DEFECT DETECTION USING ULTRASOUND SCAN DATA

• US 20190323993A1
• Filed: 06/28/2019
• Published: 10/24/2019
• Est. Priority Date: 03/29/2017
• Status: Active Grant

• Current Assignee: Fujitsu Limited
• Original Assignee: Fujitsu Limited
• Inventors: MENDES RODRIGUES, Eduarda, GEORGESCU, Serban
• Granted Patent: US 11,467,128 B2
• Time in Patent Office: Days
• CPC Class Codes: G01N 2291/0289 Internal structure, e.g. defects, grain size, texture
• CPC Class Codes: G01N 2291/044 Internal reflections (echoes), e.g. on walls or defects
• CPC Class Codes: G01N 29/069 Defect imaging, localisation and sizing using, e.g. time of flight diffraction [TOFD], synthetic aperture focusing technique [SAFT], Amplituden-Laufzeit-Ortskurven [ALOK] technique
• CPC Class Codes: G01N 29/11 by measuring attenuation of acoustic waves
• CPC Class Codes: G01N 29/38 by time filtering, e.g. using time gates
• CPC Class Codes: G01N 29/40 by amplitude filtering, e.g. by applying a threshold or by gain control
• CPC Class Codes: G01N 29/4454 Signal recognition, e.g. specific values or portions, signal events, signatures
• CPC Class Codes: G01N 29/449 Statistical methods not provided for in G01N29/4409, e.g. averaging, smoothing and interpolation

Abstract

A defect detection method and apparatus detecting a defect in an object. The method comprises: obtaining ultrasound scan data derived from an ultrasound scan of the object under consideration, the ultrasound scan data being in the form of a set of echo amplitude values representing the amplitude of echoes received from the object during ultrasound scanning at certain spatial and temporal points; processing the ultrasound scan data to remove echo amplitude values received after a predetermined threshold time; generating at least one image from the processed ultrasound scan data; subjecting each generated image to an automated defect recognition process to determine whether there is a defect in the portion of the object represented by the image; issuing a notification indicating whether or not a defect has been found; and, if a defect has been found, storing the result of the automated defect recognition process in a defect database.

Claims

1. A method of detecting a defect in an object, comprising:

obtaining ultrasound scan data derived from an ultrasound scan of the object under consideration, the ultrasound scan data being in a form of a set of echo amplitude values representing amplitude of echoes received from the object during ultrasound scanning at certain spatial and temporal points;

processing the ultrasound scan data to remove echo amplitude values received after a predetermined threshold time;

generating at least one image from the processed ultrasound scan data;

subjecting the generated at least one image to an automated defect recognition process to determine whether there is a defect in a portion of the object represented by the image;

issuing a notification indicating whether a defect has been found; and

storing, provided the defect has been found, a result of the automated defect recognition process in a defect database.

2. A method as claimed in claim 1, further comprising:

dividing the set of echo amplitude values into a plurality of sub-sets before the processing of the ultrasound scan data, and

wherein the processing of the ultrasound scan data includes removing the echo amplitude values received after the predetermined threshold time from the plurality of sub-sets.

3. A method as claimed in claim 2, wherein the processing of the ultrasound scan data further includes determining a value of the predetermined threshold time to be used.

4. A method as claimed in claim 3, wherein the determining of the value of the predetermined threshold time comprises:

for a sub-set among the plurality of sub-sets, deriving from amplitude values in the sub-set a vector including a representative amplitude value for each time point in the sub-set;

identifying in the vector an end time point of a largest sequence of positive representative amplitude values; and

selecting, from amongst all end time points identified for other vectors, the end time point with a greatest value, or a value calculated using that end time point, as the value of the predetermined threshold time.

5. A method as claimed in claim 4, wherein the deriving the vector comprises applying a mathematical function including an aggregation function, to amplitude values in the sub-set which correspond to echoes received at the same time.

6. A method as claimed in claim 5, wherein the mathematical function further comprises a smoothing function.

7. A method as claimed in claim 1, wherein the object under consideration is at least one of:

a manufactured object; and

an object used in manufacture.

8. A method as claimed in claim 1, further comprising using a defect detected in the object to determine at least one of:

a structural integrity of material forming at least part of the object; and

flaws in material forming at least part of the object.

9. A non-transitory computer readable medium having stored therein a computer program which, when run on a computer, causes the computer to carry out a method as claimed in claim 1.

10. An apparatus to detect a defect in an object, comprising:

an ultrasound scan data processor to process ultrasound scan data derived from an ultrasound scan of the object under consideration, the ultrasound scan data being in a form of a set of echo amplitude values representing amplitude of echoes received from the object during ultrasound scanning at certain spatial and temporal points, the ultrasound scan data processor operating to implement at least;

an amplitude filter to remove from the ultrasound scan data echo amplitude values received after a predetermined threshold time; and

an image generator to generate at least one image from filtered ultrasound scan data; and

a defect detector to perform the generated at least one image an automated defect recognition process to determine whether there is a defect in a portion of the object represented by the image, issue a notification indicating whether a defect has been found, and store a result of the automated defect recognition process in a defect database provided the defect has been found.

11. Apparatus as claimed in claim 10, wherein the ultrasound scan data processor further operating to implement:

a data sub-set creator to divide the set of echo amplitude values into a plurality of sub-sets before the processing of the ultrasound scan data by the amplitude filter, wherein the amplitude filter removes the echo amplitude values received after the predetermined threshold time from the plurality of sub-sets.

12. Apparatus as claimed in claim 11, wherein the ultrasound scan data processor further operating to implement a threshold determiner to determine a value of the predetermined threshold time to be used.

13. Apparatus as claimed in claim 12, wherein the threshold determiner determines the value of the threshold time to be used by:

for a sub-set among the plurality of sub-sets, deriving from amplitude values in the sub-set a vector including a representative amplitude value for each time point in the sub-set;

identifying in the vector an end time point of a largest sequence of positive representative amplitude values; and

selecting, from amongst all end time points identified for other vectors, the end time point with a greatest value, or a value calculated using that end time point, as the value of the predetermined threshold time.

14. Apparatus as claimed in claim 13, wherein the threshold determiner derives a vector by applying a mathematical function including an aggregation function, to amplitude values in the sub-set which correspond to echoes received at the same time.

15. Apparatus as claimed in claim 14, wherein the mathematical function further comprises a smoothing function.