Claims
- 1. An ultrasonic testing device for detecting flaws present in a predetermined object, said testing device comprising:
- (a) an engagement means for rolling contact with such predetermined object;
- (b) a predetermined liquid disposed within said engagement means for providing a coupling medium;
- (c) a support means connected to said engagement means for supporting said engagement means in an operating position with respect to such predetermined object;
- (d) a rotary bearing means connected to said support means for enabling said engagement means to be in rolling contact with such predetermined object;
- (e) at least one acoustic transducer assembly positioned within said engagement means, said at least one acoustic transducer assembly consisting of a block having acoustic transducers affixed to said block, said acoustic transducers in acoustic contact with said block, said block having a surface portion substantially parallel to and adjacent to a portion of said engagement means in contact with such predetermined object, a layer of said predetermined liquid and said portion of said engagement means in contact with such predetermined object providing an acoustic bridge between said block and such predetermined object; and
- (f) at least one electrical signal processing means connected to said at least one acoustic transducer assembly for generating and communicating a plurality of first electrical signals to said at least one acoustic transducer assembly and receiving a plurality of second electrical signals for analysis from said at least one acoustic transducer assembly, said at least one acoustic transducer assembly converting said plurality of first electrical signals received from said at least one electrical signal processing means into a plurality of first acoustic signals and communicating said plurality of first acoustic signals to such predetermined object and converting a plurality of second acoustic signals received from such predetermined object into said plurality of second electrical signals and communicating said plurality of second electrical signals to said at least one electrical signal processing means for analysis.
- 2. An ultrasonic testing device, according to claim 1, wherein such predetermined object is an elongated object.
- 3. An ultrasonic testing device, according to claim 2, wherein said at least one acoustic transducer assembly includes at least one transducer mounted at a predetermined angle relative to a major dimension of such elongated object, said at least one transducer for interchanging electric energy between said electrical signal processing means and said plurality of first acoustic signals in such elongated object, each of said plurality of first acoustic signals having a particular beam direction defined by said predetermined angle relative to said major dimension of such elongated object, and by refraction of said plurality of first acoustic signals between said at least one acoustic transducer assembly and such elongated object.
- 4. An ultrasonic testing device, according to claim 3, wherein said beam direction of said plurality of first acoustic signals is approximately parallel to such elongated object.
- 5. An ultrasonic testing device, according to claim 2, wherein said acoustic transducer assembly includes at least one transducer mounted at a predetermined angle relative to a minor dimension of such elongated object, said at least one transducer for interchanging electric energy between said electric signal processing means and acoustic signals in such elongated object, said acoustic signals having a particular beam direction defined by said predetermined angle relative to said minor dimension of such elongated object and by refraction of acoustic signals between said acoustic transducer assembly and such elongated object.
- 6. An ultrasonic testing device, according to claim 2, wherein said electric signal processing means generates pulses of high frequency electric energy followed by quiet times, said transducer assembly converting said pulses of said high frequency electric energy into pulses of ultrasonic acoustic energy, said pulses of said ultrasonic acoustic energy coupled into such elongated object, said transducer assembly receiving acoustic energy returned from such elongated object, said acoustic energy returned from such elongated object indicative of imperfections in such elongated object, said transducer assembly converting said acoustic energy returned from such elongated object into return electrical signals, said electric signal processing means generating signals indicative of imperfections in such elongated object.
- 7. An ultrasonic testing device, according to claim 6, wherein said ultrasonic testing device further includes a means for displaying signals indicative of such imperfections in such elongated object.
- 8. An ultrasonic testing device, according to claim 2, wherein said at least one acoustic transducer assembly is formed from a block of plastic having at least one pocket formed therein for retaining at least one transducer, said at least one pocket having at least one planar surface, said at least one transducer being cemented onto said planar surface in said at least one pocket to enhance acoustic contact with said block.
- 9. An ultrasonic testing device, according to claim 8, wherein at least one of said planar surface in said at least one pocket is inclined at a predetermined angle relative to said block, whereby said at least one transducer cemented onto said planar surface projects an acoustic beam at a predetermined angle into said block for refraction into said elongated object at a predetermined angle.
- 10. An apparatus for ultrasonic inspection of at least one rail disposed in a railroad track structure, said apparatus comprising:
- (a) a vehicle for travelling along such railroad track structure;
- (b) an engagement means for rolling contact with such at least one rail;
- (c) a predetermined liquid disposed within said engagement means for providing a coupling medium;
- (d) a support means connected to said engagement means for supporting said engagement means in an operating position with respect to such at least one rail;
- (e) a rotary bearing means connected to said support means for enabling said engagement means to be in rolling contact with such at least one rail;
- (f) at least one acoustic transducer assembly positioned within said engagement means, said at least one acoustic transducer assembly consisting of a block having acoustic transducers affixed thereto, said acoustic transducers in acoustic contact with said block, said block having a bottom surface portion substantially parallel to and adjacent to a portion of said engagement means in contact with such at least one rail, a layer of said predetermined liquid and said portion of said engagement means in contact with such at least one rail providing an acoustic bridge between said block and such at least one rail; and
- (g) at least one electrical signal processing means disposed on such vehicle, said at least one electrical signal processing means connected to said at least one transducer assembly for generating and communicating a plurality of first electrical signals to said at least one transducer assembly and receiving a plurality of second electrical signals for analysis from said at least one transducer assembly, said at least one acoustic transducer assembly converting said plurality of first electrical signals received from said at least one electrical signal processing means into a plurality of first acoustic signals and communicating said plurality of first acoustic signals to such at least one rail and converting a plurality of second acoustic signals received from such at least one rail into said plurality of second electrical signals and communicating said plurality of second electrical signals to said at least one electrical signal processing means for said analysis.
- 11. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 10, wherein said acoustic transducer assembly includes at least one transducer mounted at a predetermined angle relative to a major dimension of such railroad rail for interchanging electric energy between said electric signal processing means and said plurality of first acoustic signals in such railroad rail, said plurality of first acoustic signals having a particular beam direction defined by said predetermined angle relative to said major dimension of such railroad rail, and by refraction of acoustic signals crossing said acoustic bridge between said acoustic transducer assembly and such railroad rail.
- 12. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 11, wherein said beam direction of said plurality of first acoustic signals is approximately parallel to such railroad rail.
- 13. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 12, wherein said beam descends into such rail and is reflected from a lower surface of such rail head, thereby being reflected upward to encounter deep imperfections lying underneath surface imperfections which would otherwise prevent observation of such deep imperfections.
- 14. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 13, wherein said apparatus includes a pair of transducers oriented at a predetermined transducer angle relative to such rail to exchange electric energy with acoustic energy in a pair of beams each crossing a centerline of such rail to observe deep imperfections lying underneath surface imperfections which would otherwise prevent observation of such deep imperfections.
- 15. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 10, wherein said acoustic transducer assembly includes at least one transducer mounted at a predetermined angle relative to a width dimension of such railroad rail for interchanging electric energy between said electric signal processing means and acoustic signals in such railroad rail, said acoustic signals having a particular beam direction defined by said predetermined angle relative to said width dimension of such railroad rail and by refraction of acoustic signals between said acoustic transducer assembly and such railroad rail.
- 16. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 10, wherein said electric signal processing means generates pulses of high frequency electric energy followed by quiet times, said transducer assembly converting said pulses of said high frequency electric energy into pulses of ultrasonic acoustic energy, said pulses of said ultrasonic acoustic energy coupled into such railroad rail, said transducer assembly receiving acoustic energy returned from such railroad rail indicative of imperfections in such railroad rail, said transducer assembly converting said acoustic energy returned from such railroad rail into return electrical signals, said electric signal processing means generating signals indicative of imperfections in such railroad rail.
- 17. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 16, wherein said apparatus further includes a means for displaying signals indicative of such imperfections in such railroad rail.
- 18. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 10, wherein said transducer assembly is formed from a block of plastic having at least one pocket formed therein for retaining at least one transducer, said at least one pocket having at least one planar surface, said at least one transducer cemented onto said at least one planar surface in said at least one pocket to enhance acoustic contact with said block.
- 19. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 18, wherein said at least one planar surface in said at least one pocket has a surface inclined at a predetermined angle relative to said block, whereby said at least one transducer cemented onto said at least one planar surface projects an acoustic beam at a predetermined angle into said block, said acoustic beam for refraction into such railroad rail at a predetermined angle.
- 20. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 15, wherein said at least one transducer is oriented such that it exchanges energy with an acoustic beam which is reflected off a lower surface of a head of such railroad rail, crosses such rail approximately horizontally, and is then reflected upward from a second lower surface of such head of such railroad rail, thereby detecting flaws at an elevation of a bottom of such head of such railroad rail.
- 21. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 19, wherein said acoustic beam is directed steeply downward to penetrate a web of such railroad rail thereby detecting at least one of bolt hole flaws and other web imperfections.
- 22. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 21, wherein said apparatus includes a pair of tires mounted in tandem on such rail, said beam originating in a first transducer disposed in a first one of said pair of tires, passing downward into such web, being reflected off a bottom surface of such rail, and being detected by a second transducer disposed in a second one of said pair of tires.
- 23. An apparatus for ultrasonic inspection of rail disposed in a railroad track structure, according to claim 10, wherein said vehicle travels on such pair of railroad rails on a set of second tires, said vehicle including means in contact with a pair of gauge surfaces of such rails to guide said set of second tires to follow such rails, said vehicle capable of driving off of such rails and climbing back onto such rails.
- 24. A method for ultrasonic inspection of an object, said method comprising the steps of:
- (a) contacting a first surface of said object to be tested with an engagement means containing a predetermined coupling medium and at least one acoustic transducer assembly therein said at least one transducer assembly consisting of a block having acoustic transducers affixed thereto, said acoustic transducers in acoustic contact with said block, said block having a surface portion substantially parallel to and positioned adjacent at least a portion of said engagement means in contact with said object, a layer of said predetermined liquid and said portion of said engagement means in contact with said object providing an acoustic bridge between said block and said object;
- (b) supporting said engagement means in rolling contact with said first surface of said object;
- (c) moving said engagement means containing said coupling medium and said at least one acoustic transducer assembly over a predetermined path on said object;
- (d) generating a plurality of first electrical signals in at least one electrical signal processing means;
- (e) communicating said plurality of said first electrical signals generated in step (d) to said at least one acoustic transducer assembly;
- (f) converting said plurality of first electrical signals communicated to said at least one acoustic transducer assembly in step (e) into a plurality of first acoustic signals;
- (g) communicating said plurality of first acoustic signals generated in step (f) to said object;
- (h) receiving a plurality of second acoustic signals from said object in at least one acoustic transducer;
- (i) converting said plurality of second acoustic signals received by said at least one transducer in step (h) into a plurality of second electrical signals;
- (j) communicating said plurality of second electrical signals generated in step (i) to said electrical signal processing means; and
- (k) analyzing said plurality of second electrical signals in said electrical signal processing means for detecting flaws present in said object.
- 25. A method for ultrasonic inspection of an object, according to claim 24, wherein said object is an elongated object.
- 26. A method for ultrasonic inspection of an object, according to claim 25, wherein said elongated object is at least one rail of a railroad track structure.
- 27. A method for ultrasonic inspection of an object, according to claim 26, wherein said plurality of first acoustic signals is an ultrasonic beam which is approximately parallel to a centerline of such rail.
- 28. A method for ultrasonic inspection of an object, according to claim 27, wherein said ultrasonic beam slopes downward and is reflected off a lower surface of a railhead of such rail to produce an upward reflected beam, said upward reflected beam illuminating deep defects otherwise hidden underneath surface imperfections, said deep defects causing said back reflected acoustic signal.
- 29. A method for ultrasonic inspection of an object, according to claim 28, wherein said ultrasonic beam is generated by a transducer on a first side of a centerline of such rail and is directed across such centerline of such rail to illuminate deep defects in a second opposite side of such centerline of such rail.
- 30. A method for ultrasonic inspection of an object, according to claim 29, wherein said method includes the additional step of generating a second ultrasonic beam by a second transducer on a second side of such centerline of such rail, said second ultrasonic beam being directed across such centerline to such first side of such centerline.
- 31. A method for ultrasonic inspection of an object, according to claim 26, wherein said ultrasonic beam is directed steeply downward, thereby illuminating a web and a bottom flange of such railroad rail, whereby said back reflected acoustic signal is indicative of imperfections in such web and such bottom flange of such railroad rail.
- 32. An ultrasonic testing device for detecting flaws in a railroad rail, said device comprising:
- (a) an engagement means mounted to be rolled along such railroad rail;
- (b) a transducer assembly disposed within said engagement means, said transducer assembly consisting of a block of material having at least one acoustic transducer attached to said transducer assembly, said at least one acoustic transducer mounted in acoustic contact with said block at a predetermined orientation in relation to said block to generate an acoustic beam having a predetermined direction in said block, said block having a bottom surface portion, said block positioned within said engagement means so that said bottom surface portion of said block is adjacent a portion of said engagement means in contact with such rail;
- (c) a liquid disposed in said engagement means so that a liquid layer is provided between said bottom surface portion of said block and said portion of said engagement means in contact with such rail, so that said liquid layer and said portion of said engagement means in contact with such rail act as an acoustic bridge between said block and such rail to communicate said at least one acoustic beam from said block into such rail and to communicate reflected acoustic signals from such rail back to said block and thence to said at least one transducer, so that said at least one acoustic beam in such rail is oriented at a predetermined angle, which is substantially independent of a speed of sound in said liquid;
- (d) means connected to said at least one transducer for providing electrical signals for generation of said acoustic beams; and
- (e) means connected to said at least one transducer for receiving electrical signals indicative of said reflected acoustic signals, and for processing said electrical signals to provide signals indicative of such flaws in such rail.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of patent application Ser. No. 08/661,061, filed Jun. 10, 1996, now abandoned.
US Referenced Citations (13)
Continuations (1)
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Number |
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661061 |
Jun 1996 |
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