3D acoustic imaging using sensor array, longitudinal wave and algebraic reconstruction

• US 7,822,258 B2
• Filed: 11/15/2005
• Issued: 10/26/2010
• Est. Priority Date: 03/04/2004
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Banks, David L, Curry, Mark A, Senibi, Simon D, Carrell, Chris K
• Primary Examiner(s): Mehta; Bhavesh M
• Assistant Examiner(s): ZARKA, DAVID PETER
• Application Number:
  US11/274,863
• Publication Number:
  US 20060071668A1
• Time in Patent Office: 1,806 Days
• Field of Search: 382/141
• US Class Current: 382/141
• 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, the system comprising:

a reinforced matrix;

a plurality of piezoelectric transmitters coupled to the component configured to produce lamb waves in the component;

a plurality of sensors coupled to the component, the sensors configured to receive the lamb waves transmitted through the component from the piezoelectric transmitters; and

a circuit configured to collect and store the lamb waves received by the sensors, the circuit further configured to receive the lamb waves and process the lamb waves to form an image of a defect within the component; and

a processor configured to perform an algebraic reconstruction tomography algorithm and wherein the algebraic reconstruction tomography algorithm functions to convert the lamb waves into a image of a defect within the component, wherein the component comprises a composite material structure having a plurality of reinforced polymer layers, and wherein the plurality of sensors are disposed in a layer disposed between at least two reinforced polymer layers.

2. The system according to claim 1 wherein the piezoelectric transmitters comprise a plurality of piezoelectric transducers.

3. The system according to claim 2 wherein the piezoelectric transducers are disposed within the component.

4. The system according to claim 2 wherein the piezoelectric transducers are coupled to an exterior surface of the component.

5. The system according to claim 2 wherein the component comprises an uncured reinforced thermoplastic composite.

6. The system according to claim 2 wherein the plurality of piezoelectric transducers are arranged in an array of generally equally spaced distances.

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 component comprises first, second, third and fourth reinforced polymer layers, and wherein a first set of receivers is disposed between the first and second reinforced layers and wherein a second set of receivers is disposed between the third and fourth reinforced layers.

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

a reinforced matrix;

a plurality of piezoelectric transmitters coupled to the component configured to produce lamb waves in the component;

a plurality of sensors coupled to the component, the sensors configured to receive the lamb waves transmitted through the component from the piezoelectric transmitters; and

a circuit configured to collect and store the lamb waves received by the sensors, the circuit further configured to receive the lamb waves and process the lamb waves to form an image of a defect within the component; and

a processor configured to perform an algebraic reconstruction tomography algorithm and wherein the algebraic reconstruction tomography algorithm functions to convert the lamb waves into a image of a defect within the component, wherein the component comprises a cured thermoplastic composite.

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

a plurality of transceivers configured to send and receive lamb waves, said transceivers being disposed within the reinforced structure;

a switching component coupled to the transceivers;

a processor coupled to the switching component, wherein the switching component is configured to recursively enable a single transceiver to individually transmit the lamb wave in the form of a broad band vibrational pulse while at least one of the remaining transceivers is configured to receive the vibrational pulse, said switching component further being configured to couple the transceivers to a processor, said processor being configured to receive the lamb waves and process the lamb waves to form an image of a defect within the reinforced composite structure, wherein said composite structure has a plurality of reinforced polymer layers, and wherein the plurality of sensors are disposed between any two of the plurality of reinforced polymer layers.

11. The system according to claim 10 wherein the transceivers are configured to produce an ultrasonic vibrational pulse.

12. The system according to claim 10 wherein the transceivers are piezoelectric transceivers.

13. The system according to claim 10 wherein the processor is configured to run an algebraic reconstruction tomography algorithm.

14. The system according to claim 13 wherein the algorithm functions to convert the stored signals into the image.

15. The system according to claim 10 wherein the transceivers are located within a single plane in the reinforced structure.

16. The system according to claim 10 where the transceivers are located in a plurality of planes within the reinforced structure.

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

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

recursively enabling a plurality of transceivers of the array to individually transmit a broad band vibrational pulse and record the transmitted pulse using the receiving transceivers;

providing a processor configured to run an algebraic reconstruction tomography algorithm on the recorded pulse to form a first image of the defect within the thermoplastic composite structure;

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

storing data relating to the first image;

after a predetermined time, recursively enabling each of a plurality of transceivers of the array to individually transmit a second set of broad band vibrational pulses and recording the transmitted pulses using a plurality of 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 to evaluate a change in the defect.

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

19. The method according to claim 17 wherein the broad, band vibrational pulse is a lamb wave.

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

an array of piezoelectric transducers coupled to the component, the piezoelectric transducers configured to produce lamb waves;

a means for coupling the piezoelectric transducers to processors;

a means for collecting and storing the lamb waves received by the piezoelectric transducers; and

a means for performing an algebraic reconstruction tomography to convert the lamb waves into an image of a defect within the component, wherein the component comprises a composite material having a plurality of reinforced polymer layers, and wherein the plurality of sensors are disposed between any two of the plurality of reinforced polymer layers.

25. The system according to claim 24 wherein the lamb waves represent an image of the defect.

26. The method according to claim 24 wherein the array of piezoelectric transducers is disposed in a plurality of layers throughout the component.