System and method of automatically generating a phased array ultrasound scan plan in non-destructive inspection

Patent metadata

Field	Value
Publication number	US-2016238566-A1
Application number	US-201514621906-A
Country	US
Kind code	A1
Filing date	Feb 13, 2015
Priority date	Feb 13, 2015
Publication date	Aug 18, 2016
Grant date	—

Abstract

Disclosed is phased array inspection system with automatically generated PAUT scan plan based on a set of configurable probe operation parameters and a combination of preferred code requirement and rules given by PAUT expertise. The complex code requirements and PAUT expertise are pre-assembled into a plurality of templates applicable to categories of inspection tasks by PAUT experts. Requirements and optimization scoring schemes are then used to automatically score each of specifically proposed scan plan setup, including the selection of probe operation parameters against the corresponding template for a specific task. This allows less skilled field inspector to operate with the correct interpretation of the complex code and accurate evaluation of the scan plan.

First claim

What is claimed is:

1 . A method of preparing a scan plan for a phased array ultrasonic testing (PAUT) inspection system, the system configured to be coupled with a plurality of probes for conducting a plurality categories of inspection tasks on a plurality of corresponding test objects, the inspection tasks need to be done in accordance to a set of standardized codes and a set of expertise rules given according to PAUT expertise and operated by a field inspector, the scan plan including instrument setup, acoustic setup, the positioning and movement of the probes,
the method comprising the steps of: defining a set of code and expertise templates, each for a category of the inspection tasks, by decomposing the codes, forming applicative guidelines and integrating the expertise rules for the categories of tasks, defining a selected task out of the inspection tasks with a selected test object and defining the category of the selected task and accordingly selecting a corresponding template; defining a set of requirement scoring scheme including a target requirement score and optimization scoring scheme according to the corresponding template, defining geometric definitions of the selected test object, as part of the scan plan, determining at least one selected probe out of the plurality of the probes, and N sets of probe operation parameters for the at least one selected probe, one at a time, using one of the N set of probe operation parameters and the geometric definitions to seek requirement scores using the requirement scoring scheme and selecting the m set of probe operation parameters that reached the target requirement score, wherein m<=N, and, one at a time, seeking optimization scores by using the optimization scoring schemes among the m set of operation parameter and finding a set of probe operation parameters to be the optimal set of probe operation parameters, and, using the scan plan with the corresponding template and the optimal probe operation parameters to conduct the selected inspection task inspecting the selected test object.

2 . The method of claim 1 , wherein the step of defining a set of code and expertise templates is configured to be conducted prior to and being independent of the selected inspection task, and wherein the templates are stored in a memory of the instrument.

3 . The method of claim 1 , wherein the instrument setup including selection of the at least one probes, corresponding wedges and an acoustic unit for the selected task.

4 . The method of claim 3 , wherein the acoustic setting including aperture size, aperture position, focalization setting, beam angles and gating parameters for the at least one probe and the acquisition unit.

5 . The method of claim 4 , wherein each set of the N sets of the probe operation parameters includes positions, scan trajectory and the number of at least one probe relative to the selected test object, number of apertures, number of phased array beams and corresponding beam angles for the at least one probe.

6 . The method of claim 5 , wherein the probe operation parameters of the at least one probe include a corresponding set of probe operation parameters for a one-probe setup and/or a two-probe setup the selected task.

7 . The method of claim 5 further including a step of selecting a probe setup achieving a highest optimization score among the usage of the one-probe or the two-probe setup.

8 . The method of claim 5 , wherein the test object is a weld along a weld line, wherein the weld including a heat affected zone, at least two weld bevels, a weld top-surface width and a weld bottom width.

9 . The method of claim 8 , wherein the requirement scoring scheme includes a predetermined requirement of covering the heat affected zone, having phase array beams to be perpendicular to the weld bevels and predetermined requirement for overlap between two successive beams of the at least one probe.

10 . The method of claim 8 , wherein the requirement scoring scheme includes a predetermined requirement of maintaining a predetermined overlap distance between a first beam of a first probe of the at least one probe and the last beam of a second probe of the at least one probe.

11 . The method of claim 8 , wherein the requirement scoring scheme includes a predetermined requirement of maintaining a predetermined fraction of the overlap distance and a beam width, wherein the beam width is the maximum between the width of the first beam and the last beam at a predetermined depth.

12 . The method of claim 8 , the requirement scoring scheme includes a predetermined requirement of maintaining a predetermined fraction of the overlap distance and a probe width, wherein the probe width is the maximum is the maximum of the first probe width and the second probe width.

13 . The method of claim 8 , wherein the requirement scoring scheme includes a set of expertise rules related to any of the following: beam focalization, beam aperture, probe and wedge selection, scanning method, range of refraction angles.

14 . The method of claim 8 , wherein the optimization scoring scheme is determined by a set of optimization rules including at least one of the following: a first optimization rule to reduce the number of separate probe passes that are required to cover the selected inspection task, a second optimization rule to reduce the angular range generated by the at least one probe, a third optimization rule to minimize a distance between the at least one probe and the weld according to the geometry and a fourth optimization rule to reduce the total number of beams.

15 . The method of claim 1 , wherein the requirement scoring scheme scores in such a way that the closer the conditions set by the probe operation parameters to that of the corresponding template, the higher the requirement score is.

16 . The method of claim 1 , wherein the step of seeking optimization scores including using a step of mathematical deducing a next optimal set of probe operation parameters based on all the available set of probe operation parameters and their corresponding requirement scores and optimization scores.

17 . A phased array ultrasonic inspection apparatus configured for conducting a plurality of inspection tasks on a plurality of corresponding test objects with the usage of a plurality of probes according to standardized codes and a set of rules of industrial expertise given according to PAUT expertise and operated by a field inspector, wherein each of the inspection tasks is performed according to a scan plan including instrument setup, acoustic setup, the positioning and movement of the probes,
the instrument comprising: a template module configured to form a set of code and expertise templates, each for a category of the inspection tasks, by decomposing the codes, forming applicative guidelines and integrating the expertise rules for the categories of tasks, an electronic memory storing the templates, a test object geometry module and PAUT modeling tool configured to define a selected task out of the inspection tasks with a selected test object and selecting the category of the selected task and accordingly selecting a corresponding template which yields at least one selected probe out of the plurality of the probes, an automated optimization engine defining a set of requirement scoring scheme including a target requirement score and optimization scoring scheme finding the most optimal optimization scores according to the corresponding template, wherein the optimization engine further evaluating N sets of probe operation

Assignees

• Lepage Benoit
• St-Laurent Martin
• Olympus Scient Solutions Americas Inc

Inventors

• Lepage Benoit
• St-Laurent Martin

Classifications

• G01N2291/0289

  Internal structure, e.g. defects, grain size, texture · CPC title

• G01N29/04

  Analysing solids (using acoustic emission techniques G01N29/14) · CPC title

• G01N2291/267

  Welds · CPC title

• G01N2291/023

  Solids · CPC title

• G01N29/262 Primary

  by electronic orientation or focusing, e.g. with phased arrays (phased arrays per se G10K11/34) · CPC title