Patent Description:
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. <NPL> discloses wheel rim inspection; the phased array ultrasonic inspection is validated by means of a reference wheel provided with artificial defects located in different depths from the wheel thread.

The accuracy of ultrasonic measurements can rely upon good coupling between the inspection ultrasonic probes and a target, such as a wheel. Coupling refers to the ability of ultrasonic beams to be reliably transmitted between the ultrasonic probes and the target. That is, there is substantially no impediment for ultrasonic beams to travel between the ultrasonic probes and the target. However, bad coupling can occur when the ultrasonic probe is in poor contact with the target. In one aspect, poor contact can occur due to gaps between the ultrasonic probes and the target arising from misalignment. In another aspect, poor contact can occur due to the presence of contaminants between the inspection ultrasonic probes and the target. In some instances, the target can be a train wheel.

It can be desirable to validate ultrasonic testing results to ensure their accuracy. Absent validation, ultrasonic testing results can be misinterpreted, resulting in false conclusions that defects are absent or within acceptable limits. Such errors can lead to failure of wheels during operation, with catastrophic consequences such as equipment damage and human injury.

Accordingly, there exists an ongoing need for improved systems and methods for validating ultrasonic testing results.

An ultrasonic testing system is provided including one or more matrix array ultrasonic probes, a probe positioning assembly, and an analyzer. The probe positioning assembly is configured to mechanically couple to the one or more matrix array ultrasonic probes and to position the one or more matrix array ultrasonic probes for ultrasonic communication with a wheel including at least one coupling validation geometry. Each of the one or more matrix array ultrasonic probes is configured to emit a validation ultrasonic signal directed towards a coupling validation geometry within the wheel, to measure its emitted validation ultrasonic signal after reflection from a respective one of the at least one coupling validation geometry, and to at least one of, emit an ultrasonic inspection signal and measure an inspection ultrasonic signal reflected from a defect positioned within an inspection area of the wheel. The analyzer is configured to, receive the measured validation ultrasonic signal and the measured inspection ultrasonic signal, determine that the measured validation ultrasonic signal matches a reference validation signal, and output a first notification representing validation of the measured inspection ultrasonic signal.

In an embodiment, the analyzer can be configured to determine that the measured validation ultrasonic signal does not match the reference validation signal, and to output a second notification representing invalidation of the measured inspection ultrasonic signal.

In another embodiment, each of the matrix array ultrasonic probes can be configured to sweep the emitted validation ultrasonic beam through an arc of predetermined directions and to measure a plurality of validation ultrasonic signals after reflection from a plurality of respective coupling validation geometries.

In another embodiment, each of the matrix array ultrasonic probes emitting the inspection ultrasonic signal can be configured to sweep the inspection ultrasonic signal through an arc of predetermined directions and each of the matrix array ultrasonic probes measuring the reflected inspection ultrasonic beam can be configured to measure a plurality of inspection ultrasonic signals after reflection from a plurality of respective defects.

Embodiments of the matrix ultrasonic probes can adopt a variety of configurations. In one embodiment, the system includes at least two matrix ultrasonic probes and a probe holder can be configured to position the at least two matrix array ultrasonic probes with respect to one another in a configuration mimicking a curvature of a running tread of the wheel. In another embodiment, a first one of the at least two matrix ultrasonic probes can be configured to emit the inspection ultrasonic signal towards the inspection area, and a second one of the at least two matrix array ultrasonic probes can be configured to measure the inspection ultrasonic signal reflected from a defect within the inspection area. In a further aspect, a first one of the at least two matrix ultrasonic probes and a second one of the at least two ultrasonic probes can each be configured to emit the inspection ultrasonic signal towards the inspection area and to measure the inspection ultrasonic signal reflected from a defect within the inspection area.

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.

In another embodiment, the system can include an annunciator in communication with the analyzer. The annunciator can be configured to annunciate a first annunciation representing validation of the inspection ultrasonic signal in response to receipt of the first notification. The annunciator can also be configured to annunciate a second annunciation, different from the first annunciation, representing invalidation of the inspection ultrasonic signal in response to receipt of the second notification.

A method for ultrasonic inspection is provided. The method includes positioning one or more matrix array ultrasonic probes for ultrasonic communication with a wheel including at least one coupling validation geometry. The method also includes emitting, by each of the one or more matrix array ultrasonic probes, a validation ultrasonic signal directed towards a coupling validation geometry within the wheel. The method further includes measuring, by each of the one or more matrix array ultrasonic probes, its emitted validation ultrasonic signal after reflection from a respective one of the at least one coupling validation geometry. The method additionally includes emitting, by at least one of the matrix ultrasonic probes, an ultrasonic inspection signal towards an inspection area of the wheel. The method also includes measuring, by at least one of the matrix ultrasonic probes, the inspection ultrasonic signal after reflection from a defect positioned within the inspection area. The method additionally includes receiving, by an analyzer in communication with each of the one or more matrix array ultrasonic probes, the measured validation ultrasonic signal and the measured inspection ultrasonic signal. The method also includes determining, by the analyzer, that the measured validation ultrasonic signal matches a reference validation signal. The method additionally includes outputting, by the analyzer, a first notification representing validation of the measured inspection ultrasonic signal.

In an embodiment, the method can include, determining, by the analyzer, that the measured validation ultrasonic signal does not match the reference validation signal, and outputting, by the analyzer, a second notification representing invalidation of the measured inspection ultrasonic signal.

In another embodiment, each of the matrix array ultrasonic probes can be configured to sweep the emitted validation ultrasonic beam through an arc of predetermined directions, and to measure a plurality of validation ultrasonic signals after reflection from a plurality of respective coupling validation geometries.

In another embodiment, each of the matrix array ultrasonic probes emitting the inspection ultrasonic signal can be configured to sweep the inspection ultrasonic signal through an arc of predetermined directions, and each of the matrix array ultrasonic probes measuring the reflected inspection ultrasonic beam can be configured to measure a plurality of inspection ultrasonic signals after reflection from a plurality of respective defects within the inspection area.

In another embodiment, the at least one matrix array ultrasonic probe can adopt a variety of configurations. In one embodiemnt, the at least one matrix array ultrasonic probe can include at least two matrix ultrasonic probes. The at least two matrix array ultrasonic probes can be positioned with respect to one another in a configuration mimicking a curvature of a running tread of the wheel. In another embodiment, a first one of the at least two matrix ultrasonic probes can be configured to emit the inspection ultrasonic signal towards the inspection area, and a second one of the at least two matrix array ultrasonic probes can be configured to measure the inspection ultrasonic signal reflected from a defect within the inspection area. In another embodiment, a first one of the at least two matrix array ultrasonic probes and a second one of the at least two ultrasonic probes can each be configured to emit the inspection ultrasonic signal towards the inspection area and to measure the inspection ultrasonic signal reflected from a defect within the inspection area.

In another embodiment the one or more matrix array ultrasonic probes can be positioned with respect to the wheel while the wheel is lifted above an underlying surface.

In another embodiment, the method can further include rotating the wheel while lifted and after each matrix array ultrasonic probe measures its emitted validation ultrasonic signal and emits and/or measures its inspection ultrasonic signal.

In another embodiment, the wheel is a train wheel.

Those skilled in the art will understand that the systems, devices, and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the present invention is defined solely by the claims.

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 each 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.

<FIG> illustrates an embodiment of a train <NUM> including train wheels <NUM> positioned on rails <NUM>, and <FIG> illustrate one exemplary embodiment of an ultrasonic testing system <NUM> for inspection of a train wheel <NUM>. As shown, the train wheel <NUM> includes a wheel disk <NUM>, a running tread <NUM>, and a wheel flange <NUM>. The wheel disk <NUM> forms a center of the train wheel <NUM> and the running tread <NUM> forms a circumferential outer surface of the train wheel <NUM>. The wheel flange <NUM> can be formed on one side of the train wheel <NUM> (e.g., an interior side) and extend radially outward from the running tread <NUM>.

The wheel disk <NUM> includes one or more holes therethrough. As shown, a primary hole <NUM> is positioned at about a center of the wheel disk <NUM> and can be configured for receipt of an axle <NUM> therethrough. One or more secondary holes <NUM> can be formed radially outward from the primary hole <NUM> and configured for coupling other components to the train wheel <NUM>, such as brake disks (not shown).

The ultrasonic testing system <NUM> can include one or more ultrasonic probes <NUM> and a probe positioning assembly <NUM> including a probe holder <NUM>, a probe holder mount <NUM>, and a lift and rotation unit <NUM>. As shown, a predetermined number of ultrasonic probes <NUM> can be mechanically coupled to the probe holder <NUM> and oriented with respect to one another by the probe holder <NUM> (e.g., in an arcuate configuration mimicking a curvature of the running tread <NUM>). Each probe holder <NUM> in turn can be coupled to the probe holder mount <NUM>. When using the ultrasonic testing system <NUM> for inspection of train wheel <NUM>, the lift and rotation unit <NUM> can be configured to lift the train wheel <NUM> above the underlying rail <NUM> and rotate the train wheel <NUM> about an axis extending through the primary hole <NUM> (e.g., via one or more rotation wheels 210a). The probe holder mount <NUM> can be coupled to the probe holder <NUM> and it can be configured to position the ultrasonic probes <NUM> adjacent to or in contact with the running tread <NUM> for ultrasonic communication with the train wheel <NUM> while lifted. While not shown, an ultrasonic couplant fluid can be provided between the ultrasonic probes <NUM> and the train wheel <NUM> to facilitate ultrasonic communication.

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 wheel <NUM> can be analyzed to determine the position and size of internal defects.

<FIG> is a side view of a portion of the train wheel <NUM>, illustrating ultrasonic testing system <NUM> in the form of ultrasonic testing system <NUM> which includes two sets of ultrasonic probes <NUM> for ultrasonic testing according to an existing technique. As shown, the ultrasonic probes <NUM> are positioned on the train wheel <NUM> (e.g., an outer circumferential surface of the running tread <NUM>) and they can include one or more inspection ultrasonic probes (e.g., 304a, 304b) and a validation ultrasonic probe (e.g., <NUM>). A corresponding cross-sectional front view of the train wheel <NUM> is illustrated in <FIG>. The ultrasonic testing system <NUM> can also include the probe holder <NUM>, the probe holder mount <NUM>, and a lift and rotation unit <NUM>, which are omitted for clarity.

Each of the ultrasonic probes 302a, 302b can include a single ultrasonic active element configured to generate and/or measure ultrasonic waves (also referred to as ultrasonic beams) for ultrasonic inspection of the train wheel <NUM> within an inspection area <NUM>. The inspection area <NUM> is located between the primary hole <NUM> and the running tread <NUM>. The inspection ultrasonic probes 304a, 304b can be configured to measure defects <NUM> (e.g., <NUM>, <NUM>, <NUM>, <NUM>) within the inspection area <NUM> by sending and receiving inspection ultrasonic signals <NUM>. In one aspect, the inspection ultrasonic probes 304a, 304b can be paired, one for transmitting and one for receiving, referred to as a "V-transmission configuration. " As shown in <FIG>, a first inspection ultrasonic probe 304a can be configured to emit an inspection ultrasonic signal <NUM>. If a defect <NUM> is present in the path of the inspection ultrasonic signal <NUM>, it can reflect from that defect <NUM> (e.g., <NUM>, <NUM>, <NUM>) and be measured by a second inspection ultrasonic probe 304b. In another aspect, a single one of the inspection ultrasonic probes 304a, 304b can both generate and measure an inspection ultrasonic beam that is reflected from one of the defects <NUM>, also referred to as direct scan. As shown, the second inspection ultrasonic probe 304b can generate an ultrasonic inspection signal <NUM>' that is reflected from one of the defects <NUM> (e.g., <NUM>) within the inspection area <NUM> and measure the reflected ultrasonic inspection signal <NUM>'. In either case, analysis of the measured ultrasonic inspection signals <NUM>, <NUM>' can provide estimates of the size and location of one or more of the defects <NUM> (e.g., <NUM>, <NUM>, <NUM>, <NUM>) within the inspection area <NUM>.

The validation ultrasonic probe <NUM> is employed to validate the coupling of the inspection ultrasonic probes 304a, 304b. In general, wheel disk geometries include features that reflect ultrasonic beams with defined, characteristic, and well-known reflection properties. Such features include, but are not limited to the convex intersection from the running tread <NUM> to the wheel disk <NUM>. These features can be referred to herein as coupling validation geometries <NUM>. The validation ultrasonic probe <NUM> is configured to generate and measure validation ultrasonic signals <NUM> reflected from coupling validation geometries <NUM>. When the validation ultrasonic signals <NUM> measured by the validation ultrasonic probe <NUM> agree with an expected behavior, coupling can be considered to be good or validated. When the validation ultrasonic signals <NUM> measured by the validation ultrasonic probe <NUM> deviate from an expected behavior, coupling can be considered to be poor or not validated.

Use of the validation ultrasonic probe <NUM> separate from the inspection ultrasonic probe(s) <NUM> can be problematic for a number of reasons, however.

In one aspect, it is assumed that when the validation ultrasonic probe <NUM> validates its own coupling to the train wheel <NUM>, this result is applicable to the inspection ultrasonic probes 304a, 304b as well. However, under worst case scenarios, this assumption is not true. Therefore, existing ultrasonic testing systems, such as ultrasonic testing system <NUM>, can fail to properly validate the inspection ultrasonic probes 304a, 304b, risking incorrect interpretation of ultrasonic testing results.

In another aspect, because they are configured to generate and measure ultrasonic beams for different features within the train wheel <NUM> (e.g., the defects <NUM> as compared to coupling validation geometries <NUM>), the orientation of the inspection ultrasonic probes 304a, 304b and the validation ultrasonic probe <NUM> are different. That is, respective ones of the ultrasonic probes <NUM> cannot both measure defects <NUM> and perform validation.

In a further aspect, the need for a validation ultrasonic probe <NUM> separate from the inspection ultrasonic probes 304a, 304b can add additional cost and complexity to existing ultrasonic testing systems (e.g., ultrasonic testing system <NUM>).

Embodiments of the present disclosure provide improved systems and methods for ultrasonic testing. An improved ultrasonic testing system <NUM> can be similar to the ultrasonic testing system <NUM>, including the probe holder <NUM>, the probe holder mount <NUM>, and the lift and rotation unit <NUM> of <FIG>. However, the ultrasonic probes <NUM> are replaced with matrix array ultrasonic probes <NUM>, also referred to as phased array ultrasonic probes, illustrated in <FIG>. A matrix array ultrasonic probe <NUM> can include two or more ultrasonic active elements. These ultrasonic active elements can be configured to generate and measure ultrasonic beams and they 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 beam <NUM> in a predetermined direction. This process can be repeated as necessary to sweep the ultrasonic beam <NUM> through an arc A of different predetermined directions. Exemplary embodiments of matrix array ultrasonic probes <NUM> can be found in <CIT>.

<FIG> is a side view of a portion of the train wheel <NUM>. As shown, matrix array ultrasonic probes <NUM> can be positioned on or adjacent to the train wheel <NUM> (e.g., an outer circumferential surface of the running tread <NUM>) for ultrasonic testing. A corresponding cross-sectional front view of the train wheel <NUM> is illustrated in <FIG>. Two matrix array ultrasonic probes 402a, 402b are illustrated and remaining portions of the improved ultrasonic testing system <NUM> are omitted for clarity. However, any number of matrix array probes can be employed without limit. Under circumstances where the system is employed with wheels other than train wheels, the matrix array ultrasonic probes can be positioned on or adjacent to the wheel at a suitable location, such as an outer circumferential surface of the wheel.

Each of the matrix array ultrasonic probes <NUM> are configured to acquire measurements for detection of defects <NUM> within an inspection area <NUM> and validation their ultrasonic coupling with respect to the train wheel <NUM>. The inspection area <NUM> extends from the running tread <NUM> to the primary hole <NUM>.

As shown in <FIG>, the matrix array ultrasonic probes <NUM> are arranged in a V-transmission configuration. The matrix array ultrasonic probe 402a can be configured to generate an inspection ultrasonic signal <NUM> that is directed towards the inspection area <NUM>. If the defect <NUM> is present in the path of the inspection ultrasonic signal <NUM>, the inspection ultrasonic signal <NUM> can reflect from the defect <NUM> and be measured by matrix array ultrasonic probe 402b. As further shown, both of the matrix array ultrasonic probes 402a, 402b can also be configured to generate and measure a respective validation ultrasonic signal <NUM> reflected from a coupling validation geometry <NUM>. Accordingly, the inspection ultrasonic signal <NUM> and the validation ultrasonic signal <NUM> can be emitted and reflected in different directions from each other. As discussed above, the coupling validation geometry <NUM> represents one or more features that reflect ultrasonic beams with defined, characteristic, and well-known reflection properties (e.g., features with convex radii). While V-transmission configurations have been discussed above, embodiments of the improved ultrasonic testing system can also employ matrix ultrasonic probes in a direct scan configuration, where each matrix ultrasonic probe both generates and measures inspection ultrasonic beams after reflection from a defect.

In certain embodiments, the train wheel <NUM> can be lifted from an underlying surface (e.g., the rail <NUM>) while the inspection ultrasonic signal <NUM> and the validation ultrasonic signal <NUM> are emitted and reflected. The train wheel <NUM> can also be rotated while lifted to facilitate inspection of the substantially the entire volume of the inspection area <NUM>. In one aspect, rotation can be performed after measurement of reflected inspection ultrasonic signal <NUM> and validation ultrasonic signal <NUM>. In another aspect, rotation can be performed at a selected speed during emission of inspection ultrasonic signal <NUM> and validation ultrasonic signal <NUM>, reflection of reflected inspection ultrasonic signal <NUM> and validation ultrasonic signal <NUM>, and/or measurement of reflected inspection ultrasonic signal <NUM> and validation ultrasonic signal <NUM>.

<FIG> illustrate front cross-sectional views of additional exemplary embodiments of train wheels <NUM>, <NUM>, <NUM>, <NUM> having different additional coupling validation geometries <NUM>, <NUM>, <NUM>, <NUM> and respective matrix array ultrasonic probes <NUM> positioned thereon for ultrasonic testing. The additional coupling validation geometries <NUM>, <NUM>, <NUM>, <NUM> for each of the train wheels <NUM>, <NUM>, <NUM>, <NUM> are circled for reference. As an example, additional coupling validation geometries <NUM>, <NUM>, <NUM>, <NUM> can be present within the running tread <NUM>, the wheel disk <NUM>, or combinations thereof. As shown, embodiments of the matrix array ultrasonic probes <NUM> can direct additional validation ultrasonic signals <NUM> towards one or more of the coupling validation geometries <NUM>, <NUM>, <NUM>, <NUM> of their respective train wheel <NUM>, <NUM>, <NUM>, <NUM> in order to validate their coupling thereto. Further, as discussed above, the matrix array ultrasonic probes <NUM> can direct inspection ultrasonic signals <NUM> into the inspection area <NUM> for detection of defects <NUM>.

<FIG> illustrates an analysis system <NUM> of the improved ultrasonic testing system <NUM> configured for electronic communication with each of the matrix array ultrasonic probes <NUM>. The analysis system <NUM> can include an analyzer <NUM>, an annunciator <NUM>, and a display device <NUM>. The analyzer <NUM> can be any computing device employing a general purpose or application specific processor (e.g., processor <NUM>) and can also include a memory <NUM>. The processor <NUM> can include one or more processing devices, and the first memory <NUM> can include one or more tangible, non-transitory, machine-readable media collectively storing instructions executable by the first processor <NUM> to perform the methods and control actions described herein. Embodiments of the analyzer <NUM> can be implemented using analog electronic circuitry, digital electronic circuitry, and combinations thereof.

In one embodiment, the memory <NUM> can store a reference validation signal for each coupling validation geometry <NUM>. The reference validation signal can represent a validation ultrasonic signal <NUM> measured under conditions of good coupling. The memory <NUM> can further store instructions and/or algorithms for determining whether the measured validation ultrasonic signal <NUM> reflected from a coupling validation geometry <NUM> matches a corresponding reference ultrasonic signal for that coupling validation geometry <NUM>. As an example, a match can be determined when the strength of the measured validation ultrasonic signal <NUM> and 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 signal <NUM> and the reference validation ultrasonic signal vary from one another by greater than the predetermined threshold amount as a function of time.

In an alternative embodiment, the memory can store a reference validation signal strength for each validation coupling geometry. The reference validation signal strength can represent a threshold strength above which a validation ultrasonic signal can be considered to represent good coupling. The memory can further store instructions and/or algorithms for determining whether the measured validation ultrasonic signal reflected from a coupling validation geometry exhibits a strength greater than or equal to the reference validation signal strength for that coupling validation geometry. A measured validation ultrasonic signal having a strength greater than or equal to the reference validation signal strength can be considered to possess good coupling. Conversely, a measured validation ultrasonic signal determined having a strength less than the reference validation signal strength can be considered to possess poor coupling.

<FIG> is a flow diagram illustrating an exemplary embodiment of a method <NUM> for ultrasonic inspection in which each of the matrix array ultrasonic probes <NUM> can be configured to both perform ultrasonic inspection of the train wheel <NUM> and validate its ultrasonic coupling with the train wheel <NUM>. The method <NUM> is described below in connection with the improved ultrasonic testing system <NUM> of <FIG>. As illustrated, the method <NUM> includes operations <NUM>-<NUM>. However, alternative embodiments of the method can include more operations than illustrated in <FIG>, and the operations can be performed in a different order than illustrated in <FIG>, insofar as falling under the scope of the claims.

In operation <NUM>, one or more matrix array ultrasonic probes <NUM> are positioned for ultrasonic communication with the train wheel <NUM>. The matrix array ultrasonic probes <NUM> are positioned using the probe positioning assembly <NUM>. As an example, the one or more matrix array ultrasonic probes <NUM> can be positioned on or adjacent to the running tread <NUM> of the train wheel <NUM>. In further embodiments, the one or more matrix array ultrasonic probes <NUM> can include at least two matrix array ultrasonic probes (e.g., 402a, 402b) positioned with respect to one another in a configuration that mimics a curvature of the running tread <NUM>. In operations <NUM>-<NUM>, each of the one or more matrix array ultrasonic probes <NUM> emit the validation ultrasonic signal <NUM> towards a coupling validation geometry (e.g., <NUM>) within the train wheel <NUM> and measure the corresponding reflected validation ultrasonic signals <NUM>. The train wheel <NUM> includes one or more coupling validation geometries (e.g., <NUM>). Furthermore, each of the matrix array ultrasonic probes <NUM> can be configured to sweep the emitted validation ultrasonic signal <NUM> through an arc of predetermined directions and measure a plurality of validation ultrasonic signals <NUM> after reflection from a plurality of coupling validation geometries <NUM>.

In operation <NUM>, each of the matrix array ultrasonic probes <NUM> emits an ultrasonic inspection signal <NUM> towards the inspection area <NUM> of the train wheel <NUM>. Similar to the validation ultrasonic signals <NUM>, the emitted inspection ultrasonic signals <NUM> can be swept through an arc of predetermined directions. In operation <NUM>, at least one of the matrix array ultrasonic probes <NUM> can measure the emitted inspection ultrasonic signal <NUM> after reflection from a defect within the inspection area <NUM> (e.g., defect <NUM>). Thus, each of the matrix array ultrasonic probes <NUM> that emits an inspection ultrasonic signal <NUM> can be configured to sweep the inspection ultrasonic signal <NUM> through an arc of predetermined directions, and each of the matrix array ultrasonic probes <NUM> that measures the reflected inspection ultrasonic signal <NUM> can be configured to measure a plurality of inspection ultrasonic signals <NUM> after reflection from a plurality of respective defects <NUM>.

In certain embodiments, the one or more matrix array ultrasonic probes <NUM> can include at least two matrix array ultrasonic probes (e.g., 402a, 402b). In one aspect, a first one of the at least two matrix array ultrasonic probes 402a can be configured to emit the inspection ultrasonic signal <NUM> towards the inspection area <NUM>, and a second one of the at least two matrix array ultrasonic probes 402b can be configured to measure the inspection ultrasonic signal <NUM> reflected from a defect <NUM> (e.g., a V-transmission configuration). In another aspect, the first matrix array ultrasonic probe 402a and the second matrix array ultrasonic probe 402b can each be configured to emit the inspection ultrasonic signal <NUM> and to measure its inspection ultrasonic signal <NUM> reflected from a defect <NUM> (e.g., a direct beam configuration).

The manner in which the inspection ultrasonic signals <NUM> and validation ultrasonic signals <NUM> are generated can be chosen based upon the train wheel <NUM> under 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 signal can be generated (e.g., approximately <NUM>,) followed by one or more validation ultrasonic signal. This cycle can be repeated or varied as necessary for the duration of ultrasonic testing.

In operations <NUM>-<NUM>, the analyzer <NUM> validate the ultrasonic coupling of the matrix array ultrasonic probes <NUM>. In operation <NUM>, the analyzer <NUM> receives a measured validation ultrasonic signal <NUM> and a measured inspection ultrasonic signal <NUM> (e.g., from matrix array ultrasonic probes <NUM>). In operation <NUM>, the analyzer <NUM> can determine that the measured validation ultrasonic signal <NUM> matches a reference validation ultrasonic signal. The reference validation ultrasonic signal <NUM> can be maintained by the memory <NUM> and the processor <NUM> can conduct a comparison of the two to determine a match. As an example, a match can be identified when the measured validation ultrasonic signal <NUM> and the reference validation ultrasonic signal differ by less than a threshold amount (e.g., on the basis of strength as a function of time). The analyzer <NUM> is configured to output a first notification signal <NUM> representing validation of the measured inspection ultrasonic signal <NUM> in operation <NUM>. Conversely, under circumstances where the measured validation ultrasonic signal <NUM> and the reference validation ultrasonic signal differ by greater than or equal to the threshold amount (e.g., on the basis of strength as a function of time), the analyzer <NUM> can be configured to output also a second notification signal <NUM>' representing invalidation of the measured inspection ultrasonic signal <NUM> in operation <NUM>.

The first and second notification signals <NUM>, <NUM>' can be received by the annunciator <NUM>. The annunciator <NUM> can be configured to annunciate a first annunciation (e.g., audio, video, text, etc.) representing validation of the inspection ultrasonic signal <NUM> in response to receipt of the first notification signal <NUM>. The annunciator <NUM> can be configured to annunciate a second annunciation (e.g., audio, video, text, etc.) representing invalidation of the inspection ultrasonic signal <NUM> in response to receipt of the second notification signal <NUM>'.

Technical effects of the methods, systems, and devices described herein include integrated ultrasonic testing and ultrasonic coupling validation. In one aspect, ultrasonic coupling validation can be provided for each of the matrix array ultrasonic probes. That is, unlike existing ultrasonic testing system, ultrasonic coupling between each 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 probes 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.

Certain exemplary embodiments are described to provide an overview of the principles of the structure, function, manufacture, and use of the systems, devices, and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. The features illustrated or described in connection with one exemplary embodiment can be combined with the features of other embodiments.

Claim 1:
An ultrasonic testing system (<NUM>) and a wheel (<NUM>) to be inspected, the system comprising:
one or more matrix array ultrasonic probes (<NUM>);
a probe positioning assembly (<NUM>) configured to mechanically couple to the one or more matrix array ultrasonic probes (<NUM>) and to position the one or more matrix array ultrasonic probes (<NUM>) for ultrasonic communication with the wheel (<NUM>) which includes a wheel disk (<NUM>) forming a center of the wheel, a running tread (<NUM>) forming a circumferential outer surface of the wheel, and at least one coupling validation geometry (<NUM>) including a feature that reflects ultrasonic beams with defined, characteristic and known reflection properties;
wherein the one or more matrix array ultrasonic probes (<NUM>) is configured to:
emit a validation ultrasonic signal (<NUM>) directed towards the coupling validation geometry (<NUM>) within the wheel (<NUM>);
measure its emitted validation ultrasonic signal after reflection from a respective one of the at least one coupling validation geometry (<NUM>); and
emit an ultrasonic inspection signal (<NUM>) for measurement of an inspection ultrasonic signal reflected from a defect (<NUM>) positioned within an inspection area (<NUM>) located between a primary hole (<NUM>) positioned about the center of the wheel disk (<NUM>) and the running tread (<NUM>) of the wheel; and
an analyzer (<NUM>) configured to:
receive the measured validation ultrasonic signal (<NUM>) and the measured inspection ultrasonic signal (<NUM>);
determine whether the measured validation ultrasonic signal (<NUM>) matches a reference validation signal; and
output a first notification representing validation of the measured inspection ultrasonic signal (<NUM>) under the circumstances that the measured validation signal matches the reference validation signal;
wherein the at least one coupling validation geometry (<NUM>) comprises the convex intersection from the running tread (<NUM>) of the wheel (<NUM>) to the wheel disk (<NUM>) of the wheel (<NUM>).