Ultrasonic modeling for inspection of composite irregularities

• US 8,965,100 B2
• Filed: 01/20/2012
• Issued: 02/24/2015
• Est. Priority Date: 01/20/2012
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Lin, John Z., Tat, Hong, Bossi, Richard H.
• Primary Examiner(s): Rahmjoo, Mike
• Application Number:
  US13/355,100
• Publication Number:
  US 20130188858A1
• Time in Patent Office: 1,131 Days
• Field of Search: 382/141, 382/144, 382/145, 382/149, 382/286, 382/291, 382/152
• US Class Current: 382/141
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/2694 Wings or other aircraft parts
• CPC Class Codes: G01N 29/043 in the interior, e.g. by shear waves
• CPC Class Codes: G01N 29/0654 Imaging
• CPC Class Codes: G01N 29/4427 with stored values, e.g. threshold values
• CPC Class Codes: G01N 29/4454 Signal recognition, e.g. specific values or portions, signal events, signatures
• CPC Class Codes: G01N 29/4472 Mathematical theories or simulation

Abstract

A first simulated inspection is conducted to provide a first waveform data set associated with the at least one irregularity parameter. The first simulated inspection is conducted using a first evaluation setting. A first image is produced based on the first waveform set, and it is determined whether a quality of the first image satisfies a predetermined threshold.

Claims

1. A method for use in inspecting a composite structure, said method comprising:

generating a virtual model of the composite structure;

defining at least one irregularity parameter;

conducting a first simulated inspection of the virtual model with a modeling module configured to transmit at least one simulated wave towards the virtual model to provide a first non-transitory waveform data set associated with the at least one irregularity parameter, wherein the first simulated inspection is conducted using a first evaluation setting that facilitates forming the at least one simulated wave;

producing a first image based on the first non-transitory waveform data set;

determining whether a quality of the first image satisfies a predetermined image quality threshold that would enable inspection of the composite structure for irregularities including wrinkles; and

using the first evaluation setting to conduct a physical inspection of the composite structure with a stimulating mechanism if the first image satisfies the predetermined image quality threshold, wherein the stimulating mechanism uses the first evaluation-setting to transmit at least one physical wave towards the composite structure to detect irregularities in the composite structure.

2. A method in accordance with claim 1 further comprising identifying the first evaluation setting as an evaluation setting for use in conducting the physical inspection, wherein the first evaluation setting includes at least one of a stimulation source, a stimulation source beam width, a distance between the at least one stimulating mechanism and the composite structure, and a distance between the at least one stimulating mechanism and a sensor.

3. A method in accordance with claim 1 further comprising:

conducting a second simulated inspection of the virtual model to provide a second non-transitory waveform data set associated with the at least one irregularity parameter, wherein the second simulated inspection is conducted using a second evaluation setting that is different from the first evaluation setting, wherein the quality of the first image does not satisfy the predetermined threshold;

producing a second image based on the second non-transitory waveform data set;

determining that a quality of the second image satisfies a predetermined threshold; and

conducting the physical inspection also using the second evaluation setting.

4. A method in accordance with claim 1 further comprising generating at least one model based on the at least one irregularity parameter, wherein the model is a graphical representation of the at least one irregularity parameter.

5. A method in accordance with claim 1, wherein defining at least one irregularity parameter further comprises defining at least one irregularity parameter including at least one of an irregularity thickness, an irregularity width, an irregularity length, an irregularity location, and an irregularity shape.

6. A method in accordance with claim 1 further comprising defining at least one composite structure parameter including at least one of an outer ply thickness, an inner ply thickness, a number of plies, a ply layup, a composite structure thickness, a material used to fabricate at least a portion of the at least one composite structure, a number of element layers per ply, a resin thickness, and a resin density.

7. A method in accordance with claim 1 further comprising defining at least one stimulation parameter including at least one of a type of stimulating mechanism, a beam width, a wave mode, a relative orientation of at least one stimulating mechanism with respect to the composite structure, a distance between the at least one stimulating mechanism and the composite structure, a distance between the at least one stimulating mechanism and a sensor, an impulse shape and center frequency, a couplant, and a couplant thickness.

8. A computer-readable storage device having encoded thereon computer readable instructions that are executable by a processor to perform functions comprising:

conducting a first simulated inspection of a virtual model of a composite structure using a modeling module configured to transmit at least one simulated wave towards the virtual model to provide a first non-transitory waveform data set associated with at least one irregularity parameter, wherein the first simulated inspection is conducted using a first evaluation setting that facilitates forming the at least one simulated wave;

producing a first image based on the first non-transitory waveform set;

determining whether a quality of the first image satisfies a predetermined image quality threshold that would enable inspection of the composite structure for irregularities including wrinkles; and

identifying the first evaluation setting as an evaluation setting for use in conducting a physical inspection of the composite structure with a stimulating mechanism if the first image satisfies the predetermined image quality threshold; and

directing the stimulating mechanism, using the first evaluation setting, to transmit at least one physical wave towards the composite structure to detect irregularities in the composite structure.

9. A computer-readable storage device in accordance with claim 8, wherein the functions performed by the processor further comprise identifying the first evaluation setting as an evaluation setting for use in conducting the physical inspection, wherein the first evaluation setting includes at least one of a stimulation source, a stimulation source beam width, a distance between the at least one stimulating mechanism and the composite structure, and a distance between the at least one stimulating mechanism and a sensor.

10. A computer-readable storage device in accordance with claim 8, wherein the functions performed by the processor further comprise:

conducting a second simulated inspection of the virtual model to provide a second non-transitory waveform data set associated with the at least one irregularity parameter, wherein the second simulated inspection is conducted using a second evaluation setting that is different from the first evaluation setting, wherein the quality of the first image does not satisfy the predetermined threshold;

producing a second image based on the second non-transitory waveform data set;

determining that a quality of the second image satisfies a predetermined threshold; and

conducting the physical inspection using the second evaluation setting.

11. A computer-readable storage device in accordance with claim 8, wherein the functions performed by the processor further comprise generating at least one model based on the at least one irregularity parameter, wherein the model is a graphical representation of the at least one irregularity parameter.

12. A computer-readable storage device in accordance with claim 8, wherein the functions performed by the processor further comprise defining at least one irregularity parameter including at least one of an irregularity thickness, an irregularity width, an irregularity length, an irregularity location, and an irregularity shape.

13. A computer-readable storage device in accordance with claim 8, wherein the functions performed by the processor further comprise defining at least one composite structure parameter including at least one of an outer ply thickness, an inner ply thickness, a number of plies, a ply layup, a composite structure thickness, a material used to fabricate at least a portion of the at least one composite structure, a number of element layers per ply, a resin thickness, and a resin density.

14. A computer-readable storage device in accordance with claim 8, wherein the functions performed by the processor further comprise defining at least one stimulation parameter including at least one of a type of stimulating mechanism, a beam width, a wave mode, a relative orientation of at least one stimulating mechanism with respect to the composite structure, a distance between the at least one stimulating mechanism and the composite structure, a distance between the at least one stimulating mechanism and a sensor, an impulse shape and center frequency, a couplant, and a couplant thickness.

15. A system comprising:

an ultrasonic modeling module configured to transmit at least one simulated wave towards a virtual model of a composite structure to conduct a first simulated inspection of the virtual model such that a first non-transitory waveform data set associated with at least one irregularity parameter is provided, wherein the first simulated inspection is conducted using a first evaluation setting that facilitates forming the at least one simulated wave; and

a virtual imaging module configured to produce a first image based on the first non-transitory waveform data set, configured to determine whether a quality of the first image satisfies a predetermined image quality threshold that would enable a physical inspection of the composite structure for irregularities including wrinkles to be conducted, and configured to identify the first evaluation setting as a desired evaluation setting for conducting the physical inspection of a composite structure to detect irregularities in the composite structure if the first image satisfies the predetermined image quality threshold.

16. A system in accordance with claim 15 further comprising an evaluating module configured to identify the first evaluation setting as an evaluation setting for use in conducting the physical inspection, wherein the first evaluation setting includes at least one of a stimulation source, a stimulation source beam width, a distance between the at least one stimulating mechanism and the composite structure, and a distance between the at least one stimulating mechanism and a sensor.

17. A system in accordance with claim 15, wherein the ultrasonic modeling module is further configured to conduct a second simulated inspection of the virtual model to provide a second non-transitory waveform data set associated with the at least one irregularity parameter, the virtual imaging module is further configured to produce a second image based on the second non-transitory waveform data set, and determine that a quality of the second image satisfies a predetermined threshold, and the system further comprises an evaluating module configured to identify a second evaluation setting, wherein the second simulated inspection is conducted using the second evaluation setting that is different from the first evaluation setting, wherein the quality of the first image does not satisfy the predetermined threshold.

18. A system in accordance with claim 15, wherein the ultrasonic modeling module is further configured to generate at least one model based on the at least one irregularity parameter, wherein the model is a graphical representation of the at least one irregularity parameter.

19. A system in accordance with claim 15, wherein the ultrasonic modeling module is further configured to define at least one irregularity parameter including at least one of an irregularity thickness, an irregularity width, an irregularity length, an irregularity location, and an irregularity shape, and define at least one composite structure parameter including at least one of an outer ply thickness, an inner ply thickness, a number of plies, a ply layup, a composite structure thickness, a material used to fabricate at least a portion of the at least one composite structure, a number of element layers per ply, a resin thickness, and a resin density.

20. A system in accordance with claim 15, wherein the ultrasonic modeling module is further configured to define at least one stimulation parameter including at least one of a type of stimulating mechanism, a beam width, a wave mode, a relative orientation of at least one stimulating mechanism with respect to the composite structure, a distance between the at least one stimulating mechanism and the composite structure, a distance between the at least one stimulating mechanism and a sensor, an impulse shape and center frequency, a couplant, and a couplant thickness.