Patent ID: 12221205

DETAILED DESCRIPTION

The following detailed description of various embodiments herein makes reference to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. It should also be understood that unless specifically stated otherwise, references to “a,” “an” or “the” may include one or more than one and that reference to an item in the singular may also include the item in the plural. Further, all ranges may include upper and lower values and all ranges and ratio limits disclosed herein may be combined.

Referring toFIGS.1A and1B, in accordance with various embodiments, an inspection system100is illustrated. Inspection system100includes a cart102, sensor control system104, and a sensor assembly106.FIG.1Billustrates a cross section view of sensor assembly106within a cylinder116along line A-A ofFIG.1A. Cart102may include wheels123, a cart body124, and a top surface126. Wheels123are affixed to the bottom of cart102and allow cart102to be moved into position near a work piece. In various embodiments, wheels123may be caster wheels that may be fixed or swivel and may lock into place. In various embodiments, cart body124may be open, having shelves, and may provide support to top surface126. In various embodiments, cart body124may be closed including cabinets and/or drawers for storing tools, materials, power cables, among others. Top surface126may be a formed of any suitable material such as a metal, wood, laminate, among others. Top surface126supports sensor control system104during use of inspection system100.

Sensor control system104includes a base108, upright supports110, a boom112, and boom supports114. In various embodiments, sensor control system104includes a controller for controller movement of sensor control system104. In various embodiments, instruments122may control movement of sensor control system104. Base108is configured to move forward and backward (e.g., the x-direction). In various embodiments, base108may be moved by a motor, such as for example, a stepper motor, servo motor, DC motor, or A/C motor, among others. Base108includes a linear position sensor to monitor and report the movement of base108forward and backward (e.g., the x-direction), such as to the controller. The linear position sensor may be a resistive sensor, inductive sensor, magnetic sensor, pulse encoding, linear potentiometer, or linear variable differential transformer (LVDT), among others.

Upright supports110extend orthogonally upward (e.g., the y-direction) from base108. Illustrated inFIG.1are two upright supports110. In various embodiments, there may be more than two upright supports110. Upright supports110are configured to move up and down (e.g., the y-direction) with respect to base108. In various embodiments, upright supports110may be moved by a motor, such as for example, a stepper motor, servo motor, DC motor, or A/C motor, among others. In various embodiments, each upright support110may be coupled to a different motor such that each upright support110is able to move independent of the other upright support110.

Each upright support110further includes a boom support114. Each boom support114is connected near the top end of upright support110. Boom support114is configured to support and rotate boom112. Boom112may be an elongated member having a proximal end and a distal end, the proximal end connected to the upright supports110, such as with boom supports114. Boom supports114further include a motor configured to rotate boom112in a clockwise direction and/or a counterclockwise direction. The motor may be a stepper motor, servo motor, DC motor, or A/C motor, among others. In various embodiments, a single motor may be used to rotate boom112. A rotational position sensor may be connected to boom supports114to monitor and report the rotational position of boom112, such as to the controller, as it is rotated by the motor. The rotational position sensor may be a potentiometer, a hall effect sensor, an inductive sensor, or a rotary variable differential transformer (RVDT), among others.

Sensor assembly106is connected to the distal end of boom112and is configured to rotate with boom112. In various embodiments, a counterweight115is connected to the proximal end of boom112to counterbalance the weight of sensor assembly106. Sensor assembly106includes spring loaded arms118and sensors120. Sensors120are each connected to an end of a spring loaded arm118. Sensor assembly106is configured to be inserted into cylinder116such that sensors120physically contact an inner surface, or inner bore, of cylinder116. This allows sensors120to scan the inner surface of cylinder116for defects and/or anomalies. For example, sensors120may detect grinding burns caused by previous steps in manufacturing and/or processing of cylinder116. Sensors120may be Barkhausen sensors.

To facilitate the scan of the inner surface multiple spring-loaded arms118are used. Each spring loaded arm118is offset from the other spring loaded arms118by about 100° to about 140°, and more specifically, by about 120°. The offset allows for sensors120to overlap during scanning of the inner surface of cylinder116while minimizing the number of sensors used to perform the scan. In various embodiments, cylinder116may have a diameter of about 10 cm (3.94 inches) to about 61 cm (24 inches) and a depth of about 45 cm (18 inches) to about 244 cm (96 inches). Spring loaded arms118of varying lengths may be used to accommodate the different diameters of cylinder116. Booms112of varying lengths may be used to accommodate the different depths of cylinder116.

Sensors120are connected to instruments122. Instruments122may be located on top of surface126as illustrated inFIG.1. In various embodiments, instruments122may be located inside cart body124. Cables121connect instruments122to sensors120. There may be one instrument122connect to one sensor120via one cable121. In various embodiments, a single cable121may connect sensors120to instruments122. In various embodiments, a single instrument122may be connected to all sensors120. During use, cables121may twist, thereby limiting rotation of boom112. To overcome this, boom112may rotate a predetermined amount in a clockwise (or counterclockwise) direction and then rotate in a counterclockwise (or clockwise) direction to return to a starting position. In various embodiments, boom112may rotate about 100° to about 200°, more specifically, about 120° to about 150°. When spring loaded arms118are offset by 120°, rotating 120° provides full coverage of the inner surface of cylinder116by sensors120when scanning. Rotating more than 120° provides overlap between scans by each sensor120thereby providing redundant scanning coverage at each end of the rotation, when spring-loaded arms are offset by 120°.

Instruments122may comprise one or more processors configured to implement various logical operations in response to execution of instructions, for example, instructions stored on a non-transitory, tangible, computer-readable medium. The one or more processors can be a general purpose processor, a microprocessor, a microcontroller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete or transistor logic, discrete hardware components, or any combination thereof. Instruments122may further comprise memory to store data, executable instructions, system program instructions, and/or controller instructions to implement the control logic of instruments122.

System program instructions and/or controller instructions of instruments122may be loaded onto a non-transitory, tangible computer-readable medium having instructions stored thereon that, in response to execution by a controller, cause the controller to perform various operations. The term “non-transitory” is to be understood to remove only propagating transitory signals per se from the claim scope and does not relinquish rights to all standard computer-readable media that are not only propagating transitory signals per se.

A scan begins with sensor assembly106positioned inside cylinder116and sensors120making contact with the inner surface of cylinders116. This is the starting position. Sensor assembly106may be rotated (e.g., clockwise or counterclockwise) 150° while sensors120scan the inner surface of cylinder116. This is accomplished by rotating boom112and monitoring the rotation of boom112using the rotational position sensor. Sensors120scan the inner surface of cylinder116throughout the entire rotation of sensor assembly106. Spring loaded arms118press sensors120against the inner surface of cylinder116to provide good contact for scanning. When the 150° rotation is completed, sensor assembly106is rotated (e.g., clockwise or counterclockwise) back to the starting position. 150° back to the starting position.

The base108then moves forward (e.g., the negative x direction) advancing the sensor assembly106further into cylinder116. Base108may be advanced one full unit of measure, where one full unit of measure is equal to the length of the sensor surface of sensor120. Sensor length L, described below with respect toFIG.3, is an example of a full unit of measure. In various embodiments, base108may be advanced a fraction of one full unit of measure. For example, base108may be advanced between about 25% and about 100%, more specifically, between about 50% and about 75% of one full unit of measure. In various embodiments, boom112may be advanced forward (e.g., in the x-direction) by base108moving forward. In various embodiments, boom112may be advanced forward (e.g., in the x-direction) by cart102moving forward. The distance moved forward for each scanning pass may depend on a determined amount of overlap of each cycle. More overlap may provide a more precise scan. Less overlap may result in the scan completing faster.

The sensor assembly106is then rotated, as described above, to perform another scanning pass. This process continues until the entire inner surface of cylinder116is scanned. Instruments122record the data from each scanning pass. In various embodiments, a controller may control the scanning process, thereby automating the process. In various embodiments, the controller may be housed in instruments122.

Referring now toFIGS.2A and2B, in accordance with various embodiments, illustrated are side and front views, respectively, of sensor assembly106. Sensor assembly106, more specifically, spring-loaded arms118includes a hub140, arms144, a spring148, and a sensor holder150. Hub140is connected to, and circumferentially around, boom112and is configured to rotate with boom112. Hub140may be connected to boom112using connectors142. In various embodiments, hub140may be integral to boom112. In various embodiments, hub140may be press fit to boom112or connected to boom112by welding, adhesive, or epoxy, among others.

As illustrated, hub140includes a hub body140d, a first portion140a, a second portion140b, and a third portion140c. Hub body140dhas an annular shape and is positioned around boom112so that it rotates with boom112. First portion140aextends orthogonally outward from hub body140dand boom112. Second portion140bextends orthogonally outward from hub body140dand boom112and is offset 120° from first portion140a. Third portion140cextends orthogonally outward from hub body140dand boom112and is offset 120° from first portion140aand second portion140b. In various embodiments, hub body140d, first portion140a, second portion140b, and third portion140cmay be integral, forming a single body. In various embodiments, hub body140d, first portion140a, second portion140b, and third portion140cmay be separate and distinct members that are connected to form hub140.

Arms144a,144b,144c(collectively arms144) have a first end connected to hub140and a second end extending away from hub140. For example, arm144ais connected to first portion140a, arm144bis connected to second portion140b, and arm144cis connected to third portion140c. Each arm144a,144b,144cmay be connected to each respective hub portion140a,140b,140cusing connectors146. In various embodiments, arms144may connect to hub portions140a,140b,140cusing other means such as being press fit, push button, latch, or be slidably connected, among others. Arms144may vary in length where the length of each arm144may be about 3 cm (1.18 inches) to about 61 cm (24 inches) or longer, more specifically, the length of each arm144may be about 10 cm (3.93 inches) to about 40.64 cm (16 inches). The term “about” in this context means+/−5% of the given value. Varying the length of arm144allows sensor assembly106to fit inside cylinders116of different sizes so that a single inspection system100may be used to inspect different cylinders116. The difference in arm length is due to the difference in diameter of cylinder116, as described above. In various embodiments, arms144a,144b,144cmay be integral to hub140. In various embodiments, there may be more or fewer arms144than those illustrated and described herein.

The second end of each of arms144a,144b,144cis configured to hold spring148. In various embodiments, there may be a recess in the second end of each arm144configured to receive and secure spring148. In various embodiments, spring148may extend from the second end of each arm144instead of being seated in a recess. Spring148may be a disk spring or a wave spring, among others.

Sensor holder150is attached to the second of arm144, and over spring148, and is configured to hold sensor120allowing sensor120to rotate with hub140and boom112. Sensor holder150may include connectors, supports, clips, latches, and/or fasteners, among others, that are configured to support and secure sensor120. Sensor holder150may move up and down (e.g., the y-direction) in response to the pressure from spring148on a first end or from sensor120on a second end of sensor holder.

Referring now toFIG.3, in accordance with various embodiments, an Barkhusen sensor300is illustrated. Sensor300may an example of sensor120described above. Sensor300includes a housing302, a cable connector304, and sensor elements306. Housing302includes a back surface308, a top surface310, a front surface312, and side surfaces314. Cable connector304provides a connection (e.g., cables121) for sending measurements from sensor206to a processor (e.g., instruments122) for collection and analysis. Sensor elements306have a surface length L that is equal to the surface length of sensor elements306. Surface length L may be equal to the one full unit of measure described above with respect toFIG.1.

Returning toFIGS.2A and2B, sensor holder150may be configured to hold sensor300, as an example, with back surface308positioned against sensor holder150and front surface310and sensor elements306facing away from sensor holder150. In this configuration, the surface of sensor elements306is able to physically contact the inner surface of cylinder116. Spring148applies a force to sensor holder150so that sensor120(e.g., sensor300) maintains physical contact the inner surface of cylinder116while rotating within cylinder116. Imperfections on the inner surface of cylinder116may press

Referring now toFIG.4, in accordance with various embodiments, an alignment system400is illustrated. Alignment system400may be used with inspection system100to align sensor assembly106with a center axis402of cylinder116. Alignment system400includes an alignment target404and optical pointers406a,406b,406c(collectively optical pointers406). In various embodiments, optical pointers406may be laser pointers. Alignment target404is placed over an opening of cylinder116, as illustrated. Alignment target404may include a marking that aligns with each optical pointer406a,406b,406cto signify that a proper alignment is achieved. In various embodiments, the marking may be a circle, a triangle, or a dot, among others. When using a dot, or other such marking, the position of hub140correlates with a specific starting position as well as an alignment with center axis402of cylinder116. When using another marking (e.g., a circle), hub140is aligned with center axis402but may not be in a specific starting position.

During alignment, sensor assembly106is pointed toward alignment target404and optical pointers406are turned on. Sensor assembly106may then be moved up and/or down, back and/or forth, and/or side to side to align optical pointers406with the markings on alignment target404. After properly aligning sensor assembly106, the alignment target404is removed and sensor assembly106may be introduced into the cylinder116. Alignment system400provides an easy to use alignment procedure for accurately setting up inspection system100and accurately scanning the inner surface of cylinder116.

Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment,” “an embodiment,” “various embodiments,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

Numbers, percentages, or other values stated herein are intended to include that value, and also other values that are about or approximately equal to the stated value, as would be appreciated by one of ordinary skill in the art encompassed by various embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable industrial process, and may include values that are within 10%, within 5%, within 1%, within 0.1%, or within 0.01% of a stated value. Additionally, the terms “substantially,” “about” or “approximately” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the term “substantially,” “about” or “approximately” may refer to an amount that is within 10% of, within 5% of, within 1% of, within 0.1% of, and within 0.01% of a stated amount or value.

Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

Finally, it should be understood that any of the above described concepts can be used alone or in combination with any or all of the other above described concepts. Although various embodiments have been disclosed and described, one of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. Accordingly, the description is not intended to be exhaustive or to limit the principles described or illustrated herein to any precise form. Many modifications and variations are possible in light of the above teaching.