Patent ID: 12216092

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various embodiments of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

In the following description, like reference characters designate like or corresponding parts throughout the several views of the drawings. Also in the following description, it is to be understood that such terms as “forward”, “rearward”, “left”, “right”, “upwardly”, “downwardly”, and the like are words of convenience and are not to be construed as limiting terms. As used herein, the term “number” shall be used to refer to any non-zero integer quantity, i.e., one or any integer greater than one (e.g., 1, 2, 3, . . . ).

As employed herein, the expression “a number of” and variations thereof shall refer broadly to any non-zero quantity, including a quantity of one.

Ultrasonic testing methodologies typically have additionally required the use of some type of couplant between the ultrasonic sensor and the surface of the workpiece. Couplant materials typically have included fluids such as water, hair gel, and any of a variety of other materials that acoustically couple the ultrasonic sensor with the workpiece. Such couplant material typically has been manually applied either to the workpiece or to the ultrasonic sensor, or both. While the ultrasonic sensor typically had been manually moved among various positions on the workpiece, more recently such ultrasonic sensors have been robotically operated to move them with respect to the workpiece.

An improved ultrasonic testing apparatus4in accordance with the present disclosure is depicted generally inFIG.1. The ultrasonic testing apparatus4can include an ultrasonic testing probe8that is likewise in accordance with the present disclosure. The ultrasonic testing apparatus4can further include an automated couplant delivery system12that is in accordance with the present disclosure and which can be connectable with the ultrasonic testing probe8. The ultrasonic testing apparatus4further can be said to include a control apparatus16that includes a laptop computer20to which are connected a motion control unit24and a phased array acquisition unit28. As will be noted elsewhere herein, the couplant delivery system12can include a control box84, and it is noted that any one or more of the laptop computer20, the motion control unit24, the phased array acquisition unit28, and the control box84can include a processor or a storage or both, with the storage having stored therein instructions in the form of routines which, when executed on the processor, will cause the ultrasonic testing apparatus4to perform various operations such are set forth elsewhere herein.

The ultrasonic testing probe8is usable to perform an ultrasonic testing operation on a workpiece32and, in particular, can be received in an interior region of the workpiece32which, in the depicted exemplary embodiment, is in the form of a hollow tube. The workpiece is shown both in solid lines spaced from the ultrasonic testing probe8and is shown in dashed lines to illustrate the ultrasonic testing probe8received in the interior region of the workpiece32. The workpiece32may be mounted to a tube sheet which is not shown for reasons of clarity and simplicity.

The ultrasonic testing probe8can be said to include a support36that includes a probe wand40and a frame44, with the probe wand40being situated on the frame44. The ultrasonic testing probe8can further include a linear phased array probe48that is movably situated on the probe wand40and that is connected via a shaft with a DC servomotor/encoder52. The DC servomotor/encoder52can be connected via a motor/encoder cable56with the motion control unit24. Responsive to instructions received from the motion control unit24based upon software that is operable on the motion control unit24or on the laptop computer20or both, the DC servomotor/encoder52can be energized to cause a rotation of the shaft to, in turn, rotate the linear phased array probe48with respect to the respect wand40. An encoder portion of the DC servomotor/encoder52can output a number of electronic pulses with such rotation, wherein each pulse is representative of a predetermined angular rotation of the DC servomotor/encoder52with respect to the frame44. A belt drive can couple the DC servomotor/encoder52with the shaft that operates the linear phased array probe48. A 385° limiter mechanism58can limit rotation of the linear phased array probe48to a total movement of 385° of rotation with respect to the probe wand40, at which point the motion can be stopped by a physical stop in order to prevent breakage of data cables that extend between the linear phased array probe48and a phased array probe cable54of the ultrasonic testing probe8that is electrically connected with the phased array acquisition unit28. The aforementioned software, e.g., in the form of instructions and/or routines, can cause the linear phased array probe48to rotate with respect to the probe wand40and to generate an ultrasonic output that is directed toward the workpiece32and to receive an ultrasonic input from the workpiece32that is responsive to the ultrasonic output. The ultrasonic outputs can be communicated via the phased array probe cable54to the phased array acquisition unit28and thereafter to the laptop computer20, and elsewhere, as appropriate. It should be noted that outer housing, which can optionally be located as indicated by reference character50, is not shown for clarity.

The ultrasonic testing probe8can further be said to include a tube end water seal60and a waterbox and linear probe position lock62, with the waterbox and linear positioning lock62being situated on the probe wand40, and with the tube end water seal60being situated on the waterbox and linear probe position lock62. The ultrasonic testing probe8can further include an inflatable sealing bladder64at a free end thereof spaced from the tube end water seal60. The bladder64can be pneumatically inflatable between an initial state wherein its interior is at atmospheric pressure, or at least a reduced pressure, and an expanded state wherein the interior of the bladder64is pneumatically or otherwise inflated to be in an expanded state at an increased pressure in excess of atmospheric pressure, such as is indicated in dashed lines inFIG.2, wherein the bladder64compressively engages an interior surface of the workpiece32.

It thus can be understood that the end of the probe wand40that can include the bladder64and the portion of the probe wand40that extends between the bladder64and the tube end water seal60is received in the open end of the workpiece until the tube end water seal60is engaged with the edge of the workpiece32. In such a position, the tube end water seal60can be manually compressively retained against the edge of the workpiece32, at least initially. The bladder64can then be expanded in order to cause the bladder to engage the inner surface of the workpiece32, which holds the ultrasonic testing probe8in such position within the workpiece8, such that the ultrasonic testing probe8no longer needs to be manually held in such position. This results in the expanded bladder64and the tube end water seal60forming an enclosed region68between them that is bounded between an exterior surface of the probe wand40and the interior surface of the workpiece32. Such enclosed region68is generally airtight and watertight within the operable ranges contemplated by the disclosed and claimed concept.

The ultrasonic testing probe8can further include a bladder air in/out connector72, a water evacuation air connector76, an evacuated water connector80, and a water-to-water box connector68, all of which are connectable with the couplant delivery system12. As can be understood fromFIG.3, the couplant delivery system12can be additionally connectable with a couplant supply80and an air supply82. In the depicted exemplary embodiment, the couplant supply80can include a supply of water or other appropriate couplant that is suitable for use with the ultrasonic testing probe. In the depicted exemplary embodiment, the air supply82is a source of compressed air, e.g., a source of air that is at an increased pressure that is in excess of atmospheric pressure.

As noted hereinbefore, the couplant delivery system12can further include a control box84, and the control box84can be connectable via an electrical connector86with the motion control unit24, it being noted that the motion control unit24can also include a software control system. The control box84can be connected via a set of connectors88with a solenoid-operated couplant valve92, a number of solenoid-operated air valves that are indicated at the numerals94,98, and102, and a solenoid-operated drain valve106, any one or more of which may be referred to herein as a solenoid-operated valve, and all of which are a part of the couplant delivery system12. It is noted that the precise configuration of valves shown is exemplary and various combinations of, for example, 2-way and 3-way valves could be used with appropriate modifications to the connections shown. Software that is operable on the laptop computer20or on the control box84or both is operable to operate the various solenoid-operated valves noted hereinbefore in order to cause the ultrasonic testing apparatus4to perform useful operations on the workpiece32.

For instance, the couplant supply80may be at an increased pressure. e.g., in excess of atmospheric pressure, and the solenoid-operated couplant valve92can be opened to permit an amount of the couplant material from the couplant supply80to be provided via a couplant supply line110to the open solenoid-operated drain valve92and thereafter to the water-to-water box connector68. In such a scenario, the couplant supply80, the couplant supply line110, the solenoid-operated couplant valve92, the water-to-water box connector68, and the control box84can together be said to form a couplant delivery system96that is usable to provide an amount of the couplant material to the linear phased array probe48or the workpiece32or both. In the depicted exemplary embodiment, however, the more complex couplant delivery system12includes the couplant delivery system96and includes other systems that perform the exemplary operations that are described herein on the workpiece32.

In the depicted exemplary embodiment, and in order to perform an ultrasonic testing operation on the workpiece32, the free end of the probe wand40is received in the open end of the workpiece32when the bladder64is in its initial state, e.g., free state or relaxed state. The probe wand40is received into the interior regions32of the workpiece32until the tube end water seal60is compressively received against the end of the workpiece32. The automated portion of the inspection procedure is then initiated by providing a predetermined input to the control box84, such as by actuating a button or otherwise providing an electronic input. The further operations that are noted herein-below are performed by the control box84or by the control apparatus16, or both, by software that is stored thereon and that is executed on processors thereof.

Upon such initiation of the automated portion of the inspection operation, the solenoid-operated air valves98and102are closed (if they previously had been open), and the solenoid-operated air valve94is opened to permit the air from the air supply82to travel through an air supply line114past the solenoid-operated air valve94and into the bladder air in/out connector72in order to inflate the bladder64by moving it from the initial state to the expanded state in which it compressively engages the interior surface of the workpiece32. The solenoid-operated air valve94is then closed, and since the bladder64is compressively engaged with the interior surface of the workpiece32, any compressive force that had been manually applied to the ultrasonic testing probe8in order to receive it into the workpiece and to compressively engage the tube end water seal60with the end of the workpiece32can be removed. The bladder64in the expanded condition thus retains the ultrasonic testing probe in a fixed position within the interior of the workpiece32and centers the probe wand40and the linear phased array probe48within the interior of the workpiece32. The tube end water seal60is of a conic shape, and it likewise centers the probe wand40and the linear phased array probe48within the interior of the workpiece32.

Subsequent thereto, the solenoid-operated couplant valve92can be opened to permit an amount of the couplant to be received from the couplant supply80through the connection tube110into the water-to-water box connector68and into the enclosed region68, thereby filling the enclosed region68. In so doing, it may be desirable to open the solenoid-operated drain valve106in order to permit air within the enclosed region68that is displaced by the amount of couplant that is received in the enclosed region68to be drained through a drain connector128that is in communication with the atmosphere122. Once the enclosed region68is filled with the couplant material80, the solenoid-operated drain valve106, if it had been opened, can be now closed106. Again, all of the operations that are described herein as being performed by the solenoid-operated valves are controlled by the control box84or by the control apparatus16, or both.

Once the enclosed region68is filled with the couplant material, the control box84can communicate a signal to the motion control unit24to rotate the linear phased array probe48through a revolution in order to perform an ultrasonic testing operation. In so doing, the motion control unit24may send an instruction to the phased array acquisition unit28or elsewhere to energize the ultrasonic emitters of the linear array phased probe48as appropriate based upon output from the encoder portion of the DC servomotor/encoder52. In this regard, the operations might include, by way of example, a full rotation of the linear phased array probe48with recording of the received responsive ultrasonic signals at certain rotational positions responsive to pulses that are output by the encoder52, or still alternatively the motor portion of the DC servomotor/encoder52may be energized until a predetermined rotational position of the linear phased array probe48is achieved based upon the pulses received from the encoder52, at which point the linear phased array probe48may be energized to generate an ultrasonic output at that position that is directed at the workpiece32and from which input ultrasonic acoustic signals are detected that are responsive to the ultrasonic output. Such signals can be recorded at the phased array acquisition array unit28or at the laptop computer20or both, or elsewhere. In this regard, it is understood that additional software on the control apparatus16controls the operation of the linear phased array probe48and the DC servomotor/encoder52in order to perform the ultrasonic testing operation.

Subsequent to the completion of the ultrasonic testing operation by the linear phased array probe48, the solenoid-controlled drain valve106can be opened, and the solenoid-operated air valve102will likewise be opened in order to provide, via the air channel124that is connected with the air channel114, an amount of compressed air to the water evacuation air connector76in order to displace the couplant, i.e., water in the depicted exemplary embodiment, that is currently within the enclosed region68, and to cause such evacuated couplant to flow out of the drain tube128and into a receptacle132. Subsequent thereto, the solenoid-operated air valve98can be opened in order to permit the compressed air that is within the interior of the bladder64to be exhausted through the air channel118and thereafter to the atmosphere122. The ultrasonic testing probe8can subsequent thereto be removed from the workpiece32and can be inserted into another workpiece32, after which the aforementioned operations can be repeated. Such removal and replacement of the ultrasonic testing probe8can be performed manually or potentially could be performed robotically by other software and an appropriate actuator.

It is reiterated that all of the operations mentioned herein that are performed by the solenoid-operated valves are controlled by the control box84or by the motion control unit24, or by the phased array acquisition unit28, or by the laptop computer20, or any one or more in cooperation. By performing the delivery of couplant to the enclosed region68and by evacuating it in an automated fashion, in conjunction with operation of the linear phased array probe48, the inspection process is greatly simplified and its speed is dramatically increased compared with solely manual operations. Also, by providing sufficient valves and tubes to permit the evacuated couplant to be received in the receptacle132, an undesirable mess is avoided. Additionally, by operating the various solenoid-operated air valves in order to expand the bladder64, and thereafter to purge the couplant from the enclosed region68into the receptacle132, and thereafter to vent the pressurized air that is in the bladder64to the atmosphere, all in an automated fashion, the technician that is operating the ultrasonic testing apparatus4need not perform the various operations on couplant, air, linear array phased probe48, and drain that would otherwise be required in the absence of the automation of such operations that is provided by the control box84and the control apparatus6.

It thus can be seen that the couplant delivery system12automates the provision and removal of couplant as part of an ultrasonic testing operation, and it can further be seen that the ultrasonic testing probe8can be configured to be received in the end of the workpiece32and to be usable to automatically perform an ultrasonic testing operation on the workpiece32without further operation by the technician, other than by receiving the probe wand40in the end of the workpiece32with some compressive force and then initiating the testing operation, although this too can be automated. As such, the system increases speed, reduces cost, and improves repeatability due to the standard fashion in which the probe wand40is received in the interior region of the work-piece32and retained therein, and the ultrasonic testing operation is performed. Other benefits will be apparent.

Various aspects of the subject matter described herein are set out in the following examples.

Example 1—An ultrasonic testing probe operable to perform an ultrasonic inspection on a workpiece, the workpiece having an interior region, the ultrasonic testing probe comprising: a support; an ultrasonic testing element that is structured to generate an ultrasonic output that is directed toward the workpiece and to receive an ultrasonic input from the workpiece that is responsive to the ultrasonic output, the ultrasonic testing element being movably situated on the support; a motor apparatus structured to be electrically connected with a control apparatus, the motor apparatus comprising a motor that is being connected with the ultrasonic testing element and is structured to rotate the ultrasonic testing element with respect to the support; and a bladder that is structured to be movable between an initial state and an expanded state, the bladder in the expanded state being structured to be engaged with the workpiece within the interior region and to center the support in the interior region.

Example 2—The ultrasonic testing probe of example 1, wherein the motor apparatus includes an encoder that is structured to generate a number of pulses responsive to a rotation of the motor, and wherein the control apparatus is structured to record at least a portion of the ultrasonic output responsive to at least some of the number of pulses.

Example 3—The ultrasonic testing probe of example 1 or 2, wherein the bladder is pneumatically inflatable between the initial state and the expanded state.

Example 4—The ultrasonic testing probe of any of examples 1-3, wherein the support comprises a seal that is structured to engage the workpiece, and wherein the bladder is situated on the support at a location spaced from the seal, the ultrasonic testing element being situated between the seal and the bladder.

Example 5—The ultrasonic testing probe of any of examples 1-4, wherein the support further comprises a couplant connection, the couplant connection being structured to be connected with a couplant supply of a couplant delivery system.

Example 6—The ultrasonic testing probe of any of examples 1-5, wherein the support further comprises a number of air connections, an air connection of the number of air connections being in fluid communication with the bladder, the air connection being structured to be connected with an air supply of the couplant delivery system.

Example 7—The ultrasonic testing probe of example 6 wherein the support comprises a seal that is structured to engage the workpiece, and wherein the bladder is situated on the support at a location spaced from the seal, the ultrasonic testing element being situated between the seal and the bladder, another air connection of the number of air connections being in fluid communication with the support, the air connection being structured to be connected with the air supply of the couplant delivery system.