Manufacturing process or in service defects acoustic imaging using sensor array

• US 20050209791A1
• Filed: 03/04/2004
• Published: 09/22/2005
• Est. Priority Date: 03/04/2004
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Curry, Mark A., Banks, David L., Senibi, Simon D., Carrell, Chris K.
• Granted Patent: US 7,817,843 B2
• Time in Patent Office: Days
• US Class Current: 702/33
• CPC Class Codes: G01N 2291/0421 Longitudinal waves
• CPC Class Codes: G01N 2291/105 two or more emitters, two or more receivers
• CPC Class Codes: G01N 2291/106 one or more transducer arrays
• CPC Class Codes: G01N 29/041 on the surface of the material, e.g. using Lamb, Rayleigh or shear waves
• CPC Class Codes: G01N 29/0672 by acoustic tomography medical tomography A61B8/13

Abstract

A mobile platform is provided which has at least one component having an array of distributed piezoelectric transmitters and an associated array of distributed receivers. The receivers are configured to receive ultrasonic transmissions from the transmitters. Data from the receivers is stored in memory and processed through an algebraic reconstruction tomography algorithm which forms an image of the defect within the component. An algorithm is used to determine the position and size of the defect.

Claims

1. A system for evaluating the health of a component comprising:

a plurality of ultrasonic transmitters coupled to the component;

a plurality of sensors coupled to the component, the sensors configured to receive signals transmitted through the component from the transmitters;

a circuit configured to collect and store signals received by the sensors; and

a processor configured to receive the stored signals and process the signals to form an image of a defect within the component.

2. A system according to claim 1 wherein the processor is configured to perform an algebraic reconstruction tomography algorithm and wherein the algebraic reconstruction tomography algorithm functions to convert the received signals into a image of a defect within the component.

3. The system according to claim 1 wherein the system comprises a plurality of ultrasonic transducers.

4. The system according to claim 3 wherein the ultrasonic transducers are disposed within the component.

5. The system according to claim 3 wherein the ultrasonic transducers are coupled to an exterior surface of the component.

6. The system according to claim 3 wherein the component comprises an uncured reinforced thermoplastic composite.

7. The system according to claim 1 wherein the plurality of sensors and plurality of transmitters is an array of piezoelectric transducers.

8. The system according to claim 1 wherein the processor is configured to conduct an analysis on the received signals to form an image of a defect within the component.

9. The system according to claim 8 wherein the processor is configured to run an algebraic reconstruction tomography algorithm which analyzes the received signals to form the images.

10. The system according to claim 1 wherein the component comprises a cured thermoplastic composite.

11. The system according to claim 8 wherein the transducers are arranged in an array of generally equally spaced distances.

12. A system for analyzing the health of a reinforced composite structure, the system comprising:

a plurality of transceivers coupled to the reinforced structure;

a switch box coupled to the transceivers;

a processor coupled to the switch box, wherein the switch box is configured to recursively enable single transceivers to individually transmit a broad band vibrational pulse while the remaining transceivers are configured to receive the transmitted signal, said switch box further being configured to couple the transceivers to a processor, said processor being configured to receive the storage signals and process the signals to form an image of a defect within the component.

13. The system according to claim 12 wherein the transceivers are configured to produce an ultrasonic vibrational pulse.

14. The system according to claim 12 wherein the transceiver is a piezoelectric transceiver.

15. The system according to claim 12 wherein the processor is configured to run an algebraic reconstruction tomography algorithm.

16. The system according to claim 15 wherein the algorithm functions to convert the stored signals into the image.

17. A method of detecting a defect within a thermoplastic composite structure comprising:

operably coupling an array of ultrasonic transceivers to the thermoplastic structure, said array having a transmitting transceiver and a plurality of receiving transceivers;

recursively enabling each transceiver of the array to individually transmit a broad band vibrational pulse and record the transmitted pulse using the non-transmitting transceivers;

providing a processor configured to run an algebraic reconstruction tomography algorithm on the recorded pulse to form an image of the defect within the component; and

running the algebraic reconstruction tomography algorithm to form a first image of the defect.

18. The method according to claim 17 wherein the thermoplastic component is a uncured reinforced thermoplastic component.

19. The method according to claim 17 wherein the defect is a void.

20. The method according to claim 17 further including coupling the thermoplastic structure to a mobile platform.

21. The method according to claim 20 wherein running the algebraic reconstruction tomography algorithm is conducted after the component is coupled to the mobile platform.

22. The method according to claim 17 wherein the processor sets a counter to an initial condition for a counter less than a predetermined number of locations, and performs the following for the number of locations:

transmitting an ultrasonic signal from a single location, receiving a response signal at the remaining locations, and storing the received information in a plurality of memory locations; and

incrementing the counter.

23. The method according to claim 17 further comprising evaluating the image of the defect and taking corrective action should the image of the defect meet a predetermined criterion.

24. The method according to claim 17 further comprising storing data relating to the first image;

after a predetermined time, recursively enabling each transceiver of the array to individually transmit a second set of broadband vibrational pulses and recording the transmitted pulses using the non-transmitting transceivers;

running the algebraic reconstruction tomography algorithm to form a second image; and

comparing data related to the first image to data related to the second image.

25. A system for evaluating the health of a component comprising:

an array of ultrasonic transducers coupled to the component;

a means for coupling the ultrasonic transducers to processors;

a means for collecting and storing the signals received by the transducers; and

a means for analyzing the stored signals to produce data which corresponds to physical properties related to a defect within the component.

26. The system according to claim 25 wherein the data represents an image of the defect.