring, printed circuit board, or the like. The interface connector114may be a small computer systems interface (SCSI) connector.

The scanner device100also includes a display device216that displays images in response to the testing. The images are viewable by a tester during operation of the scanner device100. The display device216will be described further herein.

The computer processor device200includes a communications (input/output) port214coupled to the interface connector114for enabling communications between the probe118installed on the chassis102and the computer processor device200. In exemplary embodiments, the computer processor device200also includes software applications (instructions) executable by the computer processor device200for performing metallurgical nondestructive testing on a test subject109. The test subject109may be a pipe or tube, and the testing may include measuring the girth and/or integrity of seam welds on the pipe or tube. The probe118receives commands from at least one of the applications via the communications port214and the interface connector114, and transmits a test signal (e.g., ultrasonic pulse, acoustic wave, etc.) to the test subject109in response to the command. The probe118senses a response to the test signal from the test subject109and, in turn, provides a response signal to the computer processor device200.

The applications executable by the computer processor device200may include a data acquisition component206that receives response signals resulting from test signal emission by the probe118, an encoder204for determining a position of the scanner device100on the test subject109, and defining a position location on the test subject109at which the response signals are acquired, a data conversion component208for digitizing or otherwise processing the response signals, and an imaging component210for presenting processed response signals on the display device216. The type of probe118employed and the type of data acquisition components206used in the scanner device100depend upon the nature of testing to be conducted (e.g., time of flight diffraction ultrasonics, phased array ultrasonics, electromagnetic acoustic wave, etc.).

The computer processor device200may also include memory202for storing the applications executable by the computer processor device200, as well as other data, such as response signals and other test results.

In one exemplary embodiment, the computer processor device200is integrally formed with the chassis102as a single unit. In an alternative exemplary embodiment, the computer processor device200and chassis102are separable, such that the computer processor device200and chassis102may be easily separated after testing is completed. In this alternative exemplary embodiment, the computer processor device200is coupled to the chassis102(e.g., disposed in the chassis102) and is detachably fixed to the chassis102via the interface connector114and the communications port214. In addition, resilient material (e.g., foam), straps, and/or other securing means may be installed within the chassis102to prevent damage to the computer processor device200during handling of the scanner device100. In addition, the computer processor device200may be removed from the chassis102by opening a cover120of the chassis102as described further herein.

If the chassis102and the computer processor device200are separate units (i.e., not integrally formed), the chassis102may be configured, e.g., to accept commercially available tablet computers for use as the computer processor device200, which allows the display device216thereof to face outwards (i.e., with the display device216under the cover120, which may be entirely or partially transparent, and facing the operator) and includes touch-screen capability. As used herein, a “tablet computer” is a notebook, laptop or slate-shaped mobile computer having a touch-sensitive display screen that allows the user to operate the computer with a stylus, digital pen, or a fingertip, instead of, or in addition to, a keyboard or mouse. Tablet computers include so-called convertible notebooks, which have a base body with an attached keyboard, wherein the base attaches to the display at a single joint called a swivel hinge or rotating hinge. The joint allows the screen to rotate around 180° and fold down on top of the keyboard to provide a flat writing surface.

With standard input/output ports, the scanner device100may allow any commercially available tablet computer to be used, and the cover120allows viewing of the display device216while providing protection to the tablet computer. The touch screen facilitates operation of the scanner device100. Thus configured, the tablet computer can be installed in the chassis102to acquire data and then be removed from the chassis102for data analysis and/or for data upload to a network. The tablet computer need not be a costly application-specific computer dedicated for use with the scanner device100. It only needs the appropriate software.

Additionally, a second display device may be communicatively coupled to the computer processor device200to facilitate testing. For example, eyewear that includes display capabilities may be worn by the tester during operation of the scanner device100. The eyewear may be wireless (e.g., in communication with the chassis using short-range radio waves, such as Bluetooth™), or may be physically connected to the chassis via cabling.

In an exemplary embodiment, the chassis102may further include tool posts119for supporting each of the probes118. The posts119may be connected to the lower surface of the chassis102(e.g., at a base104thereof) and may be positioned between the lower surface of the base104and the probes118. Alternatively, the posts119may be attached to a sidewall106of the chassis and arranged such that the probe118extends downward, beneath the lower surface of the chassis102. In addition, the posts may include a spring-loaded mechanism to force the probes toward the test subject109for applying probe pressure on the test subject109. The posts119allow the probes118to be removed from the chassis102and replaced with different probes118. As a result, the same chassis102can be used to conduct different forms of metallurgical testing by simply changing the probes118and any required applications within the computer processor device216.

As described above, the chassis102includes a cover120. The cover120extends across the opening formed by the sidewalls106and the base104, and is movable between an open position (depicted inFIG. 2) and a closed position (depicted inFIG. 1). In the open position, the computer processor device200may be inserted into or removed from the opening; and in the closed position, the computer processor device200is stably secured in the opening. In one embodiment, one side of the transparent cover120includes one or more hinges122for stably securing the hinged side of the transparent cover120to one of the sidewalls106of the chassis102to allow the opening and closing of the cover. It is also contemplated that the cover may slide between an open and closed position, such as by the use of slots or channels disposed on the sidewalls106.

The cover120may be formed entirely from transparent material to allow the testing personnel to view the display216. Alternatively, the cover120may be partially transparent, for example by including one or more windows, to allow the testing personnel to view the display216.

The chassis102may also include wheels108disposed on each corner region of the lower surface of the chassis102(e.g., at the base104) to allow the scanner device to move along the test subject109during testing. The wheels108may be magnetic for securing the scanner device100to a test subject during testing. In one exemplary embodiment, the chassis102includes a motor110for driving the wheels108, and a power source116(e.g., a battery) that provides power to the motor110. In an alternative exemplary embodiment, the chassis102is manually propelled by an operator and, thus, no motor is needed. Advantageously, the portability of the scanner device100is increased without the added weight of the motor110.

The chassis102may further include at least one handle126formed on the chassis102(e.g., on one or more of the sidewalls106of the chassis102). The handles126enable a tester to manually guide the scanner device100on the test subject109.

In an exemplary embodiment, the scanner device100may further include a transceiver124in communication with the computer processor device200. The transceiver124sends data produced from the testing and receives communications from a remote source relating to the testing. The transceiver124communicates with the remote source over one or more wireless networks. While the transceiver124is shown inFIG. 2as being mounted to the chassis102, it is contemplated that the transceiver124may instead be mounted to the computer processor device200. For example the transceiver124may be a wireless local area network transceiver such as a Wi-Fi device.

As described above, the scanner device100is compact and self-contained, such that the chassis102and the computer processor device200form a single unit that is moved along a test subject. Thus configured, one tester alone may conduct the testing and simultaneously observe the results via a display mounted on the scanner device. In one embodiment, the computer processor device216is removable from the chassis102, allowing for the use of standard tablet computers in lieu of costly, application-specific computers. In addition, magnetic wheels disposed on the scanner device, in conjunction with the compact design, prevent or reduce fatigue otherwise resulting from manipulation of bulkier scanner devices. Also, the same chassis102may be used to conduct different forms of metallurgical testing by simply changing the probes118and any required applications within the computer processor device216.