Apparatus and methods for non-destructive inspection using microwave sensing

• US 6,940,295 B2
• Filed: 06/11/2003
• Issued: 09/06/2005
• Est. Priority Date: 06/11/2003
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Fortner, David F., Engelbart, Roger W., Wood, Nancy L.
• Primary Examiner(s): Nguyen, Vincent Q.
• Application Number:
  US10/459,957
• Publication Number:
  US 20040251920A1
• Time in Patent Office: 818 Days
• Field of Search: 324637-642, 324/534, 324/633, 324/634, 324/700, 324/71.2, 324/643
• US Class Current: 324/700
• CPC Class Codes: G01N 22/02 Investigating the presence of flaws

Abstract

Apparatus and methods for materials inspection using microwave sensing are disclosed. In one aspect, a system for detecting corrosion of a workpiece includes a scanning assembly having a support assembly adapted to be coupled to the workpiece, and a first translation device coupled to the support assembly. A microwave sensor is coupled to the first translation device. The first translation device is adapted to translate the microwave sensor along at least a first direction, and the microwave sensor is adapted to transmit incident microwave signals onto the workpiece and to receive reflected microwave signals reflected from the workpiece. In an alternate aspect, a system may further include a second translation device that is adapted to translate the microwave sensor along at least a second direction that is transverse to the first direction.

Claims

1. A system for detecting corrosion of a workpiece, comprising:

a scanning assembly including;

a support assembly adapted to be coupled to the workpiece;

a first translation device coupled to the support assembly;

a microwave sensor coupled to the first translation device, wherein the first translation device is adapted to translate the microwave sensor along at least a first direction, and wherein the microwave sensor is adapted to transmit incident microwave signals on the workpiece and to receive reflected microwave signals reflected from the workpiece, and

a second translation device operatively coupled to at least one of the support assembly, the first translation device, and the microwave sensor, the second translation device being adapted to translate the microwave sensor along at least a second direction that is transverse to the first direction.

2. The system of claim 1, wherein the support assembly includes a track assembly adapted to be coupled to the workpiece, and wherein the first translation device includes a carriage assembly moveably coupled to the track assembly, and wherein the second translation device includes a bar scanner coupled to the carriage assembly.

3. The system of claim 1, wherein the first translation device includes a bar scanner adapted to translate the microwave sensor therealong.

4. The system of claim 1, wherein the first translation device includes a scan head having a motor adapted to translate the microwave sensor.

5. The system of claim 1, further including a control system operatively coupled to the scanning assembly, the control system having a processor and a memory device operatively coupled to the processor.

6. The system of claim 1, further including a control system operatively coupled to the scanning assembly, wherein the control system includes:

a computer having a processor and a memory device operatively coupled to the processor; and

an electronics chassis operatively coupled to the computer, the electronics chassis including at least one electronics card.

7. The system of claim 1, wherein the microwave sensor is adapted to operate within at least one of a Ka band, a V band, a U band, and a W band.

8. A system for detecting corrosion of a workpiece, comprising:

a scanning assembly including;

a support assembly adapted to be coupled to the workpiece;

a first translation device coupled to the support assembly; and

a microwave sensor coupled to the first translation device, wherein the first translation device is adapted to translate the microwave sensor along at least a first direction, and wherein the microwave sensor is adapted to transmit incident microwave signals onto the workpiece and to receive reflected microwave signals reflected from the workpiece,

wherein the support assembly includes a track assembly adapted to be coupled to the workpiece, and wherein the first translation device includes a carriage assembly moveably coupled to the track assembly.

9. A system for detecting corrosion of a workpiece, comprising:

a scanning assembly including;

a support assembly adapted to be coupled to the workpiece;

a first translation device coupled to the support assembly, wherein the first translation device includes a scan head having a motor adapted to translate the microwave sensor, and a wheel that rollably engages the workpiece, the scan head being adapted to activate the motor when the wheel is rolled on the workpiece; and

a microwave sensor coupled to the first translation device, wherein the first translation device is adapted to translate the microwave sensor along at least a first direction, and wherein the microwave sensor is adapted to transmit incident microwave signals onto the workpiece and to receive reflected microwave signals reflected from the workpiece.

10. A system for detecting corrosion of a workpiece, comprising:

a scanning assembly including;

a support assembly adapted to be coupled to the workpiece, wherein the support assembly includes at least one vacuum cup assembly adapted to be removeably coupled to the workpiece;

a first translation device coupled to the support assembly; and

a microwave sensor coupled to the first translation device, wherein the first translation device is adapted to translate the microwave sensor along at least a first direction, and wherein the microwave sensor is adapted to transmit incident microwave signals on the workpiece and to receive reflected microwave signals reflected from the workpiece.

11. The system of claim 10, wherein the support assembly further includes a vacuum source operatively coupled to the at least one vacuum cup assembly.

12. A system for conducting non-destructive inspections of a workpiece, comprising:

a control system; and

a data acquisition assembly operatively coupled to the control system, the data acquisition assembly including;

a scanning assembly adapted to translate the microwave sensor along at least a first direction; and

a microwave sensor assembly coupled to the scanning assembly and adapted to be positioned proximate the workpiece, the microwave sensor assembly being a further adapted to transmit incident microwave signals onto the workpiece and to receive reflected microwave signals reflected from the workpiece, and to transmit a test signal corresponding to the reflected microwave signals to the control system, wherein the scanning assembly includes;

a track assembly adapted to be coupled to the workpiece; and

a carriage assembly moveably coupled to the track assembly and to the microwave sensor assembly, the carriage assembly being adapted to translate along the track assembly in response to a first control signal from the control system.

13. The system of claim 12, wherein the scanning assembly further includes

a bar scanner coupled to the carriage assembly and to microwave sensor assembly, the bar scanner extending transversely to the track assembly and being adapted to translate the microwave sensor assembly along bar scanner in response to a second control signal from the control system.

14. The system of claim 12, wherein the scanning assembly includes a scan head having a motor adapted to translate the microwave sensor.

15. The system of claim 14, wherein the scan head includes a wheel that rollably engages the workpiece, the scan head being adapted to activate the motor when the wheel is rolled on the workpiece.

16. The system of claim 12, wherein the scanning assembly includes a support assembly coupled to the microwave sensor assembly, the support assembly including at least one vacuum cup assembly adapted to be removeably coupled to the workpiece.

17. The system of claim 16, wherein the scanning assembly further includes a vacuum source operatively coupled to the at least one vacuum cup assembly.

18. The system of claim 12, wherein the control system includes a processor and a memory device operatively coupled to the processor.

19. The system of claim 12, wherein the control system includes:

a computer having a processor and a memory device operatively coupled to the processor; and

an electronics chassis operatively coupled to the computer, the electronics chassis including at least one electronics card.

20. The system of claim 19, wherein the control system further includes a display device operatively coupled to at least one of the computer and the electronics chassis.

21. The system of claim 12, wherein the microwave sensor assembly includes a microwave sensor adapted to operate within at least one of a Ka band, a V band, a U band, and a W band.

22. A system for conducting non-destructive inspections of a workpiece, comprising:

a control system; and

a data acquisition assembly operatively coupled to the control system, the data acquisition assembly including;

a scanning assembly adapted to translate the microwave sensor along at least a first direction; and

a microwave sensor assembly coupled to the scanning assembly and adapted to be positioned proximate the workpiece, the microwave sensor assembly being further adapted to transmit incident microwave signals onto the workpiece and to receive reflected microwave signals reflected from the workpiece, and to transmit a test signal corresponding to the reflected microwave signals to the control system, wherein the scanning assembly includes;

a support assembly adapted to be coupled to the workpiece; and

a bar scanner coupled to the support assembly and to microwave sensor assembly, the bar scanner being adapted to translate the microwave sensor assembly along bar scanner in response to a second control signal from the control system.

23. A method for detecting corrosion of a workpiece, comprising:

providing a microwave sensor coupled to a first translation device of a scanning assembly adapted to translate the microwave sensor, including providing the microwave sensor coupled to a carriage assembly mounted on a track assembly;

coupling the scanning assembly to the workpiece, the microwave sensor being operatively positioned proximate the workpiece;

transmitting microwave energy onto the workpiece;

traversing the microwave sensor over the workpiece using the scanning assembly, including, traversing the microwave sensor along the track assembly using the carriage assembly; and

receiving reflected microwave energy reflected from the workpiece.

24. The method of claim 23, wherein transmitting microwave energy onto the workpiece includes transmitting microwave energy onto the workpiece, the microwave energy being within at least one of a Ka band, a V band, a U band, and a W band.

25. The method of claim 23, further including determining a corrosion characteristic based on the reflected microwave energy.

26. A method for detecting corrosion of a workpiece, comprising:

providing a microwave sensor coupled to a first translation device of a scanning assembly adapted to translate the microwave sensor, including providing the microwave sensor coupled to a bar scanner;

coupling the scanning assembly to the workpiece, the microwave sensor being operatively positioned proximate the workpiece;

transmitting microwave energy onto the workpiece;

traversing the microwave sensor over the workpiece using the scanning assembly, including, traversing the microwave sensor along the bar scanner; and

receiving reflected microwave energy reflected from the workpiece.

27. A method for detecting corrosion of a workpiece, comprising:

providing a microwave sensor coupled to a first translation device of a scanning assembly adapted to translate the microwave sensor, including providing the microwave sensor coupled to a scan head;

coupling the scanning assembly to the workpiece, the microwave sensor being operatively positioned proximate the workpiece;

transmitting microwave energy onto the workpiece;

traversing the microwave sensor over the workpiece using the scanning assembly, including, traversing the microwave sensor laterally across the scan head; and

receiving reflected microwave energy reflected from the workpiece.

28. The method of claim 27, wherein the scan head is adapted to rollably engage with the workpiece, and traversing the microwave sensor over the workpiece includes activating the traversing of the microwave sensor by rolling the scan head on the workpiece.

29. A method for detecting corrosion of a workpiece, comprising:

providing a microwave sensor coupled to a first translation device of a scanning assembly adapted to translate the microwave sensor;

coupling the scanning assembly to the workpiece, the microwave sensor being operatively positioned proximate the workpiece;

transmitting microwave energy onto the workpiece;

traversing the microwave sensor over the workpiece using the scanning assembly; and

receiving reflected microwave energy reflected from the workpiece wherein providing a microwave sensor coupled to a first translation device includes, providing a microwave sensor coupled to first and second translation devices, and wherein traversing the microwave sensor over the workpiece includes traversing the microwave sensor along a first direction using the first translation device, and traversing microwave sensor along a second direction using the second translation device, the first and second directions being transverse.

30. The method of claim 29, wherein the first translation device includes a carriage assembly mounted on a track assembly, and wherein the second translation device includes a bar scanner mounted on the carriage assembly.

31. A method for detecting corrosion of a workpiece, comprising:

providing a microwave sensor coupled to a first translation device of a scanning assembly adapted to translate the microwave sensor;

coupling the scanning assembly to the workpiece, the microwave sensor being operatively positioned proximate the workpiece, including applying a vacuum to secure the scanning assembly to the workpiece;

transmitting microwave energy onto the workpiece;

traversing the microwave sensor over the workpiece using the scanning assembly; and

receiving reflected microwave energy reflected from the workpiece.