Cylindrical ultrasonic scanning apparatus
Inventors
Jack, David A. • Blandford, Benjamin M. • Ravindranath, Pruthul Kokkada • Blackman, Nathaniel J. • Pulipati, Daniel • Gravagne, Ian
Assignees
Baylor University • Verifi Technologies LLC
Publication Number
US-11835484-B2
Publication Date
2023-12-05
Expiration Date
2041-06-29
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Abstract
An apparatus for scanning a cylindrical part is provided. The apparatus includes an ultrasonic transducer operable to emit ultrasonic waves into and receive ultrasonic waves from the part, with the ultrasonic transducer connected to a translation stage to move it up and down the part and around the circumference of the part. The apparatus does not mechanically contact the cylindrical or maintains contact only with soft elements, such that the apparatus does not damage sensitive parts. The apparatus also contains no magnetic parts, nor any elements that rely on magnetic detection, such that the apparatus is capable of being used in the vicinity of a part exhibiting a strong magnetic field.
Core Innovation
The invention provides an apparatus for ultrasonic non-destructive testing, specifically designed for scanning cylindrical or tubular parts. The system incorporates at least one ultrasonic transducer housed within a fluid-filled chamber, which is attached to a scanner support structure. The scanner is operable to scan the side wall of a test object, such as a cylindrical component, without mechanically contacting the object or only contacting it with soft elements.
A central challenge addressed by the invention is the need to scan sensitive cylindrical parts, especially in environments with strong magnetic fields, where prior art solutions that use clamp-based attachments, contact mechanisms, or magnetic components are unsuitable. The apparatus leverages a support structure to position and move the ultrasonic transducers axially and circumferentially around the part, maintaining a constant distance and orientation relative to the surface, and thereby providing high-resolution and interpretable scan data without damaging sensitive materials or requiring immersion tanks.
The system avoids ferromagnetic materials and magnetic detection elements, enabling its use near components exhibiting strong magnetic fields. Features such as robotic arms, optical encoders, and gel applicators may be included to facilitate operation, positioning, and acoustic coupling. The apparatus can use spherically focused transducers within fluid chambers, allowing precise, high-frequency inspection while eliminating the need for direct physical coupling or continuous water streams.
Claims Coverage
There are three independent claims in this patent, each introducing a distinct inventive feature for non-destructive testing of cylindrical parts.
Non-destructive scanner with fluid-coupled transducer and non-contact operation
A system consisting of: - At least one scanner support. - At least one transducer housing assembly featuring an interior fluid-filled chamber attached to the scanner support. - A support apparatus capable of supporting and rotating at least one test object about its central axis. - The chamber contains an ultrasonic transducer able to emit and receive ultrasonic waves from the test object. - An elongate member connected to the ultrasonic transducer, extending through an opening in the transducer housing, where rotating the elongate member moves the ultrasonic transducer relative to the housing. - The system is operable to scan at least a portion of the side wall of the test object without mechanically contacting the side wall.
Non-destructive scanner with integrated gel applicator for cylindrical objects
A system consisting of: - At least one scanner support. - At least one transducer housing assembly with an interior fluid-filled chamber attached to the scanner support. - A support apparatus operable to rotate at least one test object about its central axis. - At least one gel applicator positioned near the test object, operable to apply acoustic gel to its external surface. - The chamber includes an ultrasonic transducer that emits and receives ultrasonic waves from the test object. - An elongate member connected to the ultrasonic transducer, extending through the housing and allowing movement of the transducer by rotation. - The gel applicator, scanner support, and relevant elements cooperate to maintain acoustic coupling without direct mechanical contact.
Phased array scanner system with stabilization wheel for rotating cylindrical objects
A system consisting of: - At least one scanner support. - A phased array apparatus of ultrasonic transducers attached to the scanner support, at least one of which is housed within an interior fluid-filled chamber. - A support apparatus capable of rotating at least one test object about its central axis, with at least one support bar connected to an attachment point on the test object. - At least one stabilization wheel attached to the scanner support, which contacts the outer surface of the test object. - An elongate member connected to at least one ultrasonic transducer in the housing assembly. - The elongate member extends through the housing and allows movement of the transducer inside the assembly by rotation.
The inventive features cover non-contact ultrasonic scanning using fluid-coupled transducers, integrated gel application for acoustic coupling, phased array configurations for comprehensive inspection, and avoidance of ferromagnetic components. The systems enable high-resolution, non-destructive testing of cylindrical objects without damage or interference from magnetic fields.
Stated Advantages
Permits ultrasonic scanning of sensitive cylindrical parts without mechanical contact, reducing the risk of damage to delicate surfaces.
Allows operation in strong magnetic fields by excluding magnetic and ferromagnetic components and encoders.
Eliminates the need for immersion tanks or constant water coupling, enabling safer inspection of parts sensitive to water exposure.
Provides high-resolution and interpretable scan data through consistent distance and orientation maintenance between transducer and part surface.
Supports rapid scanning of the full length and circumference of large cylindrical parts, and can handle parts of different sizes.
Utilizes spherically focused ultrasonic transducers in fluid-filled chambers for improved spatial resolution without immersion.
Documented Applications
Non-destructive ultrasonic testing and scanning of cylindrical or tubular parts, including those with sensitive outer coatings such as carbon fiber layers.
Inspection of parts in environments exhibiting strong magnetic fields, such as components of electric motors.
Generation of three-dimensional and two-dimensional representations of part thickness, material characteristics, ply orientation, wrinkles, foreign objects, and delamination using ultrasonic scan data.
Use with axially symmetric parts requiring high-resolution, non-contact assessment without the hazards associated with water immersion or mechanical clamping.
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