Ultrasonic inspection using acoustic modeling

• US 8,909,492 B2
• Filed: 02/21/2011
• Issued: 12/09/2014
• Est. Priority Date: 07/07/2006
• Status: Active Grant

• Current Assignee: Sonix, Inc. (Fortive Corp.)
• Original Assignee: Sonix, Inc. (Fortive Corp.)
• Inventors: McKeon, James C. P.
• Primary Examiner(s): Desta, Elias
• Application Number:
  US13/031,340
• Publication Number:
  US 20110144935A1
• Time in Patent Office: 1,387 Days
• US Class Current: 702/66
• CPC Class Codes: G01N 2291/02854 Length, thickness
• CPC Class Codes: G01N 2291/044 Internal reflections (echoes), e.g. on walls or defects
• CPC Class Codes: G01N 2291/101 one transducer
• CPC Class Codes: G01N 29/043 in the interior, e.g. by shear waves
• CPC Class Codes: G01N 29/4418 with a model, e.g. best-fit, regression analysis
• CPC Class Codes: G01N 29/4472 Mathematical theories or simulation

Abstract

Configuration of an ultrasonic inspection system is facilitated using an ultrasound response predicted by a simulation tool. In one embodiment, estimated material properties of an object to be inspected are input to the simulation tool. Also input to the simulation tool is at least one estimated property of an ultrasonic transducer of the ultrasonic inspection. The simulation tool predicts the response of the object to ultrasound from the ultrasonic transducer. This response is dependent upon the estimated material properties of the object to be inspected and the at least one estimated property of the ultrasonic transducer. The ultrasonic inspection system is then configured dependent upon a feature of the predicted response. The system may be configured, for example, by setting the position of a time gate, selecting an appropriate ultrasonic transducer, selecting the position of the transducer to achieve good focus, or selecting parameters for signal processing.

Claims

1. A computerized method for characterizing properties of an object under inspection by an ultrasonic inspection system, the method comprising:

executing, by a processor, a software simulation tool to predict an ultrasonic wave scattered by the object under inspection from estimated properties of the object under inspection;

measuring an ultrasonic wave scattered by the object under inspection by the ultrasonic inspection system;

enabling a comparison of the predicted ultrasonic wave with the measured ultrasonic wave by;

displaying the predicted ultrasonic wave to a user of the software simulation tool; and

displaying the measured ultrasonic wave to the user of the software simulation tool;

responsive to user input, adjusting the estimated properties to improve the degree of match between the predicted ultrasonic wave and the measured ultrasonic wave; and

generating an output dependent upon the adjusted estimated properties.

2. A method in accordance with claim 1, wherein the object under inspection comprises a plurality of layers and wherein the properties of the object under inspection comprise the thickness of layers, the sound speed of the layers and the density of the layers.

3. A method in accordance with claim 1, wherein the object under inspection comprises a plurality of layers and wherein the properties of the object under inspection comprise the thickness of layers and the acoustic impedance of the layers.

4. A method in accordance with claim 1, wherein the properties of the object under inspection comprises the attenuation rate of ultrasound in the object under inspection.

5. A method in accordance with claim 1, wherein adjusting the estimated properties to improve the degree of match between the predicted ultrasonic wave and the measured ultrasonic wave comprises adjusting the estimated properties in response to the user of the software simulation tool inputting at least one new estimated property of the object.

6. A method in accordance with claim 1, wherein executing the software simulation tool to predict the ultrasonic wave scattered by the object under inspection from estimated properties of the object under inspection is responsive to the user of the software simulation tool selecting the estimated properties of the object via a user interface.

7. A method in accordance with claim 1, wherein predicting an ultrasonic wave, comparing the predicted ultrasonic wave with the measured ultrasonic wave and adjusting the estimated properties to improve the match between the predicted ultrasonic wave and the measured ultrasonic wave are performed by the software simulation tool.

11. A method in accordance with claim 1, wherein the object under inspection comprises a plurality of layers, wherein the estimated properties of the object under inspection comprise the thicknesses of the layers and acoustic properties of the layers, and wherein executing the software simulation tool on the processor to predict the ultrasonic wave scattered comprises predicting reflections of the ultrasonic wave at one or more material interface in the object under inspection.

12. A method in accordance with claim 1, wherein generating an output comprises determining configuration properties of the ultrasonic inspection system dependent upon the adjusted estimated properties, the configuration properties comprising one or more of:

a position of a time gate;

an ultrasonic transducer selection; and

a position of an ultrasonic transducer to achieve good focus.

13. A method in accordance with claim 1, further comprising:

presenting a first user interface to the user to enable the user to enter the estimated properties of the object to be inspected; and

presenting a second user interface to the user to enable the user to enter at least one property of an ultrasonic transducer,

wherein the software simulation tool is responsive to the estimated properties of the object to be inspected and the at least one property of an ultrasonic transducer.

8. A system for characterizing properties of an object under inspection, the system comprising:

a processor operable to execute a software simulation tool to predict an ultrasonic wave scattered by the object under inspection from estimated properties of the object;

an ultrasonic inspection system operable to measure an ultrasonic wave scattered by the object under inspection;

a display coupled to the processor and operable to display the predicted ultrasonic wave and the measured ultrasonic wave to a user of the software simulation tool; and

a user input device operable to receive user input;

wherein the system is operable to adjust the estimated properties of the object in response to the user input to improve the degree of match between the predicted ultrasonic wave and the measured ultrasonic wave.

9. The system of claim 8, wherein the software simulation tool of the system is operable to compare the predicted ultrasonic wave with the measured ultrasonic wave.

14. A system in accordance with claim 8, wherein the object under inspection comprises a plurality of layers, wherein the estimated properties of the object under inspection comprise the thicknesses of the layers, and acoustic properties of the layers, and wherein the software simulation tool is operable to predict reflections of the ultrasonic wave at one or more material interface in the object under inspection.

15. A system in accordance with claim 8, wherein a configuration of the ultrasonic inspection system is determined dependent upon the adjusted estimated properties of the object under inspection, the configuration comprising one or more of:

a position of a time gate;

an ultrasonic transducer selection; and

a position of an ultrasonic transducer to achieve good focus.

10. A non-transitory computer readable medium containing program instructions that, when executed on a processor, characterize properties of an object under ultrasonic inspection by:

a software simulation tool executed on the processor predicting an ultrasonic wave scattered by the object under inspection from estimated properties of the object;

measuring an ultrasonic wave scattered by the object under inspection on an ultrasonic inspection system;

enabling a comparison of the predicted ultrasonic wave with the measured ultrasonic wave by;

displaying the predicted ultrasonic wave to a user of the software simulation tool; and

displaying the measured ultrasonic wave to the user of the software simulation tool; and

responsive to user input, adjusting the estimated properties to improve the degree of match between the predicted ultrasonic wave and the measured ultrasonic wave.

16. A non-transitory medium in accordance with claim 10, wherein the object under inspection comprises a plurality of layers, wherein the estimated properties of the object under inspection comprise the thicknesses of the layers, and acoustic properties of the layers, and wherein the software simulation tool predicting the ultrasonic wave scattered by the object under inspection comprises the software simulation tool predicting reflections of the ultrasonic wave at one or more material interface in the object under inspection.