U.S. patent application number 14/970054 was filed with the patent office on 2016-06-16 for matrix phased array system for inspection of brazed welds.
The applicant listed for this patent is EDISON WELDING INSTITUTE, INC.. Invention is credited to Lance S. CRONLEY, Roger L. SPENCER, Evgueni I. TODOROV.
Application Number | 20160169840 14/970054 |
Document ID | / |
Family ID | 56110911 |
Filed Date | 2016-06-16 |
United States Patent
Application |
20160169840 |
Kind Code |
A1 |
TODOROV; Evgueni I. ; et
al. |
June 16, 2016 |
MATRIX PHASED ARRAY SYSTEM FOR INSPECTION OF BRAZED WELDS
Abstract
A system for non-destructively inspecting brazed joints that
includes at least one matrix phased array probe that further
includes plurality of ultrasonic transducer elements arranged in an
array at one end of the probe, wherein the transducer elements are
operative to both generate ultrasonic signals and to receive
reflections thereof; and at least one tip adapted to be removably
mounted over the array of ultrasonic transducer elements, wherein a
region of the at least one tip has been shaped to correspond to the
geometric characteristics of an item or a specific portion of an
item that includes a brazed joint to be inspected; and a processor
running software that includes at least one imaging algorithm for
processing data received from the at least one matrix phased array
probe and generating color coded ultrasonic C-scan images of
inspected brazed joints.
Inventors: |
TODOROV; Evgueni I.;
(Dublin, OH) ; SPENCER; Roger L.; (Ashville,
OH) ; CRONLEY; Lance S.; (Mount Victory, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
EDISON WELDING INSTITUTE, INC. |
Columbus |
OH |
US |
|
|
Family ID: |
56110911 |
Appl. No.: |
14/970054 |
Filed: |
December 15, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62091869 |
Dec 15, 2014 |
|
|
|
Current U.S.
Class: |
73/588 |
Current CPC
Class: |
G01N 29/262 20130101;
G01N 29/11 20130101; G01N 29/0645 20130101; G01N 2291/044 20130101;
G01N 2291/0234 20130101; G01N 2291/267 20130101; G01N 2291/106
20130101 |
International
Class: |
G01N 29/04 20060101
G01N029/04 |
Claims
1) A system for non-destructively inspecting brazed joints,
comprising: (a) at least one matrix phased array probe, wherein the
matrix phased array probe further includes: (i) a plurality of
ultrasonic transducer elements arranged in an array at one end of
the probe, wherein the transducer elements are operative to both
generate ultrasonic signals and to receive reflections thereof; and
(ii) at least one tip adapted to be removably mounted over the
array of ultrasonic transducer elements, wherein a region of the at
least one tip has been shaped to correspond to the geometric
characteristics of an item or a specific portion of an item that
includes a brazed joint to be inspected; and (b) a processor
running software that includes at least one imaging algorithm for
processing data received from the at least one matrix phased array
probe and generating A-scans and color coded C-scan images of
inspected brazed joints.
2) The system of claim 1, further comprising at least one phased
array control unit in electrical communication with at least one
matrix phased array probe.
3) The system of claim 1, further comprising at least one monitor
for visually displaying the color coded ultrasonic C-scan images of
inspected joints in real time.
4) The system of claim 1, further comprising an enclosure, wherein
the enclosure is designed to be placed on a flat surface, and
wherein the enclosure includes: (a) at least one input for
connecting to the at least one matrix phased array probe; (b)
ultrasonic phased array transmitting and receiving circuitry in
electrical communication with the at least one input; and (c) at
least one external mount for supporting the matrix phased array
probe.
5) The system of claim 1, further comprising a locking member,
wherein the locking member is adapted to secure the at least one
tip to the at least one matrix phased array probe.
6) The system of claim 1, wherein the at least one matrix phased
array probe is a tow-dimensional probe and the array of ultrasonic
transducer elements is a 14.times.9 configuration.
7) The system of claim 1, wherein the tip is manufactured from a
thermoset cross-linked styrene copolymer.
8) The system of claim 1, wherein the item that includes a brazed
joint to be inspected is an electrical terminal that includes a
contact portion braze welded to a body portion.
9) A system for non-destructively inspecting brazed joints,
comprising: (a) a phased array control unit; (b) at least one
matrix phased array probe connected to the phased array control
unit, wherein the matrix phased array probe further includes: (i) a
plurality of ultrasonic transducer elements arranged in an array at
one end of the probe, wherein the transducer elements are operative
to both generate ultrasonic signals and to receive reflections
thereof; and (ii) at least one tip adapted to be removably mounted
over the array of ultrasonic transducer elements, wherein a region
of the at least one tip has been shaped to correspond to the
geometric characteristics of an item or a specific portion of an
item that includes a brazed joint to be inspected; (c) a processor
running software that includes at least one imaging algorithm for
processing data received from the at least one matrix phased array
probe and generating A-scans and color coded C-scan images of
inspected brazed joints; and (d) at least one monitor for visually
displaying the color coded ultrasonic C-scan images of inspected
joints in real time.
10) The system of claim 9, further comprising a locking member,
wherein the locking member is adapted to secure the at least one
tip to the at least one matrix phased array probe.
11) The system of claim 9, wherein the at least one matrix phased
array probe is a tow-dimensional probe and the array of ultrasonic
transducer elements is a 14.times.9 configuration.
12) The system of claim 9, wherein the tip is manufactured from a
thermoset cross-linked styrene copolymer.
13) The system of claim 9, wherein the item that includes a brazed
joint to be inspected is an electrical terminal that includes a
contact portion braze welded to a body portion.
14) The system of claim 9, wherein the processor is a laptop
computer.
15) A system for non-destructively inspecting brazed joints,
comprising: (a) a phased array control unit; (b) at least one
matrix phased array probe connected to the phased array control
unit, wherein the matrix phased array probe further includes: (i) a
plurality of ultrasonic transducer elements arranged in an array at
one end of the probe, wherein the transducer elements are operative
to both generate ultrasonic signals and to receive reflections
thereof; and (ii) at least one tip adapted to be removably mounted
over the array of ultrasonic transducer elements, wherein a region
of the at least one tip has been shaped to correspond to the
geometric characteristics of an item or a specific portion of an
item that includes a brazed joint to be inspected; (c) an
enclosure, wherein the enclosure includes: (i) at least one input
for connecting to the at least one matrix phased array probe; (ii)
ultrasonic phased array transmitting and receiving circuitry in
electrical communication with the at least one input; and (iii) at
least one external mount for supporting the matrix phased array
probe; (d) a processor running software that includes at least one
imaging algorithm for processing data received from the at least
one matrix phased array probe and generating A-scans and color
coded C-scan images of inspected brazed joints; and (e) at least
one monitor for visually displaying the color coded ultrasonic
C-scan images of inspected joints in real time.
16) The system of claim 15, further comprising a locking member,
wherein the locking member is a nut that is adapted to secure the
at least one tip to the at least one matrix phased array probe.
17) The system of claim 15, wherein the at least one matrix phased
array probe is a tow-dimensional probe and the array of ultrasonic
transducer elements is a 14.times.9 configuration.
18) The system of claim 15, wherein the tip is manufactured from a
thermoset cross-linked styrene copolymer.
19) The system of claim 15, wherein the item that includes a brazed
joint to be inspected is an electrical terminal that includes a
contact portion braze welded to a body portion.
20) The system of claim 15, wherein the processor is a laptop
computer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S.
Provisional Patent Application Ser. No. 62/091,869 filed on Dec.
15, 2015 and entitled "Matrix Phased Array System for Inspection of
Brazed Welds," the disclosure of which is hereby incorporated by
reference herein in its entirety and made part of the present U.S.
utility patent application for all purposes.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to inspection
systems for use in assessing the performance of industrial
manufacturing processes, and more specifically to a nondestructive
inspection system for assessing the quality of brazed joints and
fusion or solid state sheet metal joints.
[0003] Sheet metal joining processes are widely used in many
industries including the aerospace and automotive industries.
Resistance spot welding, seam welding, weld bonding, adhesive
joining, soldering, and brazing are used for various applications
in different industries. Among these processes, the brazing
procedure is used to join metal sheets where good electrical
conductivity, as well as mechanical and thermal strength, is
required from the joint. The quality control of such joining
processes has been recognized as an important issue to
manufacturers. The quality of brazed joints is affected by the
joining process itself and by the design of the joint. Many factors
are considered, including metallurgic reaction conditions; thermal
behaviors; chemical composition; starting condition of the base
metal; brazing and bonding conditions; and the particular brazing
and bonding equipment used during the process. Furthermore, the
intricate relationship between these factors makes it difficult to
control the quality of the brazed joint and difficult to inspect
the weld joint in a nondestructive manner. It is particularly
difficult to inspect on-line small areas such as electrical
contacts brazed to terminal or arm sheet metal conductors due to
the strong geometry and edge effects presented by such items.
[0004] Certain acoustic methods enable nondestructive testing of
welded parts that is useful for various inspection applications.
Unlike other nondestructive testing methods, acoustic methods
provide both surface and internal information about a particular
weld joint. Moreover, acoustic methods allow for deeper penetration
into test specimens and provide higher sensitivity regarding small
discontinuities that may be present in a weld joint. Acoustic
methods, however, do have limitations, including the requirement of
having a skilled and knowledgeable operator for using a test device
and then analyzing acoustic data derived from a test specimen.
Accordingly, the field of ultrasonic nondestructive evaluation
(NDE) is in need of a reliable process or technique for identifying
poor quality brazed joints in a manner that eliminates the
requirement of a skilled operator and the subjective interpretation
of test data.
SUMMARY OF THE INVENTION
[0005] The following provides a summary of certain exemplary
embodiments of the present invention. This summary is not an
extensive overview and is not intended to identify key or critical
aspects or elements of the present invention or to delineate its
scope.
[0006] In accordance with one aspect of the present invention, a
first system for non-destructively inspecting brazed welds or
brazed joints is provided. This system includes at least one matrix
phased array probe that further includes a plurality of ultrasonic
transducer elements, arranged in an array at one end of the probe,
that are operative to both generate ultrasonic signals and to
receive reflections thereof; and at least one tip adapted to be
removably mounted over the array of ultrasonic transducer elements,
wherein a region of the at least one tip has been shaped to
correspond to the geometric characteristics of an item or a
specific portion of an item that includes a brazed joint to be
inspected; and a processor running software that includes at least
one imaging algorithm for processing data received from the at
least one matrix phased array probe and generating A-scans and
color coded C-scan images of inspected brazed joints.
[0007] In accordance with another aspect of the present invention a
second system for non-destructively inspecting brazed welds or
brazed joints is provided. This system includes a phased array
control unit; at least one matrix phased array probe connected to
the phased array control unit, wherein the matrix phased array
probe further includes a plurality of ultrasonic transducer
elements, arranged in an array at one end of the probe, that are
operative to both generate ultrasonic signals and to receive
reflections thereof; and at least one tip adapted to be removably
mounted over the array of ultrasonic transducer elements, wherein a
region of the at least one tip has been formed or shaped to
correspond to the geometric characteristics of an item or a
specific portion of an item that includes a brazed joint to be
inspected; a processor running software that includes at least one
imaging algorithm for processing data received from the at least
one matrix phased array probe and generating A-scans and color
coded C-scan images of inspected brazed joints; and at least one
monitor for visually displaying the A-scans and color coded C-scan
images of inspected joints in real time.
[0008] In yet another aspect of this invention, a third system for
non-destructively inspecting brazed welds or brazed joints is
provided This system includes a phased array control unit; at least
one matrix phased array probe connected to the phased array control
unit, wherein the matrix phased array probe further includes a
plurality of ultrasonic transducer elements arranged in an array at
one end of the probe, wherein the transducer elements are operative
to both generate ultrasonic signals and to receive reflections
thereof; and at least one tip adapted to be removably mounted over
the array of ultrasonic transducer elements, wherein a region of
the at least one tip has been shaped to correspond to the geometric
characteristics of an item or a specific portion of an item that
includes a brazed joint to be inspected; an enclosure that may be
portable or that may be designed to be placed on a flat surface and
that includes at least one input for connecting to the at least one
matrix phased array probe; ultrasonic phased array transmitting and
receiving circuitry in electrical communication with the at least
one input; and at least one external mount for supporting the
matrix phased array probe; a processor running software that
includes at least one imaging algorithm for processing data
received from the at least one matrix phased array probe and
generating A-scans and color coded C-scan images of inspected
brazed joints; and at least one monitor for visually displaying the
A-scans and color coded ultrasonic C-scan images of inspected
joints in real time.
[0009] Additional features and aspects of the present invention
will become apparent to those of ordinary skill in the art upon
reading and understanding the following detailed description of the
exemplary embodiments. As will be appreciated by the skilled
artisan, further embodiments of the invention are possible without
departing from the scope and spirit of the invention. Accordingly,
the drawings and associated descriptions are to be regarded as
illustrative and not restrictive in nature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings, which are incorporated into and
form a part of the specification, schematically illustrate one or
more exemplary embodiments of the invention and, together with the
general description given above and detailed description given
below, serve to explain the principles of the invention, and
wherein:
[0011] FIG. 1 is an exploded view of a matrix phased array probe,
in accordance with an exemplary embodiment of the present
invention;
[0012] FIG. 2 is a side view of the matrix phased array probe of
FIG. 1, shown in its assembled state;
[0013] FIG. 3 is cross-sectional side view of the a matrix phased
array probe of FIG. 2;
[0014] FIG. 4 is a cross-sectional top view of a section of the
matrix phased array probe of FIG. 2 showing the tip and orientation
slot aspects of the matrix phased array probe;
[0015] FIG. 5 is a bottom view of an exemplary embodiment of the
matrix phased array probe of the present invention showing the
layout and appearance of the sensor array;
[0016] FIG. 6 is a schematic of the sensor array of the matrix
phased array probe of the present invention illustrating certain
relevant dimensions of the array;
[0017] FIG. 7 is a front view of the tip component of the present
invention;
[0018] FIG. 8 is a perspective view of the tip component of FIG.
7;
[0019] FIG. 9 rear view of the tip component of FIG. 7;
[0020] FIG. 10 is a side view of the tip component of FIG. 7;
[0021] FIG. 11 is a side view of the matrix phased array probe of
FIG. 2 in contact with a test specimen having a braze weld joint to
be analyzed;
[0022] FIG. 12 is a cross-sectional front view of the assembly of
FIG. 11;
[0023] FIG. 13 is a drawing of the matrix phased array NDE system
of the present invention;
[0024] FIG. 14 is a close-up drawing of the probe and bracket
components of the matrix phased array NDE system of FIG. 13;
and
[0025] FIG. 15 is a graphic illustration of an acoustic signal on a
C-scan (all elements) and an A-scan (single element) selected on
the C-scan.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Exemplary embodiments of the present invention are now
described with reference to the Figures. Although the following
detailed description contains many specifics for purposes of
illustration, a person of ordinary skill in the art will appreciate
that many variations and alterations to the following details are
within the scope of the invention. Accordingly, the following
embodiments of the invention are set forth without any loss of
generality to, and without imposing limitations upon, the claimed
invention.
[0027] The present invention provides a matrix phased array (MPA)
inspection system for non-destructive (NDE) evaluation of brazed
weld joint and other types of weld joints. The exemplary embodiment
of this inspection system shown in the Figures and described herein
uses high frequency (12 MHz) ultrasonic energy to determine the
area of lack of braze (LOB) in flat brazed contacts. This system
typically includes the following basic components; (i) a matrix
phased array probe; (ii) one or more removable tips that are
mounted on the probe during weld joint analysis; (iii) a phased
array unit to which the probe is connected; (iv) a processor
connected to the phased array unit and running specific software
for processing and analyzing data generated by the phased array
unit; and (v) a monitor for visualizing A-scans and C-scans
generated by the software. The phased array unit and other system
components associated with the phased array unit may be assembled
in an enclosure that includes a fixed bracket for holding the
matrix phased array probe during the evaluation of test
specimens.
[0028] FIGS. 1-4 provide various illustrative views of a matrix
phased array probe, in accordance with an exemplary embodiment of
the present invention. Matrix phased array (MPA) probe 20 includes
cylindrical probe housing 22, threaded region 24, sensor array 26,
and orientation pin 28. With reference to FIGS. 5-6, in this
embodiment, MPA probe 20 includes two-dimensional (2-D) matrix
array 26 having the following characteristics: (i) number of
channels (Nx.times.Ny): 14.times.9 elements; (ii) pitch in primary
axis (Px): 0.8 mm; (iii) pitch in secondary axis (Py): 1.0 mm; (iv)
inter-element spacing (IEx): 0.1 mm; (v) inter-element spacing
(IEy): 0.1 mm; (vi) element height: 0.9 mm; (vii) element width 0.7
mm; (viii) total active area (Lx.times.Ly): 11.1.times.8.9
mm.sup.2; (ix) center frequency: 12 MHz; and (x) acoustical
impedance matching (for tip 40): thermoset cross-linked styrene
copolymer tip (e.g., Rexolite.RTM.). In other embodiments, the
inter element spacing for IEx and IEy is about 0.5 mm.
[0029] As shown in FIGS. 10, an exemplary embodiment of plastic
cylindrical tip 40 includes base 42; orientation slot 44, which
cooperates with orientation pin 28 for properly aligning tip 40 on
the end of MPA probe 20; tip body 46, upon which various
identifying indicia may be placed; and recess 48, the geometry of
which has been adapted to match or closely cooperate with the shape
of a specific flat terminal contact that has been braze welded to a
terminal body. As shown in FIGS. 11-12, an exemplary part to be
inspected 100 includes terminal body 102 and terminal contact 104,
which has a specific geometry that corresponds to the geometry of
recessed area 48 in tip 40. During evaluation, probe 20 is inverted
and mounted within bracket 66, which is typically mounted on one
side of enclosure 60, as shown in FIGS. 13-14. Sensor array 26 is
coated with acoustic couplant gel, tip 40 is placed over sensor
array 26 on MPA probe 20, and locking member (nut) 50 is tightened
onto threaded region 24 to secure tip 40 to the tip of MPA probe
20. Part 100 is then positioned such that terminal contact 104 is
seated within recessed area 48 of tip 40. Phased array unit (PAU)
61 and sensor array 26 are then activated for the purpose
evaluating the braze weld between terminal body 102 and terminal
contact 104. Tip 40, and particular the shape and other geometric
characteristics of recessed area 48, which is formed in body 46 of
tip 40, may be modified to fit any number of different contacts (or
other structures) that a brazed welded to terminal bodies or other
items. Accordingly, a great many variants of tip 40 are
possible.
[0030] As shown in FIGS. 13-14, ultrasonic multi-channel cable 62
with Ipex connector 63 is used for connecting MPA probe 20 to
phased array unit 61 (32/128: Advanced OEM Solutions), which is
housed within enclosure 60. Suitable enclosures include Carlon.RTM.
types 1 and 2, and other components included in the enclosure
typically include a cooling fan (e.g., 4'' AC Brushless, 115 VAC,
Rotation Speed 2100 RPM, Airflow 65 CFM, 119.times.119.times.38 mm,
Mounting holes 4.2 mm.); a switch mode power supply (e.g.,
Model--ETSA240270UD; P/N--ETSA240270UDC-P5P-SZ;
Input--100-240V.about., 50-60 Hz, 1.5 A; Output--24V 2.7 A); and a
relocatable power tap (e.g., model UTPB 1115 (YLPT-22A); Maximum
Load--15 A, 125 VAC, 60 Hz). Serial cable 64 is used to connect
phased array unit 61 to processor 70, which is typically a laptop
or desktop computer that is connected to a monitor 90. Processor 70
runs software that that includes at least one imaging algorithm for
processing data received from MPA probe 20 and generating color
coded ultrasonic C-scan images of characterized brazed weld, as
well as other drivers to control phased array unit 61 and the data
acquisition process. An example of suitable imaging software is
SpotSight.RTM., which is available from EWI, Inc. (Columbus,
Ohio).
[0031] When inspection system 10 is in use, recessed area 48
centers terminal contact 104 with respect to the rectangular area
coverage of sensor array 26. Recessed area 48 permits slight
movements along the length and width thereof to maximize LOB
indications, if present. If an LOB indication is present that
exceeds a predetermined threshold on the A-scan, it will be imaged
in red color on the C-scan (see FIG. 15). Indications with
amplitude smaller than the predetermined threshold are imaged in
blue or other colors. The threshold is adjusted so that only the
area of the brazed joint 106 between terminal contact 104 and
terminal body 102 is tested and imaged. The elements of MPA probe
20 are interrogated in a predetermined sequence to cover the entire
area under the probe. The areas where the signal is larger than the
threshold are summed to determine the total LOB area. It is
displayed as absolute value in mm.sup.2 and relative percent (%) of
the region of interest (see FIG. 15). An area or region of interest
is specified for each terminal contact 104 as shown on the C-scan.
The MPA area coverage is designed for the largest contact area.
Other contacts 104 that are smaller in size are tested by selecting
an appropriate tip 40 and recessed area 48 that fits the contact
and adjusting the region of interest on the C-scan so that the same
probe can be used to test all contact sizes. A single percentage
LOB acceptance criterion can be specified for all contacts 104
regardless of their size. The C-scan image with measured LOB is
captured and stored for reporting purposes. A determination of weld
integrity is based on whether sound passes through the brazed weld
or not. Algorithms included in the SpotSight.RTM. software assist
in generating both an A-scan and a color (red/green/yellow)
representation of the welded region, which is a C-scan (see FIG.
15). Each part to be inspected 100 typically receives a custom tip
40 and some applications of this invention utilize a flexible probe
membrane.
[0032] Advantageously, exemplary embodiments of the system of the
present invention includes (i) a fixed sensor; (ii) numerous tips
with recessed areas or slots to guide and center various contacts;
(iii) regions of interest are specified on a C-scan; (iv) a single
sensor may be used for all contact sizes; (v) a region of interest
can also be used when several elements of the MPA probe are grouped
to focus and steer the ultrasonic beam for contacts that have
curved surfaces as opposed to flat contacts.
[0033] While the present invention has been illustrated by the
description of exemplary embodiments thereof, and while the
embodiments have been described in certain detail, it is not the
intention of the Applicant to restrict or in any way limit the
scope of the appended claims to such detail. Additional advantages
and modifications will readily appear to those skilled in the art.
Therefore, the invention in its broader aspects is not limited to
any of the specific details, representative devices and methods,
and/or illustrative examples shown and described. Accordingly,
departures may be made from such details without departing from the
spirit or scope of the applicant's general inventive concept.
* * * * *