Abstract:
An ultrasonic sensor assembly includes a flexible supporting material that has flexibility configured for allowing bending of the supporting material to conform to a cylindrical shape of a pipe. The assembly includes a plurality of operable sensor elements arranged in a matrix formation upon the flexible supporting material. The matrix formation includes a plurality of rows of the sensor elements and a plurality of columns of the sensor elements. The flexible supporting material is configured for placement of the columns of the matrix formation to extend along the elongation of the pipe and the flexible supporting material is configured for placement of the rows of the matrix formation to extend transverse to the elongation of the pipe. The flexible support material is configured to flex for positioning the sensor elements within each row in a respective arc that follows a curve of the cylinder shape of the pipe.

Description:
RELATED APPLICATION 
       [0001]    Benefit of priority is hereby claimed from U.S. patent application Ser. No. 13/680,183, filed Nov. 19, 2012, entitled TWO-DIMENSIONAL TR PROBE ARRAY, the entire disclosure of which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to ultrasonic sensor assemblies, and more particularly, to an ultrasonic sensor assembly including a sensor array of sensor elements. 
         [0004]    2. Discussion of the Prior Art 
         [0005]    Ultrasonic sensor assemblies are known and used in many different applications. Ultrasonic sensor assemblies are used, for example, to inspect a test object and detect/identify characteristics of the test object, such as corrosion, voids, inclusions, length, thickness, etc. In pipeline corrosion monitoring applications, the test object typically includes a metallic pipe. In such an example, a transmitter-receiver (“TR”) probe is provided for detecting/identifying the characteristics of the pipe. However a single TR probe occupies a relatively small area and, thus, has a relatively small testing range. Also, the pipe may have an arcuate contour surface. Detecting characteristics of the entire pipe with one TR probe can be inaccurate and time consuming. Accordingly, it would be beneficial to provide an ultrasonic sensor assembly that can address such issues. Further, it would be beneficial to provide this sensor array with a contoured shape that matches the shape of the test object. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0006]    The following presents a simplified summary of the invention in order to provide a basic understanding of some example aspects of the invention. This summary is not an extensive overview of the invention. Moreover, this summary is not intended to identify critical elements of the invention nor delineate the scope of the invention. The sole purpose of the summary is to present some concepts of the invention in simplified form as a prelude to the more detailed description that is presented later. 
         [0007]    In accordance with one aspect, the present invention provides an ultrasonic sensor assembly for testing a tubular pipe that has a cylindrical shape and has an elongation along the extent of the pipe. The ultrasonic sensor assembly includes a flexible supporting material that has flexibility configured for allowing bending of the supporting material to conform to the cylindrical shape of the pipe. The ultrasonic sensor assembly includes a plurality of operable sensor elements arranged in a matrix formation upon the flexible supporting material. The matrix formation includes a plurality of rows of the sensor elements and a plurality of columns of the sensor elements. The flexible supporting material is configured for placement of the columns of the matrix formation to extend along the elongation of the pipe and the flexible supporting material is configured for placement of the rows of the matrix formation to extend transverse to the elongation of the pipe. The flexible support material is configured to flex for positioning the sensor elements within each row in a respective arc that follows a curve of the cylinder shape of the pipe. 
         [0008]    In accordance with another aspect, the present invention provides a method for testing a tubular pipe that has a cylindrical shape and that has an elongation along the extent of the pipe using an ultrasonic sensor assembly. The method includes providing the ultrasonic sensor assembly. The assembly includes a flexible supporting material that has flexibility configured for allowing bending of the supporting material to conform to the cylindrical shape of the pipe. The assembly includes a plurality of operable sensor elements arranged in a matrix formation upon the flexible supporting material. The matrix formation includes a plurality of rows of the sensor elements and a plurality of columns of the sensor elements. The flexible supporting material is configured for placement of the columns of the matrix formation to extend along the elongation of the pipe and the flexible supporting material is configured for placement of the rows of the matrix formation to extend transverse to the elongation of the pipe. The flexible support material is configured to flex for positioning the sensor elements within each row in a respective arc that follows a curve of the cylinder shape of the pipe. The method includes placing the ultrasonic sensor assembly onto the pipe. The step of placing the assembly includes engaging the flexible supporting material to the pipe to place the columns of the matrix formation extending along the elongation of the pipe and the rows of the matrix formation extending transverse to the elongation of the pipe. The step of placing the assembly includes bending the flexible support material for positioning the sensor elements within each row in a respective arc that follows a curve of the cylinder shape of the pipe. The method includes operating the sensor elements. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The foregoing and other aspects of the present invention will become apparent to those skilled in the art to which the present invention relates upon reading the following description with reference to the accompanying drawings, in which: 
           [0010]      FIG. 1  is a schematic, perspective view of an example ultrasound sensor assembly being used a test object in accordance with an aspect of the present invention; 
           [0011]      FIG. 2  is a schematic view of an example sensor array of the ultrasound sensor assembly; 
           [0012]      FIG. 3  is a schematic view of one example sensor element for use in the sensor array of  FIG. 2 ; and 
           [0013]      FIG. 4  is a schematic, perspective view of the example sensor array being moved with respect to the test object. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0014]    Example embodiments that incorporate one or more aspects of the present invention are described and illustrated in the drawings. These illustrated examples are not intended to be a limitation on the present invention. For example, one or more aspects of the present invention can be utilized in other embodiments and even other types of devices. Moreover, certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. Still further, in the drawings, the same reference numerals are employed for designating the same elements. 
         [0015]      FIG. 1  illustrates a perspective view of an example ultrasonic sensor assembly  10  according to one aspect of the invention. In short summary, the ultrasonic sensor assembly  10  includes a controller  20  and a sensor array  30  that can be positioned in proximity to a test object  12 . The sensor array  30  transmits ultrasonic waves into the test object  12  to detect characteristics of the test object  12 . These characteristics include corrosion (e.g., thickness and location of corrosion), wall thickness, voids, inclusions, etc. The sensor array  30  is operatively attached to the controller  20  by means of a wire  22  (or may be wireless). To provide improved sensing of the test object  12 , the sensor array  30  includes a plurality of sensor elements arranged in a two dimensional array. 
         [0016]    The test object  12  is shown to include a tubular pipe having a generally cylindrical shape extending between a first end  14  and an opposing second end  16 . The test object  12  can include a non-solid body (e.g., hollow body) or may be solid. It is to be appreciated that the test object  12  is somewhat generically/schematically depicted in  FIG. 1  for ease of illustration. Indeed, the test object  12  is not limited to the pipe extending along a linear axis, and may include bends, undulations, curves, or the like. The test object  12  has an outer surface  18  forming a generally cylindrical shape. In other examples, the test object  12  could include other non-cylindrical shapes and sizes. For example, the test object  12  could have a non-circular cross-sectional shape, such as by having a square or rectangular cross-section. In other examples, the test object  12  further includes a tubular shape, conical shape, or the like. Even further, the test object is not limited to pipes, but instead, could include walls, planar or non-planar surfaces, etc. As such, the test object  12  shown in  FIG. 1  comprises only one possible example of the test object. 
         [0017]    Turning to the controller  20 , the controller is somewhat generically/schematically depicted. In general, the controller  20  can include any number of different configurations. In one example, the controller  20  is operatively attached to the sensor array  30  by means of the wire  22 . As will be described in more detail below, the controller  20  is configured to send and receive information (e.g., data, control instructions, etc.) from the sensor array  30  through the wire  22 . This information can be related to characteristics of the test object  12 . For example, in pipeline corrosion monitoring applications, the test object  12  may be susceptible to imperfections, such as corrosion, cracks, voids, inclusions, or the like. As such, this information includes, but is not limited to, dimensions of the test object  12  (e.g., thickness, length, etc.), the presence or absence of corrosion for corrosion mapping, cracks, or the like. The controller  20  can include circuits, processors, running programs, memories, computers, power supplies, ultrasound contents, or the like. In further examples, the controller  20  includes a user interface, display, and/or other devices for allowing a user to control the ultrasonic sensor assembly  10 . 
         [0018]    Focusing upon the operation of the sensor array  30 , the sensor array  30  is placed in proximity to the outer surface  18  of the test object  12  and/or in contact with the outer surface  18 . The ultrasonic sensor assembly  10  can include a single sensor array (as shown), or a plurality of sensor arrays. The sensor array  30  is not limited to the position shown in  FIG. 1 , as the sensor array  30  is moved along the outer surface  18  of the test object  12 . Indeed, the sensor array  30  could be positioned at any number of locations along the test object  12 , such as closer towards a center, closer towards the first end  14  or second end  16 , etc. In one example, the sensor array  30  has a shape that substantially matches a shape of the outer surface  18  of the test object  12 . For instance, as shown in  FIG. 1 , the sensor array  30  includes a curvature that substantially matches a curvature of the test object  12 . The curvature could be larger or smaller in further examples, depending on the size and shape of the test object  12 . However, in other examples, the sensor array  30  need not have such a curvature, and may instead have a substantially planar shape. 
         [0019]    Turning now to  FIG. 2 , the sensor array  30  will be described in more detail. The sensor array  30  is not shown in proximity to the test object  12  in  FIG. 2  for illustrative purposes and to more clearly illustrate the elements of the sensor array  30 . However, in operation, the sensor array  30  is placed in proximity to the test object  12  as described with respect to  FIG. 1 . 
         [0020]    The sensor array  30  can include a supporting material  32  that provides support to the sensor array  30 . In one example, the supporting material  32  is a resilient member having a predetermined shape. The supporting material  32  can be non-flexible or, in other examples, could be provided with some degree of flexibility or movement. As described above, the supporting material  32  can include the curved shape that matches the shape of the outer surface  18  of the test object  12 . However, the supporting material  32  could also include the substantially planar shape. The supporting material  32  can include any number of materials, such as engineering plastics, polyimide materials, etc. In further examples, the supporting material  32  could include a flexible or semi-flexible member, allowing for the supporting material  32  to be bent or molded to a desired shape. 
         [0021]    The sensor array  30  further includes one or more sensor elements  34  for detecting characteristics of the test object  12 . The sensor elements  34  are somewhat generically depicted in  FIG. 2 , as the sensor elements  34  include a number of different sizes, shapes, and configurations. As shown in  FIG. 2 , the sensor elements  34  are arranged in a matrix formation. In the matrix formation, the sensor elements  34  may include one or more rows  36  extending along a first direction (e.g a first axis). Within the shown example of  FIG. 2 , the first axis  38  extends generally linearly along the sensor array  30 . Of course, if the array  30  has a curvature, the first direction can follow along such curvature. 
         [0022]    The rows  36  each include a plurality of the sensor elements  34 . In the shown example, the rows  36  each include eight sensor elements  34  (as shown) in a sequence, though the rows  36  could include as few as one or more sensor elements or greater than eight sensor elements. The sensor elements  34  within each of the rows  36  are generally equidistant from each other, such that the sensor elements  34  are substantially equally spaced from adjacent sensor elements along the length of the sensor array  30 . In further examples, the sensor elements  34  could be spaced closer together or farther apart than as shown. In the shown example, there are eight rows arranged in a non-staggered orientation (i.e., one row above another row), though in further examples, the rows  36  could be staggered with respect to adjacent rows. 
         [0023]    The matrix formation of the sensor array  30  further includes one or more columns  40  extending along a second direction (e.g., a second axis). Within the shown example, the second axis  42  extends generally linearly along the sensor array  30  in a direction that is substantially transverse to the first axis  38 . For example, the second axis  42  can be perpendicular to the first axis  38 . However, in further examples, the second axis  42  is not so limited to this transverse orientation, and could extend at other angles with respect to the first axis  38 . Of course if the array  30  has a curvature, the second direction can follow the curvature. 
         [0024]    Each of the columns  40  includes a plurality of the sensor elements  34 . In the shown example, the columns  40  can each include eight sensor elements in a sequence, though the columns  40  could include as few as one or more sensor elements or greater than eight sensor elements. The sensor elements  34  within each of the columns  40  are generally equidistant from each other, such that the sensor elements  34  are substantially equally spaced from adjacent sensor elements along the length of the sensor array  30 . In further examples, the sensor elements  34  could be spaced closer together or farther apart than as shown. By spacing the sensor elements  34  apart, signal cross talk between sensor elements  34  is limited/reduced. In the shown example, there are eight columns arranged in a non-staggered orientation (i.e., one column next to another column), though in further examples, the columns  40  could be staggered with respect to adjacent columns. 
         [0025]    The matrix formation of the sensor array  30  includes the rows  36  and columns  40  as shown in  FIG. 2 . In the shown example, there are a total of eight rows and eight columns. As such, the sensor elements  34  in the matrix formation include an 8×8 matrix formation. It is to be appreciated that the matrix formation is not limited to the 8×8 matrix formation. In further examples, the matrix formation could be larger or smaller than as shown, such as by including a 9×9 matrix formation (or larger), or by including a 7×7 matrix formation (or smaller). 
         [0026]    In further examples, the matrix formation is not limited to including an equal number of sensor elements  34  in each of the columns  40  and rows  36 . Rather, the matrix formation may include columns  40  and rows  36  having different numbers of sensor elements  34 . In some examples, the matrix formation includes an 8×6 matrix formation, a 6×8 matrix formation, or the like. In other examples, each of the rows and/or each of the columns could have a different number of sensor elements  34  than in adjacent rows or columns, respectively. For instance, one of the rows could have eight sensor elements while another row has a larger or smaller number of sensor elements. Likewise, one of the columns could have eight sensor elements while other columns have a larger or smaller number of sensor elements. Accordingly, the matrix formation is not limited to the example as shown in  FIG. 2 , and could include nearly any combination of sensor elements arranged in rows  36  and columns  40 . The matrix formation is not limited to including the rectangularly shaped configuration of sensor elements  34 . In yet another example, the matrix formation can include the sensor elements  34  arranged in an “X” type shape, “T” type shape, or the like. 
         [0027]    Turning now to  FIG. 3 , the sensor elements  34  will be described in more detail. It is to be appreciated that while  FIG. 3  depicts only one sensor element  34 , the remaining, unshown sensor elements  34  may be similar or identical in shape, structure, and function as the sensor element  34  shown in  FIG. 3 . Moreover, the sensor element  34  is not shown in attachment with the supporting material  32  for illustrative purposes and to more clearly depict portions of the sensor element  34 . However, in operation, the sensor elements  34  will be supported by (e.g., attached to) the supporting material  32 . 
         [0028]    Each sensor element  34  further includes a transmitter  52 . The transmitter  52  is supported (e.g., fixed) to the supporting material  32  and spaced a distance away from the outer surface  18  of the test object  12 . The transmitter  52  can transmit one or more signals  53 , such as energy, pulses, and/or other impulses, into the test object  12 . As is generally known, the transmitter  52  can be controlled such that the signal  53  has various timings, durations, shapes, etc. Similarly, the signal  53  includes any number of frequencies, depending on the material of the test object  12 . It is to be appreciated that the signal  53  is somewhat generically depicted in  FIG. 3  as a straight line. In operation, the signal  53  need not travel along a linear path, and could include bends or the like as a result of being transmitted into the test object  12 . 
         [0029]    Each sensor element  34  further includes a receiver  54  attached to the supporting material  32 . The receiver  54  is supported (e.g., fixed) to the supporting material  32  and spaced a distance away from the outer surface  18  of the test object  12 . The receiver  54  can receive the reflected signals  53  from the transmitter  52 . In particular, the receivers  54  of each of the sensor elements  34  receive the signals  53  after the signals  53  have reflected from within the test object  12 . The receiver  54  is spaced a distance away from the transmitter  52 . In one example, to further improve transmission and reception of the signal  53 , the receiver  54  is separated from the transmitter  52  by an acoustic barrier  56 . The acoustic barrier  56  is somewhat generically depicted, as it is to be understood that the acoustic barrier  56  can comprise a number of different structures. In one example, the acoustic barrier  56  includes a cork material or the like, though any number of structures and materials are envisioned. 
         [0030]    The signal  53  is used to detect a characteristic  60  of the test object  12 . In the shown example of  FIG. 3 , the characteristic  60  includes corrosion in the test object  12 . However, the characteristic  60  is not limited to including corrosion, and may further include imperfections (flaws, cracks, voids, inclusions, etc.), dimensions (wall thickness, length, etc.), or the like. Indeed, the characteristic  60  is somewhat generically depicted in  FIG. 3  as it is to be appreciated that the characteristic  60  represents any number of items to be detected. Further, while the characteristic  60  is shown to be positioned at a wall of the test object  12  (e.g., an inner wall), the characteristic  60  could be positioned entirely within the walls of the test object  12 . 
         [0031]    In operation, the sensor elements  34  detect both the presence/absence of the characteristic  60  (e.g., corrosion, etc.), and can map the location of the characteristic  60  in the test object  12 . For example, the transmitter  52  transmits the signal  53  into the test object  12 . The signal  53  passes from the transmitter  52  and at least partially into the test object  12  (signal  53  represented in dashed-line form within the test object  12 ). The signal  53  may at least partially reflect from within the test object  12 . In the shown example, the signal  53  can reflect from the characteristic  60  of the test object  12 . The signal  53  may completely reflect off the characteristic  60  or, in other examples, may only partially reflect off the characteristic  60 . The portion of the signal  53  that is reflected off the characteristic  60  is received with the receiver  54 . Based on the reception of the signal  53  by the receiver  54 , the ultrasonic sensor assembly  10  can detect the presence/absence and location of the characteristic  60  on the curved wall. In particular, information pertaining to the signal  53  received by the receiver  54  is sent to the controller  20 . As is generally known, the controller  20  can analyze the signal  53  to determine the presence/absence and location of the characteristic  60 . 
         [0032]    Turning now to  FIG. 4 , the ultrasonic sensor assembly  10  is shown in the process of mapping the characteristics  60  (e.g., corrosion) of the test object  12 . In particular, the sensor array  30  is positioned in proximity to the outer surface  18  of the test object  12 . The sensor array  30  is then moved with respect to the test object  12 . The sensor array  30  can be moved in a variety of directions. For example, the sensor array  30  can be moved in a first direction  80  that extends along a length of the test object  12 . Similarly, the sensor array  30  could be moved in a second direction  82  that is substantially transverse to the length of the test object  12 . In further examples, the sensor array  30  is not limited to being moved in the first direction  80  or the second direction  82 , and instead could be moved at an angle (e.g., 45° angle, etc.) with respect to the first direction  80  and second direction  82 . 
         [0033]    As the sensor array  30  is moved along the test object  12 , the transmitters  52  of each of the sensor elements  34  in the sensor array  30  are triggered to transmit the signals  53 . In one example, the transmitters  52  of all of the sensor elements  34  are triggered to transmit the signals  53  simultaneously. In another example, the transmitters  52  of the sensor elements  34  are not triggered simultaneously, and instead, may be triggered separately, such as by triggering only a portion of the transmitters  52  followed by another portion of the transmitters  52  to transmit the signals  53 . Indeed, it is to be appreciated that the transmitters  52  of the sensor elements  34  can be triggered to transmit the signals  53  in any number of combinations (e.g., simultaneously or non-simultaneously). The receivers  54  of each of the sensor elements  34  will receive the respective signal sent from that transmitter  52  of the same sensor element  34 . 
         [0034]    The sensor elements  34  can be used to detect and map the location of the characteristics  60  in the test object  12 . For example, the controller  20  may include an electronic representation of the test object  12 , such as a two-dimensional or three-dimensional representation of the test object  12 . As is generally known, the controller  20 , in operative association with the sensor array  30 , can correlate the location of the sensor array  30  respective to the test object  12  with the electronic representation of the test object  12 . The controller  20  tracks the sensor array  30  as the sensor array  30  moves along the outer surface  18  of the test object  12 , such as in the first direction  80  and/or second direction (or other directions). The sensor array  30  can detect the characteristics  60  of the test object  12  as the sensor array  30  is moved along the test object  12  and convey this information to the controller  20 . These characteristics  60  are then mapped and stored by the controller  20  with respect to the electronic representation of the test object  12 . Accordingly, the controller  20  can map and plot the characteristics  60  of the test object  12  (as detected by the sensor array  30 ) on the electronic representation as the sensor array  30  is moved along the test object  12 . 
         [0035]    By providing the ultrasonic sensor assembly  10  with the sensor array  30 , the test object  12  can be more quickly and accurately analyzed. In particular, the sensor array  30  will detect the characteristics  60  of the test object  12  and map these characteristics on the electronic representation of the test object  12 . The sensor array  30  has a larger area, thus allowing for a larger detection range of the test object  12  at one location. Further, providing the plurality of sensor elements  34  in the sensor array  30  gives more accurate detection and mapping of the characteristics  60 . 
         [0036]    The invention has been described with reference to the example embodiments described above. Modifications and alterations will occur to others upon a reading and understanding of this specification. Example embodiments incorporating one or more aspects of the invention are intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.