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Ultrasonic testing (UT) of objects with complex geometries often requires the use of a robotic arm to position the probe perpendicular to the local surface. Using immersion makes it possible to test these objects with standard ultrasonic linear array probes. Here, the probe positions and orientations provided by the robot are used for merging the locally acquired image data into a 3D-reconstruction. The quality of this reconstruction is highly dependent on the alignment of the tool center point (TCP) of the physical probe with the TCP used in the digital model. For common industrial tools, the TCP is usually acquired using geometric features of the tools. However, for ultrasonic arrays in immersion, there is a water standoff between the probe and the test object, therefore the TCP is in free space in front of the array and cannot be acquired with the common method. To overcome this challenge, we propose a method that allows the robotic ultrasonic system to automatically self-adjust the positioning of the UT probe using a test block made of steel with defined geometric features as a target for referencing. For each of the six degrees of freedom, a scan and adjustment routine are established using the data acquired by the UT probe to update the TCP’s position and orientation in the robot control. Given a coarse pre-definition of the TCP and the known target test block, no human interaction is required while the system determines the optimum tool position and orientation. Part of this work will be used to improve and extend standards for robotic ultrasonic test systems, e.g. ISO 24647.
The vast experience with the automated, ultrasonic system for the inspection of hollow railway axles used by Deutsche Bahn shows that much smaller flaws are detectable than required. This results in a number of false calls. False calls lead to unnecessary demounting and disassembling of wheelsets, which generates unnecessary additional costs. In order to adjust the sensitivity of the inspection system to reduce the number of false calls without compromising safety, the capability of the system to detect cracks needs to be comprehensively established. This capability can be quantified by using probability of detection (POD) curves for the system. The multi-parameter POD model makes it possible to include several factors that influence the crack detection in the analysis. The analysis presented in this paper shows that crack position, orientation, depth extension, and shape as well as the geometry of the axle all have influence on the ultrasonic response amplitude. For future work, calculation of the POD using multi-parameter POD model with these parameters is planned.
Elastic wave propagation of ultrasound in bituminous road surfaces – simulations and measurements
(2015)
Maintenance costs of road infrastructure are increasing steadily. Adverse environmental impacts on infrastructure get more and more important as well. Therefore, it is important to determine how limited financial resources can be directed with an optimum pay-out. The present study takes first steps towards the usage of low-frequency ultrasound as a tool to evaluate the road condition.
The canister for the permanent storage of spent nuclear fuel used by SKB in Sweden consists of a cast iron insert surrounded by a five centimetre thick shell of copper. It is a safety critical component and in order to secure long-term structural integrity non-destructive methods are used to inspect 100% of the volume of each canister, before it is disposed of in the repository. One of the critical components that requires inspection is a sealing weld, joining the copper tube and the lid. The friction stir weld is inspected using an ultrasonic phased array system. The area of the weld is inspected with several inspection channels with different angles and varying coverage. To make sure that no defects that might occur in the weld are overseen, the reliability of the inspection must be quantified. The reliability of NDT is usually quantified with the probability of detection curves. The influence of the parameters that might influence the POD of the flaws in the weld is investigated analysing the experimental results, as well as with a help of a numerical simulation of the inspection.
Reliability analysis of the ultrasonic inspection system for the inspection of hollow railway axles
(2016)
Axles are safety critical train components that are subjected to significant cyclic loading during operation. If the crack is initiated in the axle, cyclic loading will lead to crack propagation. To maintain structural integrity, axles must be periodically inspected for fatigue cracks in the material. Deutsche Bahn uses mechanized ultrasonic inspection system to inspect hollow railway axles. The inspections are performed from the bore surface, using several conventional transducers with different incident angles, inspecting the axle along the entire length. As with the every safety critical system, the reliability of these inspections must be determined with regard to their flaw detection capabilities. Traditionally this is done according to the relevant standards for railway vehicles. To investigate the capability of the NDT system more thoroughly, we want to evaluate the capability of the inspection system to detect flaws by means of probability of detection (POD) curves. It will be shown that other parameters, beside the size of the crack, for example crack position in the axle, influence the detection of the crack. The influence of these parameters was evaluated using ultrasonic simulation. The evaluation served as an input for the manufacturing of the flaws in the real scale axle. Once these axles are inspected and the data evaluated, using data from both measurement and simulation, we will express the POD of the crack as function of influencing parameters using the multiparameter POD model.
The canister for the permanent storage of spent nuclear fuel used by SKB in Sweden consists of a cast iron insert surrounded by a five centimetre thick shell of copper. It is a safety critical component and in order to secure long-term structural integrity non-destructive methods are used to inspect 100% of the volume of each canister, before it is disposed of in the repository. One of the critical components that requires inspection is a sealing weld, joining the copper tube and the lid. The friction stir weld is inspected using an ultrasonic phased array system. The area of the weld is inspected with several inspection channels with different angles and varying coverage. To make sure that no defects that might occur in the weld are overseen, the reliability of the inspection must be quantified. The reliability of NDT is usually quantified with the probability of detection curves. The influence of the parameters that might influence the POD of the flaws in the weld is investigated analysing the experimental results, as well as with a help of a numerical simulation of the inspection.