JP2017509873A - Portable matrix phased array spot weld inspection system - Google Patents

Abstract

A portable system for non-destructive characterization of spot welds, including at least one matrix phased array probe and a body, the body being designed to be portable and ergonomically designed An outer casing, at least one input for connection to at least one matrix phased array probe, an ultrasonic phased array transceiver circuit in electrical communication with the at least one input, and processing data received from the probe; A touch screen computer further comprising at least one data processor executing software including at least one image algorithm for generating a color-coded ultrasonic C-scan image of the characterized weld, and the characterized weld Color-coded ultrasonic C scan Further comprising at least one monitor for displaying the images in real time.

Description

Cross-reference of related applications
[0001] This patent application claims the benefit of US Provisional Patent Application No. 61 / 484,312 entitled "Three-Dimensional Matrix Phased Spot Weld Inspection System" filed on May 10, 2011, 2012. Which is a continuation-in-part of US patent application Ser. No. 13 / 468,502, entitled “3-D Matrix Phased Spot Weld Inspection System” filed on May 10, Is incorporated herein and made a part of this US utility patent application for all purposes.

  [0002] The present invention relates generally to inspection systems used in evaluating the performance of industrial manufacturing processes, and more particularly to non-destructive inspection systems for evaluating the quality of resistance spot welds and other weld joints.

  [0003] Sheet metal joining processes are widely used in many industries, including the aerospace and automotive industries. Among these processes, resistance spot welding is a very common procedure used to join metal sheets because it has a high process speed and is easily adopted in mass production lines. . Seam welding, weld bonding, adhesive bonding, soldering and brazing have also been accepted. Quality control of such joining processes has been recognized as an important issue for manufacturers. The quality of welded joints is influenced by the joining process itself and by the joint design. Many factors are considered, including metallurgical reactions, thermal behavior, chemical composition, matrix initiation conditions, welding and bonding conditions, and welding and bonding equipment used during the process. Furthermore, the complex relationship between these factors makes it difficult to control the quality of the welded joint and to inspect the welded joint in a non-destructive manner.

  [0004] The acoustic method is a commonly used non-destructive testing method for various inspection applications. Unlike other nondestructive testing methods, acoustic methods provide both surface and interior information. Moreover, the acoustic method allows for deeper penetration into the specimen and higher sensitivity to small discontinuities in the weld joint. However, the acoustic method has limitations. The most serious limitation is the need to identify unsuitable welds such as unfused or cold welds or kissing bonds in addition to the requirements of skilled workers using test equipment and analyzing acoustic data Including subjective properties. Therefore, the field of ultrasonic non-destructive evaluation (NDE) requires a reliable process or technique for identifying defective joints in a manner that eliminates the involvement of skilled workers and subjective interpretation of test data.

  One embodiment of the present invention relates to a portable matrix phased array spot weld inspection system, for example.

  [0005] The following provides an overview of certain exemplary embodiments of the invention. This summary is not an extensive overview and is not intended to identify key or critical aspects or elements of the invention or to delineate its scope.

  [0006] According to one aspect of the present invention, a first portable system for non-destructively characterizing a spot weld is provided. The system includes at least one matrix phased array probe and a body. A matrix phased array probe operates to generate an ultrasonic signal and receive its reflections, a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe, and test conditions A combination of materials that allows the probe to conform to the contoured surface of the spot weld while allowing sound energy to be transmitted directly into the lower spot weld, and is attached to the end of the probe And a combination of materials further including a fluid-filled chamber or a solid sound delay material placed between the membrane and the array. The body is designed to be portable and ergonomically designed outer casing, at least one input for connection to at least one matrix phased array probe, and at least one input and telecommunications An ultrasonic phased array transceiver circuit for executing and software including at least one image algorithm for processing data received from the probe and generating a color-coded ultrasonic C-scan image of the weld to be characterized A touch screen computer further including at least one data processor and at least one monitor for displaying in real time a color-coded ultrasonic C-scan image of the weld to be characterized.

  [0007] According to another aspect of the invention, a second portable system for non-destructively characterizing a spot weld is provided. The system also includes at least one matrix phased array probe and body. A matrix phased array probe operates to generate an ultrasonic signal and receive its reflections, a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe, and test conditions A combination of materials that allows the probe to conform to the contoured surface of the spot weld while allowing sound energy to be transmitted directly into the lower spot weld, and is attached to the end of the probe And a combination of materials further including a fluid-filled chamber or a solid sound delay material placed between the membrane and the array. The body is designed to be portable and has an ergonomically designed outer casing having a handle adapted to receive a matrix phased array probe, and at least one input for connection to the probe An ultrasonic phased array transceiver circuit in electrical communication with at least one input; and at least one for processing data received from the probe and generating a color-coded ultrasonic C-scan image of the weld to be characterized A touch screen computer further comprising at least one data processor executing software including one image algorithm, at least one monitor for displaying in real time a color coded ultrasound C-scan image of the weld to be characterized, With at least one rechargeable battery To include.

  [0008] In yet another aspect of the present invention, a third portable system for non-destructively characterizing a spot weld is provided. The system also includes at least one matrix phased array probe and body. A matrix phased array probe is a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe, further arranged in individual subgroups, each subgroup being the other Transducer elements that may be operated independently of the subgroup and at different time intervals and that operate to generate ultrasonic signals and receive their reflections, and spot welding under test conditions A combination of materials to allow the probe to conform to the contoured surface of the spot weld while allowing sound energy to be transmitted directly into the part and is flexible to be attached to the end of the probe And a combination of materials further including a fluid-filled chamber or a solid sound retardation material disposed between the membrane and the array. An ergonomically designed outer casing having a handle designed to be portable and adapted to receive a matrix phased array probe, and at least one armrest for supporting the body At least one input for connection to the probe, an ultrasonic phased array transceiver circuit in electrical communication with the at least one input, and a touch screen computer for processing and characterizing data received from the probe Further comprising at least one data processor executing software including at least one image algorithm for generating a color-coded ultrasonic C-scan image of the weld and wherein the C-scan image is characterized Average of weld nugget and melting range A touch screen computer further comprising a diameter, and at least one monitor for displaying the ultrasonic C-scan image to color-coded welds characteristics in real time, further comprising at least one rechargeable battery.

  [0009] Additional features and aspects of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the exemplary embodiments. As will be appreciated by those skilled in the art, further embodiments of the invention are possible without departing from the scope and spirit of the invention. Accordingly, the drawings and associated descriptions are to be regarded as illustrative in nature and not as restrictive.

  [0010] The accompanying drawings, which are incorporated in and form a part of this specification, schematically illustrate one or more exemplary embodiments of the present invention and are given above. Together with the general description and detailed description given below, it serves to explain the principles of the invention.

[0011] FIG. 2 is a block diagram illustrating the main components of a three-dimensional matrix phased array spot weld inspection system in accordance with an exemplary embodiment of the present invention. [0012] FIG. 2a provides an illustration of test results derived from analyzing a good spot weld using the system of FIG. FIG. 2b provides an illustration of the test results derived from analyzing a good spot weld using the system of FIG. FIG. 2c provides an illustration of test results derived from analyzing a good spot weld using the system of FIG. [0013] A visualization representation in A-scan mode of an electronic gate included in the weld inspection system of FIG. 1 is provided. [0014] FIG. 4a provides an illustration of test results derived from analyzing a poor spot weld using the system of FIG. FIG. 4b provides an illustration of the test results derived from analyzing a poor spot weld using the system of FIG. FIG. 4c provides an illustration of the test results derived from analyzing a poor spot weld using the system of FIG. [0015] FIG. 5a provides an illustration of test results derived from analyzing an unfused weld using the system of FIG. FIG. 5b provides an illustration of test results derived from analyzing an unfused weld using the system of FIG. [0016] FIG. 6a illustrates various firing sequences for subelement groups in addition to the shape of the 3D curved probe element. FIG. 6b illustrates various firing sequences for subelement groups in addition to the shape of the 3D curved probe element. [0017] FIG. 7a provides modeling validation of the benefits of 3D curved probe design over 2D planar probe design. FIG. 7b provides modeling validation of the benefits of 3D curved probe design versus 2D planar probe design. FIG. 7c provides modeling validation of the benefits of 3D curved probe design versus 2D planar probe design. FIG. 7d provides modeling validation of the benefits of 3D curved probe design versus 2D planar probe design. [0018] FIG. 6 provides a data flow chart for an exemplary embodiment of the spot weld inspection process of the present invention. [0019] Provide examples of imaging results for various spot weld conditions. [0020] FIG. 4 is a front perspective view of a portable system for non-destructively characterizing a spot weld according to an exemplary embodiment of the present invention. [0021] FIG. 11 is a block diagram of the basic functionality of the system of FIG.

  [0022] Exemplary embodiments of the present invention will now be described with reference to the figures. Reference numerals are used throughout the detailed description to refer to the various elements and structures. In other instances, well-known structures and devices are shown in block diagram form in order to simplify the description. Although the following detailed description includes many details for purposes of illustration, those skilled in the art will recognize that many variations and modifications to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention will be described without loss of generality to and without imposing limitations on the claimed invention.

  [0023] This application incorporates US patent application Ser. No. 12 / 186,047 in its entirety by reference for all purposes. With respect to the terminology used herein, the present invention is described as being useful for analyzing the health of a resistance spot weld between first and second workpieces or upper and lower metal sheets. However, the present invention is applicable to all welds regardless of the material, construction or number of workpieces, as well as adhesive bonding. Thus, while the present disclosure generally refers to unfused welds, those skilled in the art will recognize that the present invention detects unfused portions of joints often referred to as kissing bonds or weak bonds in the field of adhesives. Let's go. The present invention is equally applicable to metals and non-metals and is not limited to fusion welding, but may also be used to investigate solid state welds, brazing and solder joints. Thus, while the method has particular applicability in spot weld automatic analysis, it may also be used to evaluate continuous bonding.

  [0024] An unfused weld when a workpiece (eg, a sheet metal piece) is held together by local fusion at the weld interface, but the weld button or weld nugget has not formed as a result of the welding process. Or an unfused joint is produced. Unfused welds typically result from the heat at the weld interface being insufficient to cause nugget growth. In the absence of a properly formed weld nugget, fusion may occur at some point of contact between the metal sheets. With respect to the coating material, the coating can melt and resolidify, effectively soldering the parts together. The resulting connection is often strong enough to hold the workpieces together under light loads, but with a reasonable force it will pull them apart. If ultrasonic testing is used to analyze weld integrity, the transmitted ultrasonic beam (ie, sound waves) will not pass through the interface between the sheets if fusion has not occurred. If an unfused weld occurs, resulting in a fusion but not a weld nugget, the transmitted ultrasonic beam will partially pass through the sheet interface. If the weld nugget is properly formed, the transmitted ultrasonic beam will pass completely through the sheet interface.

  [0025] Phased array ultrasonic testing (PAUT) may be used for wound detection, sizing and imaging. PAUT technology is the ability to electronically modify acoustic probe characteristics. Probe correction is performed by introducing time shifts in the signals sent (pulses) to and received from (echoes) the individual elements of the array probe. Three common formats for collecting and displaying ultrasound data for nondestructive evaluation purposes are A-scan, B-scan and C-scan presentation. Each presentation mode provides a means for visualizing and evaluating the material region being examined. An A-scan is a simple RF waveform presentation that illustrates the time and amplitude of an ultrasound signal, as commonly provided by conventional ultrasound flaw detectors and waveform display thickness meters. The A scan is an amplitude modulation scan, and the horizontal and vertical sweeps are proportional to time or distance and amplitude or magnitude, respectively, as generally applied to pulse echo ultrasound. Thus, the location and size of the acoustic interface is indicated with respect to the depth under the transducer. The relative amount of received energy is plotted along the vertical axis, and the elapsed time (which may be related to the sound energy propagation time within the material) is displayed along the horizontal axis. Most instruments that utilize an A-scan display allow the signal to be displayed in its native radio frequency form (RF) as a full rectified RF signal or as a positive or negative half of the RF signal. In A-scan presentation, the relative discontinuity size can be estimated by comparing the signal amplitude obtained from the unknown reflector with that from the known reflector. The reflector depth can be determined by the position of the signal on the horizontal sweep. A C-scan from a phased array system involves the ultrasound probe being physically moved along one axis while the beam is electronically scanned along the other axis according to a focus law sequence. Signal amplitude or depth data is collected within the gated region of interest. Data is plotted with each focus law progression using a programmed beam aperture. Utilizing a matrix phased array probe, beam steering can be achieved in multiple directions.

  [0026] Referring to the figures, exemplary embodiments of the present invention provide a non-destructive inspection system for assessing the quality of resistance spot welds. In the block diagram of the exemplary embodiment, as illustrated in FIG. 1, the spot weld inspection system 10 is operative to evaluate the quality of the weld 12, which is formed at the interface 14, which is It is provided between the sheet 16 and the lower sheet 18 (both have a sheet thickness of about 0.6 mm to about 2.0 mm). An air gap of about 0.1 mm to about 0.5 mm may exist between the upper sheet 16 and the lower sheet 18. A three-dimensional matrix phased array probe 100 is placed in the region of the upper sheet 16 provided over the welding area. A curved array of ultrasonic elements 106 is used to transmit a plurality of ultrasonic beams 108 to the weld area and to capture the associated reflections 110 of those ultrasonic beams. Phased array unit 200 is in electrical communication with a plurality of ultrasonic elements 102 through a plurality of signal paths 202. Phased array unit 200 is also in electrical communication with computer 300, which processes incoming ultrasound data and generates a visualized representation of the weld area. The probe 100 includes a flexible membrane 102 that allows the probe tip to conform to the contour of the weld area, and a fluid-filled chamber 104 or solid sound delay material for focusing and steering the ultrasonic beam 108. including. Since the flexible membrane 102 can conform to a curved surface as illustrated in FIG. 1 and the array of transducer elements 106 is configured in a curved geometric shape (see FIG. 1), it is flat. In contrast to a “two-dimensional” system that uses a probe with an array and a planar tip, the matrix phased array system of the present invention is referred to as “three-dimensional”.

  [0027] FIGS. 2a-c provide an illustration of test results derived from analyzing a good spot weld using the system 10. FIG. In FIG. 2 a, the ultrasonic beam propagates completely through the weld 12 and the interface 14 and is reflected back to the probe 100 from the back side of the lower sheet 18. FIG. 2 b schematically illustrates the direction and relative intensity of each sound wave as it is transmitted and reflected at the interface 14. In FIG. 2b, the thinner line represents the loss of acoustic energy when the sound wave interacts with the interface. The reflected signals shown as circle numbers 1, 2 and 3 correspond to the peaks illustrated in the A-scan presented in FIG. 2c. FIG. 2c provides a signal derived from testing in A-scan mode, where signal 1 represents reflection from the top surface of the upper sheet 16, signal 2 represents first complete backside reflection, and signal 3 is Represents the second complete backside reflection. The horizontal line drawn through signal 2 represents the surface gate and the horizontal line adjacent to signal 2 represents the interface gate (see discussion below).

  [0028] Based on ultrasonic energy transfer and reflections on the weld interface 14 and the back side of the lower sheet 18, the system 10 uses two adjustable electronic gates to filter out all unwanted reflected signals. The two signals passing through the gate are either the reflected signal from the back side of the second metal sheet or the reflected signal from the interface of the two sheet metals. The first gate is called the “surface gate” and the second gate is called the “interface gate”. This method is different from the current commercially available system that uses the attenuation coefficient compensation method. In such a system, the loss of acoustic energy caused by spot weld fusion is determined, assuming that the fusion microstructure of the spot weld has a higher damping coefficient compared to the unfused weld condition. In order to make corrections to, multiple reflections from all of the surfaces and interfaces are considered. As disclosed and claimed in US patent application Ser. No. 12 / 186,047, incorporated herein by reference, each ultrasound element in array 106 produces a primary ultrasound beam and a secondary ultrasound beam; Here the primary ultrasound beam has a high gain, the secondary ultrasound beam has a low gain, and here the primary and secondary ultrasound beams ignite very close to each other (ie in a few milliseconds) Is done. As illustrated in FIG. 4, channel 2 is a low amplitude replica of channel 1 at each peak. The initial time interval shown is measured from the center of the first peak to the surface gate start position. The surface gate start position is fixed by adding an initial time interval to the first peak of channel 2. The interface gate start position is fixed at the surface gate start position. System 10 measures the assignment of signal amplitude (height) between gates A and B, and only signals between gate start and end positions are considered.

  [0029] FIGS. 4a-c provide an illustration of test results derived from analyzing a poor spot weld using the system 10. FIG. In FIG. 4a, since there is no weld nugget, the ultrasound beam does not propagate completely through the interface 14, but rather reflects back from the interface 14 to the probe 100. FIG. 4 b schematically illustrates the direction and relative intensity of each sound wave as it reflects off the interface 14. In FIG. 4b, the thinner line represents the loss of acoustic energy when the sound wave interacts with the interface. The reflected signals shown as circle numbers 1, 2, 3, 4 and 5 correspond to the peaks illustrated in the A-scan presented in FIG. 4c. FIG. 4 c provides a signal derived from testing in A-scan mode, where signal 1 represents the first reflection from the top surface of the upper sheet 16 and signal 2 represents the first reflection from the interface 14. , Signal 3 represents the second reflection from interface 14, signal 4 represents the third reflection from interface 14, and signal 5 represents the fourth reflection from interface 14. The horizontal line drawn through signal 3 represents the surface gate and the horizontal line drawn through signal 4 represents the interface gate (see discussion above).

  [0030] FIGS. 5a-b provide an illustration of test results derived from analyzing an unfused weld using the system 10. FIG. Since there are imperfect or poorly formed welds, the ultrasonic beam only propagates partially through the interface 14, while intermediate echoes between the interface 14 echo and the complete backwall reflection. Appears. FIG. 5 a schematically illustrates the direction and relative intensity of each sound wave as it is transmitted and reflected at the interface 14. In FIG. 5a, the thinner line represents the loss of acoustic energy when the sound wave interacts with the interface. The reflected signals shown as circle numbers 1, 2, 3, 4 and 5 correspond to the peaks illustrated in the A-scan presented in FIG. 5b. FIG. 5b provides a signal derived from testing in A-scan mode, where signal 2 represents the first reflection from interface 14, signal 3 represents the first complete backside reflection, and signal 4 is A second reflection from interface 14 represents signal 5 and a second complete backside reflection. The horizontal line drawn through signal 3 represents the surface gate and the horizontal line drawn through signal 4 represents the interface gate (see discussion above).

  [0031] FIGS. 6a-b illustrate various firing sequences (FIG. 6b) for a group of sub-elements, as well as the geometry of a curved three-dimensional probe element (FIG. 6a). The acoustic probe 100 is arranged in a three dimensional array and allows the probe to conform to the contour surface of the spot weld while allowing sound energy to be transmitted directly into the spot weld under test. A plurality of ultrasonic transducer elements 106 having a combination of materials. Excitation elements (phased array unit 200) are coupled to the array and a subset of transducer elements are combined to send an ultrasonic beam toward the spot weld. Each transducer element in the subset may be tuned at different time intervals (phase lags) and their individual waves are summed to produce a steering effect in addition to the beam focusing effect. Other three-dimensional arrangements are possible to optimize performance for a particular application. The total number of elements, overall dimensions and operating frequency determine the overall 3D surface contour shape and its operating characteristics and parameters.

  [0032] The design of the three-dimensional probe allows inspection of a larger physical range with a smaller probe, thereby allowing for wider applicability besides improved probe access compared to the two-dimensional design. The three-dimensional geometric arrangement provides optimized accuracy and sensitivity in a specific area of the weld joint. As illustrated by FIGS. 7a-d, the angular element results of the three-dimensional curved probe illustrated in FIG. 7a are typical of the beam launch angle when compared to the two-dimensional planar probe illustrated in FIG. 7c. Illustrates being steered by the normal direction of the spot weld recess. There is no significant change in beam quality for the central element for both three-dimensional (FIG. 7b) and two-dimensional (FIG. 7d) probes. Without losing the high fidelity of the inspection capability with the two-dimensional matrix phased array probe, the three-dimensional probe extends the application range from the built-in curvature of the probe itself. The present invention thus allows inspection of larger weld areas with smaller probe diameters and allows improved access. It may still cover the entire weld area and also allow the use of a smaller number of elements, reducing the overall system cost.

  [0033] In various embodiments of the present invention, a computerized controller is coupled to the acoustic probe 100 and transducer element 106 to guide the transmission of ultrasound signals and sum and receive responses therefrom. Referring generally to FIG. 8 (providing a flowchart illustrating the functionality of one possible operating system), the controller (i) generates and acquires acoustic signals and (ii) spots for each element grouping. Detect the surface of the weld, (iii) adjust instrument gating to compensate for differences in surface profile and probe orientation, and (iv) signals between responses reflected from uncoupled and well-coupled areas Measuring the amplitude ratio, (v) recognizing that a subset of the response is reflected from the unbonded range associated with the spot weld, separating the subset from the remaining response, and (vi) Measure the range and (vii) operate to present a two-dimensional color-coded image (see FIG. 9) of non-delamination of the spot weld. In summary, some of the distinct advantages of the present invention are: (i) a three-dimensional matrix probe element, (ii) a phase lag with respect to subelement groups that form beam focusing and steering capabilities, and (iii) a matching membrane (damping). And (iv) an image process that utilizes electronic gates to filter out unwanted reflections.

  [0034] In one exemplary embodiment, the present invention provides a fully integrated portable (ie, portable) battery powered that reduces the need for destructive testing of parts and components including welded or brazed joints. Assembled into a non-destructive inspection system. This unit is less costly, includes a smaller size ultrasonic phased array circuit and has the ability to be battery powered, so that the device is cost effective and portable for production line use It is. Thus, the system can be used as a tool for confirming the health of a welded product that is significantly cost-effective and efficient. This system may be referred to as “EWI SpotSight ™” and utilizes matrix phased array (MPA) ultrasound imaging technology to provide visual real-time feedback and visually visualize an ultrasound C-scan image of the examination range. To accurately evaluate the condition of the joint range. This system can be utilized in a wide variety of manufacturing settings for the inspection of parts and components made of metal and non-metal. The system is effective to evaluate the quality of various joint configurations including resistance spot welding, resistance seam welding, laser welding, friction stir spot welding, MIG spot welding, brazing, and the like. The invention relates to (i) the automotive industry with respect to assessing the quality of spot welds to steel, resistance spot welds to steel and aluminum, friction stir spot welds to aluminum, and laser welds to steel, (ii) aluminum , Resistance spot welds and resistance seam welds to titanium and stainless steel, and aerospace industry for assessing brazing quality to aerospace grade nickel alloys, and (iii) MIG spot welds to steel, and copper And is particularly useful for in-place cleaning (CIP) applications related to evaluating brazing to tin-coated copper.

  [0035] With reference to FIGS. 10-11, the portable version of the present invention is intended for use as an inspection system in one or more production environments. The basic components of the system are: (i) an ultrasonic phased array transceiver circuit, (ii) a fully integrated computer with data processing capabilities and image algorithms, (iii) at least one matrix phased array probe with quick disconnect electrical connections, And (iv) an ergonomically designed and fully portable case with a carry handle that provides a secure containment space for the matrix phased array probe inside. As illustrated in FIG. 10, the exemplary embodiment of the portable weld joint inspection unit 400 includes a body 410 and a handle 424. Body 410 includes power switch 412, side access for USB and external monitor connection 413, screen 414, aluminum plate 416, connector adapter 417 (e.g., Hypertronix Omni Connector adapter), cord wrap 418, stylus housing area 420, and armrest 422 is further included. The handle 424 further includes a probe receiving area 426. The probe 100 is connected to a probe connector 103 (eg, a multi-pin Omni connector), which then connects to the weld joint inspection unit 400 with a connector adapter 417. In various exemplary embodiments, the ultrasonic phased array transceiver circuit further includes a 64-channel phased array circuit with 16-channel simultaneous multiplexing capability, by eliminating the need for a computer mouse and keyboard in the production environment. Including an Intel i7 dual-core powered enhanced tablet computer running on Windows 7 or Windows 8 operating software with a flat touch screen display that improves inspection speed, and the image algorithm is suitable for processing data from phased array electronics Further comprising SpotSight ™ imaging software (EWI, Inc .; Columbia, Ohio) for providing an image algorithm, at least one matrix The phased array probe further comprises a 64 element 3D matrix phased array probe, and the ergonomic casing handles all the features necessary to allow cooling for the internal electronics, handle from carrying the instrument And various features that allow for secure housing of the probe and access to all necessary power and data ports. Wireless connectivity (eg, Bluetooth, Wi-Fi, cellular network, etc.) and rechargeable batteries are also typically included. The above aspects of this embodiment provide the present invention with the following advantageous features: (i) the ability to quantitatively evaluate welds and other types of joint materials with numerical data displayed on a screen; (ii) self Built-in non-destructive ultrasonic inspection system, (iii) portable portability, (iv) battery power, (v) touch screen and wireless functionality, and (vi) robust rapid electrical / mechanical connection of the probe to the unit Bring effectively.

  [0036] FIG. 11 provides a system block diagram illustrating the basic functionality of an exemplary embodiment of the portable weld joint inspection unit 400. In this embodiment, the phased array electronics 520 activates the matrix phased array probe 510 with an activation command from the data processing software. Next, the ultrasound signal detected by the matrix phased array probe 510 is sent to the image algorithm 530 and processed for fusion and non-fusion states of the junction area under examination. Finally, the color-coded ultrasound C-scan image 540 is displayed on the screen along with additional numerical data such as the nugget and the average diameter of the fusion range. As the ultrasonic signal is detected by individual subgroups of the probe array using two gates, one for front reflection and the other for interface reflection, the EWI SpotSight ™ Process. As the raw ultrasound data is processed in real time with a double-gate image algorithm, an ultrasound C-scan image is plotted. Feedback time for the operator is negligible and probe adjustment is relatively easy and fast compared to a system where the probe must be repositioned if the results are unsatisfactory. Despite these advantages, in investigating various welds, several factors are (i) changes in the acoustic impedance of the membrane over time, (ii) the natural nature of the piezoelectric elements included in the sensor / probe. It can cause undesirable fluctuations including degradation, (iii) slight differences between transducers, and (iv) the natural tendency of the system to reduce the size of all welds. To compensate for these variables, some embodiments of the present invention include features that allow the ratio between the first image gate and the second image gate to be adjusted. This feature gives the system operator the ability to calibrate the system to a known diameter weld, thereby increasing the overall accuracy of the system. To accomplish this, the system operator places the probe on a reference that includes a weld nugget with a known or predetermined diameter. If the image can be read slightly larger or smaller than the reference, the gate ratio is adjusted by the operator through specific inputs in the software. The image that appears on the screen of the portable weld joint inspection unit 400 is essentially created by comparing the signal strength from the first gate to the strength from the second gate.

  [0037] Although the invention has been illustrated by way of illustration of exemplary embodiments thereof and the embodiments have been described in certain details, the scope of the appended claims should be limited to such details or in any way Any limitation is not the applicant's intention. Additional advantages and modifications will readily occur to those skilled in the art. Accordingly, the invention in its broader aspects is not limited to any of the specific details, representative apparatus and methods, and / or illustrative examples shown and described. Accordingly, developments from such details may be made without departing from the spirit or scope of applicant's general inventive concept.

Claims (20)

A portable system for characterizing spot welds non-destructively,
(A) at least one matrix phased array probe;
(I) a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe, the reflection of which also generates an ultrasonic signal A transducer element that also operates to receive, and
(Ii) The probe conforms to the contoured surface of the spot weld while allowing sound energy to be directly transmitted into the spot weld under test conditions ( a combination of materials to allow conformation, a flexible membrane attached to the end of the probe, and the membrane and the array A matrix phased array probe further comprising a combination of materials further comprising a fluid filled chamber or a solid sound delay material disposed therebetween;
(B) a body designed to be hand-held,
(I) an outer casing that is ergonomically designed;
(Ii) at least one input for connection to the at least one matrix phased array probe;
(Iii) an ultrasonic phased array transceiver circuit in electrical communication with the at least one input;
(Iv) processing at least one image algorithm for processing the data received from the probe and generating a color coded ultrasonic C-scan image of the weld to be characterized A touch screen computer further comprising at least one data processor executing software; and
(V) a system comprising: a main body further comprising at least one monitor for displaying in real time the color-coded ultrasonic C-scan image of the characterized weld.   The oscillator element may be further arranged in discrete subgroups, and each subgroup may be activated independently of the other subgroups and at different time intervals. System.   Actuating each subgroup independently of the other subgroups and at different time intervals for each element in the subgroup provides signal focusing and steering capacity. Item 3. The system according to Item 2.   The system of claim 1, wherein the body further comprises at least one rechargeable battery.   The system of claim 1, wherein the ergonomically designed outer casing further includes a handle, and the handle is adapted to receive the matrix phased array probe.   The system of claim 1, wherein the ergonomically designed outer casing further comprises at least one armrest for supporting the body.   The system of claim 1, wherein the ultrasonic phased array transceiver circuit further comprises a 64-channel phased array circuit having 16-channel simultaneous multiplexing capability.   The system software first scans a known diameter weld joint using the matrix phased array probe and then adjusts the system gating ratio accordingly to calibrate the system. The system of claim 1, further comprising an input permitting.   The system of claim 1, wherein the color-coded ultrasound C-scan image further comprises an average diameter of a weld nugget and a fused area for each characterized weld. A portable system for non-destructive characterization of spot welds,
(A) at least one matrix phased array probe;
(I) a plurality of ultrasonic transducer elements disposed in a curved array at one end of the probe, the transducer elements operating to generate and receive reflections of ultrasonic signals; and,
(Ii) a combination of materials to allow the probe to conform to the contour surface of the spot weld while allowing sound energy to be transmitted directly into the spot weld under test conditions; A matrix phased array probe further comprising: a flexible membrane attached to the end of the probe; and a material combination further comprising a fluid-filled chamber or a solid sound delay material placed between the membrane and the array When,
(B) a body designed to be portable;
(I) an ergonomically designed outer casing further including a handle adapted to receive the matrix phased array probe;
(Ii) at least one input for connecting to the probe;
(Iii) an ultrasonic phased array transceiver circuit in electrical communication with the at least one input;
(Iv) at least one data processor executing software including at least one image algorithm for processing data received from the probe and generating a color-coded ultrasonic C-scan image of the weld to be characterized Further including a touch screen computer,
(V) at least one monitor for displaying in real time the color-coded ultrasound C-scan image of the characterized weld; and
(Vi) a system comprising: a main body further comprising at least one rechargeable battery.   The system of claim 10, wherein the transducer elements are further arranged in individual subgroups, and each subgroup may be activated independently of the other subgroups and at different time intervals.   12. The system of claim 11, wherein operating each subgroup independently of the other subgroups and at different time intervals for each element in the subgroup provides signal focusing and steering capabilities.   The system of claim 10, wherein the ergonomically designed outer casing further comprises at least one armrest for supporting the body.   The system of claim 10, wherein the ultrasonic phased array transceiver circuit further comprises a 64 channel phased array circuit having 16 channel simultaneous multiplexing capability.   The system software further includes an input that allows the system to be calibrated by first scanning a weld joint of known diameter using the matrix phased array probe and then adjusting the system gating ratio accordingly. The system according to claim 10.   The system of claim 10, wherein the color-coded ultrasound C-scan image further comprises a weld nugget for each characterized weld and an average diameter of the fusion range. A portable system for non-destructive characterization of spot welds,
(A) at least one matrix phased array probe;
(I) A plurality of ultrasonic transducer elements arranged in a curved surface array at one end of the probe, further arranged in individual subgroups, each subgroup being another subgroup A transducer element that may be activated independently and at different time intervals and that operates to generate an ultrasonic signal and receive its reflection; and
(Ii) a combination of materials to allow the probe to conform to the contour surface of the spot weld while allowing sound energy to be transmitted directly into the spot weld under test conditions; A matrix phased array probe further comprising: a flexible membrane attached to the end of the probe; and a material combination further comprising a fluid-filled chamber or a solid sound delay material placed between the membrane and the array When,
(B) a body designed to be portable;
(I) an ergonomically designed outer casing, the casing further comprising a handle adapted to receive the matrix phased array probe, and at least one armrest for supporting the body;
(Ii) at least one input for connecting to the probe;
(Iii) an ultrasonic phased array transceiver circuit in electrical communication with the at least one input;
(Iv) at least one data processor executing software including at least one image algorithm for processing data received from the probe and generating a color-coded ultrasonic C-scan image of the weld to be characterized And a touch screen computer further comprising a weld nugget and an average diameter of the fusion range for the weld where each C-scan image is characterized
(V) at least one monitor for displaying in real time the color-coded ultrasound C-scan image of the characterized weld; and
(Vi) a system comprising: a main body further comprising at least one rechargeable battery.   18. The system of claim 17, wherein operating each subgroup independently of the other subgroups and at different time intervals for each element in the subgroup provides signal focusing and steering capabilities.   The system of claim 17, wherein the ultrasonic phased array transceiver circuit further comprises a 64 channel phased array circuit having 16 channel simultaneous multiplexing capability.   The system software further includes an input that allows the system to be calibrated by first scanning a weld joint of known diameter using the matrix phased array probe and then adjusting the system gating ratio accordingly. The system of claim 17.