Manually operated small envelope scanner system
Inventors
Assignees
Publication Number
US-9625421-B2
Publication Date
2017-04-18
Expiration Date
2034-04-16
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Abstract
A scanner system and method for acquisition of position-based ultrasonic inspection data are described. The scanner system includes an inspection probe and a first non-contact linear encoder having a first sensor and a first scale to track inspection probe position. The first sensor is positioned to maintain a continuous non-contact interface between the first sensor and the first scale and to maintain a continuous alignment of the first sensor with the inspection probe. The scanner system may be used to acquire two-dimensional inspection probe position data by including a second non-contact linear encoder having a second sensor and a second scale, the second sensor positioned to maintain a continuous non-contact interface between the second sensor and the second scale and to maintain a continuous alignment of the second sensor with the first sensor.
Core Innovation
The invention disclosed relates to a manually operated, small envelope scanner system and method for image inspection of an object using ultrasonic inspection or eddy current inspection probes. The scanner system includes an inspection probe and at least one non-contact linear encoder with a sensor and scale. The sensor is positioned to maintain a continuous non-contact interface with the scale and continuous alignment with the inspection probe, enabling acquisition of position-based inspection data correlated with imaging data.
The invention addresses problems associated with existing scanners which are complex, costly, require frequent maintenance, and have large spatial requirements making inspection of certain objects like thermal sleeves and welds in pipes impractical. Existing scanners typically require a minimum axial clearance of about 7 inches, limiting inspection capabilities for objects with limited access or complex shapes. Prior art scanners also either use motor-driven carriages with mechanical encoders or hand-operated devices that are not optimized for specific inspection scenarios.
The disclosed system solves these problems by providing a simpler, lower-cost scanner system that employs non-contact linear encoders to track probe position while fitting within a small spatial envelope (as little as approximately 2.125 inches clearance). The system can be configured as a single-axis or two-axis scanner, allowing acquisition of one-dimensional or two-dimensional position data correlated with ultrasonic or eddy current inspection data. The use of magnetic or optical non-contact linear encoders provides benefits such as greater misalignment tolerance, resistance to contaminants like oil or water, and protection of scales via protective foils, thereby extending utility and reliability in field inspection applications.
Claims Coverage
The patent discloses six main inventive features across two independent system claims and two independent method claims related to a scanner system and methods for image inspection using non-contact linear encoders.
Scanner system with non-contact linear encoder maintaining continuous non-contact interface and alignment
A scanner system comprising an inspection probe and a first non-contact linear encoder with a first sensor and first scale, where the first sensor is positioned to face the scale, maintain a continuous non-contact interface, be movable relative to the scale, and maintain continuous alignment with the inspection probe throughout the inspection.
Scanner system incorporating first track, first carriage, and probe mount to maintain alignment and interface
A scanner system including a first track with the first scale affixed, a first carriage to which the first sensor is affixed and movable along the track, and a probe mount connecting the carriage to the inspection probe to maintain continuous alignment and the non-contact interface during movement.
Scanner system with second non-contact linear encoder aligned perpendicularly to first for two-axis tracking
A scanner system further comprising a second non-contact linear encoder with second sensor and scale. The second sensor is positioned to face its scale, maintain a continuous non-contact interface and movement relative to the scale, and maintain continuous perpendicular alignment with the first sensor to enable two-axis position tracking.
Method for image inspection using a scanner system with one non-contact linear encoder
A method comprising moving an inspection probe on the object and generating a signal representing probe position by moving a first sensor along a first scale while maintaining continuous non-contact interface and alignment with the inspection probe during the movement.
Method for image inspection using a scanner system with two non-contact linear encoders
A method comprising generating signals representing position of the inspection probe on a first axis by moving a first sensor along a first scale with maintained non-contact interface and alignment, and on a second axis by moving a second sensor along a second scale perpendicularly aligned with the first sensor, also maintaining continuous non-contact interface.
The claims cover scanner systems and methods that utilize one or two non-contact linear encoders configured to maintain continuous non-contact interface and alignment with inspection probes and scales, enabling compact, precisely tracked ultrasonic or eddy current inspection with improved spatial accommodation and reduced complexity.
Stated Advantages
Reduced complexity and cost of scanner systems compared to existing motor driven and mechanically complex scanners.
Capability to operate within small spatial envelopes, fitting in constrained inspection locations with limited axial clearance (as little as 2.125 inches).
Use of magnetic non-contact linear encoders providing greater misalignment tolerance, resistance to oil and water contamination, and ability to protect scales with foils for extended lifetime.
Ability to obtain two-dimensional inspection probe position data, facilitating use with conventional ultrasonic and eddy current probes that scan in a single direction.
Rapid design and deployment of scanner systems at relatively low cost and lead time (e.g., less than two months and under $16,000 for single-axis systems).
Documented Applications
Inspection of welds on stainless steel pipes (e.g., 14-inch pipe with weld toes having limited clearance).
Inspection of thermal sleeves installed on pipes to detect stress corrosion cracking and fatigue cracks.
Periodic inspection and monitoring of fatigue cracks in welds in small diameter pipes (e.g., one-inch pipes) using two-axis scanning to track crack initiation and growth.
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