The present invention relates to ultrasonic measurement.
In many circumstances, it is useful to be able to identify the appearance or growth of surface deposits or films, or to be able to characterise the nature of the deposit. Understanding these effects is particularly important in machine components such as vehicle engine components or bearings and can also be useful in testing the performance of an associated system, such as a lubrication system. For example these matters may affect performance. In other circumstances, it is useful to be able to obtain information about paint deposits or other coatings.
Examples of the present invention provide a method of ultrasonic measurement, the method comprising the steps of:
causing an ultrasonic signal to be transmitted into an item;
causing an echo of the transmitted ultrasonic signal to be received from the item;
measuring the echo; and
undertaking a comparison with another echo to extract information relating to additional material at a surface of the item.
The term “additional material” refers to material which forms as a deposit at the surface while the item is in use, or which is intentionally applied as a deposit to the surface, such as a paint or other coating. During use, the additional material may grow or may be removed by wear, erosion, chemical processes, or in other ways.
Echoes may be repeatedly measured for comparison as aforesaid to extract information relating to additional material. The frequency spectrum of the echo may be measured for comparison with another frequency spectrum. Information may be extracted by comparing the shapes of the frequency spectra. The comparison of shapes of the frequency spectra may be used to characterise the composition of the additional material. The frequency spectrum of an echo measured in the item in the absence of additional material may be subtracted from the frequency spectrum of an echo measured subsequently, to create a difference spectrum which is used to characterise the additional material. The difference spectrum may indicate the material of the additional material. The frequency spectrum of the echo may be obtained by an FFT analysis.
A measurement indicative of the energy returned in the echo may be made. The energy measurement may be used to indicate the thickness of the additional material. The energy measurement may be made by measuring the maximum amplitude of the echo. The energy measurement may be made by measuring the difference between the maximum and minimum values of the echo. The energy measurement may be made by an integration procedure. The integration may be applied to the echo in the time domain. The integration may be applied to a FFT of the echo.
The transmitted ultrasound signal may include a spectrum of frequencies. The said another echo may be an echo measured previously from the same item. The said another echo may be an echo derived by a mathematical model of the change. The mathematical model may be based on the geometry and material properties of the item and of the additional material at the surface.
The steps of transmitting and receiving may be repeated to measure a plurality of echoes, the plurality of echoes being combined for comparison with the said another echo.
The item may be a part having a surface within an engine.
The transmitted signal may include ultrasound at a frequency between 0.5 MHz and 100 MHz, such as 10 MHz.
Examples of the present invention also provide apparatus for ultrasonic measurement of an item, comprising:
a transmitter operable to transmit an ultrasonic signal into the item;
a receiver operable to receive from the item an echo of the transmitted signal; and
the apparatus being operable to measure the echo and to make a comparison with another echo to extract information relating to additional material at a surface of the item.
Echoes may be repeatedly measured for comparison as aforesaid to extract information relating to additional material. The frequency spectrum of the echo may be measured for comparison with another frequency spectrum. The apparatus may be operable to extract information by comparing the shapes of the frequency spectra. The comparison of shapes of the frequency spectra may be used to characterise the composition of the additional material. The frequency spectrum of an echo measured in the item in the absence of additional material may be subtracted from the frequency spectrum of an echo measured subsequently, to create a difference spectrum which is used to characterise the additional material. The difference spectrum may indicate the material of the additional material.
The transmitter may be operable to transmit an ultrasound signal which includes a spectrum of frequencies.
The apparatus may be operable to obtain the frequency spectrum of the echo by an FFT analysis.
A measurement indicative of the energy returned in the echo is made. The energy measurement may be used to indicate the thickness of the additional material. The energy measurement may be made by measuring the maximum amplitude of the echo. The energy measurement may be made by measuring the difference between the maximum and minimum values of the echo. The energy measurement may be made by an integration procedure. The integration may be applied to the echo in the time domain. The integration may be applied to a FFT of the echo.
The said another echo is an echo measured previously from the same item. The said another echo may be an echo derived by a mathematical model of the change.
The apparatus may be operable to repeat the steps of transmitting and receiving to measure a plurality of echoes, and further operable to combine the plurality of echoes comparison with the said another echo.
The item may be a part having a surface within an engine.
The transmitter may be operable to transmit a signal which includes ultrasound at a frequency between 0.5 MHz and 100 MHz, such as 10 MHz.
In another aspect, examples of the present invention provide software which, when installed on a computer system, is operable to perform the whole or any part of the method set out above.
Examples of the present invention will now be described in more detail, by way of example only, and with reference to the accompanying drawings, in which:
In this example, the item 12 is a body of material which, in use, is associated with a second item 13, there being relative motion between the items 12, 13 during use. Examples include parts having a surface within an engine, such as power cylinder components, piston and cylinder liner assemblies, bearings etc. Changes may occur at the surface 15, during use, even if a second item 13 is not present. For example, chemical deposits (not shown) may grow on the surface 15, by adsorption or other processes. Hydrocarbon films may form as a result of coking within an engine. Engine oil may form hydrocarbon deposits and/or thermally derived films when encountering hot surfaces. Sliding or rolling contact between the items 12, 13, or other surface interactions may result in the growth of a tribofilm at the surface 15. Additional material may be present in the form of paint or other surface coating. This additional material may also be removed over time, by wear, erosion, chemical processes or in other ways.
The transmitter 14 and the receiver 18 are transducers of a type which can inject an ultrasonic signal into the item 12, and receive an echo. For example, the transducers 14, 18 may be piezo-ceramic transducers. In this example, the transducers 14, 18 are bonded to the item 12 in order to ensure a consistent interface between the transducers 14, 18 and the item 12, for reasons which will become apparent. Separate transducers 14, 18 are illustrated in the attached drawings, but it is envisaged that a single transceiver transducer could alternatively be used for both purposes.
The apparatus 10 also includes a data acquisition and processing unit 19. The unit 19 acquires data by generating signals applied to the transceiver 14 to inject an ultrasonic signal into the item 12, and by receiving signals detected by the transceiver 18, representing ultrasonic echoes created in response to the injected signal. The echo signals are processed by the unit 19 in order to extract information relating to a deposit of additional material at a surface 15 of the item 12, as will be described. In particular, FFT analysis is used in one example to measure the frequency spectra of echoes, and comparisons are made between spectra, to extract information relating to the item 12.
Many different technologies can be used to implement the unit 19. In one example, some or all of the processes which will be described are executed by a general purpose computing device operating under appropriate software control and communicating with the transducers 14, 18 by means of appropriate input and output interfaces (not illustrated separately). In another example, some or all of the processes are executed by dedicated devices. In other examples, a mixture of these approaches is used.
Operation with a Uniform Body
In order to understand the operation of the apparatus 10, it is appropriate first to describe this in relation to an item 12 which consists of a uniform body of a single material, as shown in
In many practical situations, the item of interest will not be a simple, uniform body of a single material. Examples include bearings with a working surface on which deposits or tribofilms may arise during use. In other examples, such as combustion chamber walls, various types of deposit may grow on the surface, or be removed. Surfaces may be coated during manufacture, by paints, wear protection layers, etc.
These scenarios are schematically illustrated in
In this example the apparatus 10 is used to transmit a signal 16 into the main body 22. The signal 16 may again be a short pulse of 10 MHz ultrasound. The signal 16 will propagate through the main body 22 as a pressure wave, until meeting the boundary 30 between the main body 22 and the surface deposit layer 24. When the signal 16 encounters the boundary 30, some of the energy will propagate into the surface layer 24 as a signal 32; some of the energy will reflect from the boundary 30 as a first echo 34.
The signal 32 will propagate onward toward the outer surface 26. The first echo 34 will propagate back toward the receiver 18. When the signal 32 reaches the outer surface 26, it is reflected to create a second echo 36, which propagates back through the surface layer 24 and then through the main body 22, toward the receiver 18. The second echo (or additional echoes) may occur also, only or primarily within the layer 24, depending on the nature of interactions with the material of the layer 24. (It is to be noted that the indications of the signals and echoes in the drawings have been simplified in order to achieve clarity, particularly by ignoring the rules by which angles of incidence and reflection will be related in any practical situation. It is also to be noted that the strength of the echo 36 will be affected by the thickness of the surface layer 24, as discussed below).
When the second echo 36 reaches the receiver 18, the total path length traveled is longer than the total path length of the first echo 34 (which has traveled only to the boundary 30, before returning). Consequently, the second echo 36 is delayed in time, relative to the first echo 34. The two echoes 34, 36 form a wave superposition of the corresponding ultrasonic pressure waves and it is this superposition which is detected by the receiver 18 as an echo signal.
Each of the echoes resulted in time-domain data from the receiver 18, similar to that illustrated in
Various explanations could be made for these results. For example, they may be considered to illustrate different levels of absorption of certain frequencies by the titanium dioxide than by the silicone, and greater excitation of other frequencies. It is therefore envisaged that the difference spectra obtained as described above and illustrated in
It is envisaged that other effects may be occurring which will affect the spectrum measured from the echo but which can be expected to be constant for any particular set-up. For example, a higher sampling speed is expected to create better resolution of the data, as can be seen from
Thus, the techniques described above are expected to create spectra which can represent a fingerprint for the characterisation of the deposit layer 24. The spectrum which is measured from an item can be compared with another spectrum, or a library of spectra, measured from the same item carrying different known surface deposit layers, or a spectrum or spectra modelled mathematically or otherwise.
The arrangement illustrated in
An initial measurement is taken in the main body 22, in the absence of any deposit layer 24. The transmitter 14 is used to inject a short pulse of ultrasound (for example, a pulse of duration 50 ns at 10 MHz). An echo 34 propagates to the receiver 18, after reflection at the surface 30. The echo 34 is measured as will be described, to provide a measurement indicative of the energy returned in the echo 34. This provides a first data point 60 on a plot of results, shown in
A deposit layer 24 is then applied to the surface 30. In this example, the deposit layer 24 is a layer of titanium dioxide applied in the presence of solvents and then allowed to dry. Once the deposit layer 24 is dry, a further signal 16 is sent from the transmitter 14 and the energy returned in the echo received at the receiver 18 is measured to provide a second data point 62 in
A measurement indicative of the energy returned in the echo received at the receiver 18 can be achieved in various ways. In one simple example, the amplitude of the echo is recorded in the time domain. This allows the highest peak and the deepest trough (negative—going peak) to be identified. The difference between these measurements can be taken as a coarse measure of the energy in the echo pulse. The amplitude of the highest peak could alternatively be used in a similar manner.
In some circumstances, the energy in the echo pulse may be spread out in the time domain, so that the amplitude of the pulse does not strongly correlate with the energy of the pulse. Accordingly an energy measurement made by an integration procedure may be provided in order to take the measurement from the whole of the echo pulse. This integration may be performed in the time domain. Alternatively, the received echo may be processed in the frequency domain, for example by conducting a FFT analysis. Again, various data techniques can be applied to the FFT data, such as an integration technique to return a measurement indicative of the energy in the echo.
Each of these measurement techniques is found to return measurements which exhibit properties similar to those illustrated in
The thickness of deposit layer 24 at which the process saturates is expected to be influenced by various factors, such as the frequency (or centre frequency) of the transmitter 14 and the bandwidth of the receiver 18. The response may also be non-linear with the energy of the transmitted signal 16. We envisage that a higher frequency signal 16 may carry less energy and therefore not penetrate as far into a deposit layer 24 and may thus saturate its response at a thinner deposit layer than would be the case with a lower frequency signal 16. We also envisage that the observed response (a reduction in energy with increased thickness, followed by a saturation) is likely to be true for longitudinal and also for shear waves.
We have therefore shown that by measuring the echo in the manner described, to provide a data point of the type illustrated in
The value of the data points 60 etc. are likely to be influenced by the identity of the material forming the deposit layer 24, as noted. Consequently, if the identity of the material is known, the example just described is expected to be able to provide a measurement of the thickness of the deposit layer 24. If the identity of the material is not known initially, we envisage that this technique could be combined with the previous example (
This second example again shows how the comparison of the measured echo with another echo (which may be previously measured or previously modelled) can be used to extract information relating to additional material at a surface of the item.
These examples illustrate that the techniques can be used to extract several different types of information about additional material at a surface of an item. In one example, the initial appearance or further growth of a surface layer can be identified, such as by the occurrence of a reduced echo energy (
Various examples of additional materials may grow as surface layers, surface deposits or films in a bearing or other structure, and are expected to be observable by the techniques set out above. These include, but are not limited to, those that form a tribofilm. “Tribofilm” is here intended to define chemistry that creates a film as a consequence of surface interactions such as sliding or rolling contact, and which is adhered on its parent worn surface but has different chemical composition, structure, and tribological behaviour. For example the tribofilm may include a layer formed from extreme pressure agents, antiwear agents, alkaline earth metal carbonate (typically calcium carbonate) typically from detergents, metal passivators, corrosion inhibitors, and friction modifiers. Of these the extreme pressure agents, antiwear agents and the calcium carbonate from detergents are believed to be the most common tribofilm forming chemistry. Extreme pressure agents typically deposit sulphur species such as sulphides on the surface, antiwear agents typically form polyphosphate or polythiophosphate films on the surface. The polyphosphate or polythiophosphate films tend to form from zinc dialkyldithiophosphates, and sulphides from sulphurised olefins.
Other examples include hydrocarbon deposits, hydrocarbon based deposits and other deposits which form during use, as a result of various processes. Processes may include chemical processes, thermal reactions, oxidation, wear, erosion etc.
In any of the examples described above, the measured echo for comparison with another echo can be derived as a single (instantaneous) measurement. However, it may be advantageous to make repeated measurements (perhaps a large number, such as 200) to measure a plurality of echoes, so that these plurality of echoes can be combined for comparison purposes. This allows some averaging or other statistical analysis to be used to improve the data obtained. It is expected that a large number of repeated measurements can be taken very quickly in comparison with the rate at which deposits will grow at the surface, in any practical situation.
We envisage that the techniques described above can be used in practice to provide real-time characterisation and thickness measurement of deposits (including applied coatings and those which arise during use) in machines, during normal use, allowing improved monitoring, maintenance scheduling and reliability. We envisage that these techniques will be successful across a range of temperatures. We envisage that, in some circumstances, the echoes which are compared should each have been measured at or modelled for substantially the same temperature within the items being measured. Temperature calibration prior to testing is also desirable. In other circumstances, the mechanisms which give rise to echoes, particularly within the layer 24, may be independent of, or less dependent on temperature.
We envisage that these techniques will allow detection at a resolution which depends on the ultrasound frequency used.
The techniques make comparisons between measurements made at different times and it is therefore important that the arrangement of the measurement apparatus and the workpiece remains consistent throughout or can be calibrated with adequate accuracy. In particular, we envisage it will be particularly advantageous to use a transducer which is bonded to the workpiece, as described above, for consistency of data.
Many variations and modifications can be made without departing from the scope of the present invention. An ultrasound frequency of 10 MHz has been described; other frequencies could be used. Other arrangements could be used for injecting ultrasound into a workpiece, detecting echoes and measuring and comparing them.
Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.
Filing Document | Filing Date | Country | Kind |
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PCT/US2014/056899 | 9/23/2014 | WO | 00 |
Number | Date | Country | |
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61884247 | Sep 2013 | US |