Abstract:
An ultrasonic detector has a housing containing a transducer, a battery or other power supply, and any other necessary electronics. At a front end of the housing is a socket into which one of a plurality of interchangeable probes can be inserted. At the rear end of the housing, there is a handle by which an operative can hold the detector in use. On the inside of the housing, extending at least partially into the handle, is an elongate chamber within which at least one probe can be stored. A cover of the handle closes a rear end of the probe storage chamber and can be removed to expose a portion of the probe storage chamber and allow a probe to be inserted or removed.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention relates to passive ultrasonic detectors, especially for the detection of leaks and other mechanical problems in machinery. 
       BACKGROUND OF THE INVENTION 
       [0002]    It has previously been proposed to detect certain types of mechanical problem by sensing distinctive sounds that they produce, especially ultrasonic sounds. For example, a fluid leak from a pressurized system can produce a hissing sound, and a failing bearing can produce a grinding sound. In order to detect ultrasonic sound, it is necessary for the sound to be fed to a transducer that will convert it to frequencies that are audible to the human operative. When inspecting machinery, this typically involves a handheld device containing the transducer, and having at its front end a probe that can be placed near to, or in contact with, the machinery that is to be inspected. 
         [0003]    Different probes are usually preferred for contact with the machinery and for air pickup near the machinery. A contact probe is typically a solid rod of material that transmits the ultrasonic frequencies of interest. An air probe is typically a tube that guides the sound in air to the transducer, while excluding extraneous noises. 
         [0004]    Detectors with interchangeable probes have previously been proposed. One example of such a detector is sold by the assignees of the present application under the trademark Spectroline® Marksman II. A disadvantage of most detectors with interchangeable probes is that a separate carrying case is necessary to contain the detector and the various probes. That can be inconvenient when working in the field, because the operative may want to change from one probe to the other in places where it is inconvenient to bring the carrying case or to set down the carrying case in order to take out one probe and put away another probe. 
         [0005]    There is, therefore, a need for a more compact and portable handheld ultrasonic detector. 
       SUMMARY OF THE INVENTION 
       [0006]    According to one embodiment of the invention, there is provided an ultrasonic detector comprising a housing containing a transducer, a battery or other power supply, and any other necessary electronics. At a front end of the housing is a socket into which one of a plurality of interchangeable probes can be inserted. At the rear end of the housing, there is a handle by which an operative can hold the detector in use. On the inside of the housing, extending at least partially into the handle, is an elongate chamber within which at least one probe can be stored. A cover of the handle closes a rear end of the probe storage chamber and can be removed to expose a portion of the probe storage chamber and allow a probe to be inserted or removed. 
         [0007]    Preferably, the probe storage chamber is sufficiently wide to contain all of the probes provided with the detector, or at least to contain all except one of the probes. 
         [0008]    Removing the handle cover may also expose other devices that are not usually needed while actually using the detector, for example, a port for a battery charger, a data port for reprogramming the detector, or a battery compartment. 
         [0009]    Devices that are commonly needed while actually using the detector, for example, a socket for headphones and any controls and displays needed by the operative, may be provided on top or side surfaces of the housing. 
         [0010]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. 
           [0012]    In the drawings: 
           [0013]      FIG. 1  is a perspective view of an embodiment of an ultrasonic detector with a probe installed. 
           [0014]      FIG. 2  is a perspective view of the probe of  FIG. 1  with the probe detached and the handle cover removed. 
           [0015]      FIG. 3  is a longitudinal cross-sectional view through the detector of  FIG. 1 . 
           [0016]      FIG. 4  is a partial cross-sectional view of an alternate embodiment of the invention with a removable front portion. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Reference will now be made in detail to various embodiments of the present invention, an example of which is illustrated in the accompanying drawings. 
         [0018]    Referring to the drawings, one form of ultrasonic detector, indicated generally by the reference numeral  10 , comprises a housing  12  having at or near its front end an ultrasonic transducer  14  with a socket  16  into which a base end of a probe  32  can be inserted. The socket  16  may be provided with screw threading, a bayonet connector, or any other convenient mechanism for releasably securing the probe in its operating position. The interior of the housing  12  may contain a microprocessor controller  22 , an amplifier  20 , an adapter  18  for a headphone socket and/or data port  24  on the exterior of the housing  12 , and/or any other convenient electrical or electronic equipment, such as conventional noise control electronics to detect and reduce ambient noise, and self-adjusting automatic gain control circuitry to enhance sensitivity and simplify operation. A display  26  may be provided on the exterior of the housing  12  for displaying information related to the sensed signal or other features of the detector (e.g., battery power). As shown, the display  26  may contain an LED  52  indicating that the device is powered on and a row of LEDs  54  for indicating a sensitivity setting. A light or pair of lights  58  may be provided at the front of the housing  12  to illuminate a work area around the tip of the probe. 
         [0019]    The housing  12  may also have switches  56  for turning the detector  10  on or off, raising or lowering the sensitivity or other variable setting, and turning on or off the lights  58 . The LEDs  52 ,  54  and the switches  56  may be covered by a cover sheet  59  (shown in  FIG. 2 ) with appropriate transparent and flexible areas and with explanatory or decorative markings. 
         [0020]    A handle  28  is formed on a rear portion of the housing  12  and protrudes rearward from a main portion of the housing  12 . The handle  28  is preferably angled slightly downwards relative to the main portion of the housing  12 . The handle  28  may be formed integral with or separately attached to the main portion of the housing. As is best seen in  FIG. 2 , the handle  28  includes a top  28 A, bottom  28 B, side walls  28 C and an end wall  28 D which define an internal, preferably elongated storage chamber  30 . As shown, an opening  29  is formed in at least a rear portion of the top  28 A and preferably the end wall  28 D. The opening  29  provides access to the storage chamber  30  as will become more apparent below. The chamber  30  extends through the handle and may extend into a portion of the housing  12 . Alternatively, an inner front wall  31  may be included that separates the chamber from the main portion of the housing  12 . One or more holes  33  are formed in the front wall. 
         [0021]    One or more probes  32  are removably stored within the storage chamber  30  of the handle  28 . As shown in  FIG. 2 , the probes are different. By way of example, the probes  32  shown in  FIG. 2  are a contact probe and an air probe. Generally, an air probe is used to isolate leak sources in cramped places, and a contact probe is used to find gear and bearing wear in internal parts and electric motors. As shown in  FIG. 2 , the chamber  30  is sufficiently wide to contain two probes  32  side-by-side. The rear end of the handle  28  is sufficiently large to accommodate the base ends of probes, which may be wider than the main parts of probes. The front portions of the probes preferably extend through the hole or holes  33  in the front wall  31  and into the main portion of the housing. As shown in  FIGS. 1 and 3 , a handle cover  36  closes off the opening in the handle  28 . The cover  36  may attach to or engage the handle in various ways. In the illustrated embodiment, the handle  28  is tapered and the cover  36  is configured to slide onto the handle  28  over the opening  29 . Alternately, the cover could be detachable from or hinged to the periphery of the opening  29  and include a locking mechanism to secure the cover in the dosed position. 
         [0022]    An upper part of the storage chamber  30 , under the top  28 A of the handle, has a cradle  60  to receive a replaceable battery  62 . The cradle  60  is mounted on rails  64  to slide between backward and forward positions. In the forward position, the battery  62  is under a solid part of the handle top  28 A, and contacts on the battery connect with contacts  38  mounted on the partition wall  31  so that the battery  62  supplies power to the detector  12 . In the rearward position of the cradle  60 , the battery  62  projects through the opening  29 , so that it can easily be removed and replaced. A commonly available square 9 volt battery (type NEDA 1604, IEC 6LR61, or similar) is suitable, because that type of battery has snap-in connectors, which may reduce the risk of the battery becoming disconnected in use. If a battery with simple applied pressure contacts is used, the cradle  60  may be provided with a latch or detent to hold it in the forward, fully inserted, position. 
         [0023]    As an alternative, the housing  12  may contain a rechargeable battery (not shown) and the storage chamber  30  may have a connector for a recharger. 
         [0024]    In use of the detector  10 , the probes  32  are stored in the chamber  30  until they are actually needed, thereby protecting them from damage, contamination or loss. The detector  10  illustrated in the figures is extremely compact, and can easily be carried in an operative&#39;s hand, pocket, or tool bag. When the operative wishes to use the device, he or she merely needs to remove the cover  36 , select and remove a desired one of the probes  32 , replace the handle cover  36 , attach a connector  34  on the selected probe  32  to the socket  16 , insert the jack of a pair of headphones into the socket  24  if desired, and start work. 
         [0025]    When the operative wishes to change to a different probe  32 , it is merely necessary to detach the old probe  32  from the socket  16 , remove the cover  36 , exchange probes, mount the new probe  32  in socket  16 , replace the cover  36 , and continue working. The operative does not need to have immediate access to his or her tool bag, which may have been left outside the immediate working area. 
         [0026]    Various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. 
         [0027]    For example, in one embodiment shown in  FIG. 4 , a front portion  12 A of the housing  12  that includes the transducer  14  may be detachable to function as a remote unit. The front portion may include a magnet or other mechanism (not shown) for attaching the front portion to a component being monitored. The front portion also includes a Bluetooth, RFID, or other wireless transmitter  70  for transmitting the signals detected by the transducer  14 . The housing  12  includes a wireless receiver  72  configured to receive the signals transmitted by the transducer. This embodiment has several advantages. First, the removable front portion can be placed in locations that the entire housing  12  cannot easily reach. Second, the removable front portion can be left in position on a device being monitored when it is not being used. As such, if the sound that the operator is attempting to capture occurs infrequently, or the operator is required to make changes on the operating machinery to attempt to locate the sound and the machinery controls are at a location that is not close to the area where the sound is being monitored, the operator can leave the remote unit at the location of leak while making the changes to the machinery and still be able to detect when the sound of interest occurs. 
         [0028]    This embodiment also allows for successive measurements to be easily taken with the remotely unit located in exactly the same place, which means that the measurements are more consistent, and changes over time in the ultrasonic signals can be detected more easily and more accurately. 
         [0029]    Third, if the removable front portion has a battery and a (preferably non-volatile) memory, the remotely located unit can detect and store data while unattended, which data can be uploaded to the detector  10  at a later time. If the remotely located unit does not have a battery, the remote unit can be powered from the detector  10  by, for example, standard RFID techniques, although the remote unit cannot then gather data except when the detector  10  is present. 
         [0030]    In an alternative embodiment or as an addition to any of the other embodiments, the housing  12  may include a remote electrical port (not shown) which permits a remote sensor to be electrically connected to the internal circuitry through a plug in wire. The remote sensor could be located at a place spaced apart from the housing  12  to acquire the necessary readings. The circuitry and programming in the sensor and detector  10  could be configured to permit the user to toggle between readings from the onboard sensor and the remote sensor. It is also contemplated that the onboard programming can be set to permit the user to input certain data related to the sensor(s), such as where the sensor is positioned, when it was positioned and on what equipment, thus permitting a more accurate and detailed reporting. 
         [0031]    The remote sensor could include a memory and power source so that the data related to the sensed signals can be collected and stored on the remote sensor. The data would later be transferred to the detector what the remote is communicating with the detector (either wirelessly or through a wired connection). This permits the remote to remain in a location of interest over a period of time. 
         [0032]    It is contemplated that a kit may be provided with multiple remote sensor units or multiple remote sensor units can be sold that have a unique unit identifier. This allows the remote units to be located in various locations on one or more machines. Along with transmitting the detected signals, the remote sensor units would also transmit the sensor unit identifier such that the detector  10  can discern which remote sensor unit is transmitting the data received. 
         [0033]    Instead of LED indicators lights, the detector may include an LCD, LED or other type of display which can depict an alphanumeric unit identifier. 
         [0034]    If the detector  10  is provided with a data port  24 , the detector  10  preferably includes non-volatile memory and a suitable controller to store detected data until such time as the data can be downloaded. 
         [0035]    However, a simple device in which ultrasonic signals received through a probe  32  by the transducer  24  are simply played back at audible frequency in real time through a headphone jack  24  is also very useful, and may be significantly less expensive. 
         [0036]    It is also contemplated that the detector could take advantage of existing WiFi systems and include suitable wireless circuitry to transmit sensed signals from a remote sensor to the detector using the wireless system in the facility. Those skilled in the art would be readily capable of incorporating appropriate circuitry into the detector and remote sensor units to utilize a wireless system. 
         [0037]    Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.