Automated weld inspection system with weld acceptability pass or fail indications

1. A system for non-destructively evaluating spot welds, comprising:

(a) at least one matrix phased array probe, wherein the matrix phased array probe includes:

(i) a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and receive reflections thereof; and

(ii) a combination of materials for allowing the probe to conform to a contoured surface of a spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on a tip of the probe and a fluid filled chamber or solid sound delay material disposed between the membrane and the array;

(b) a fixture adapted to be mounted on a robot or other mechanical actuator, wherein the fixture is further adapted to retain the at least one matrix phased array probe; and

(c) an enclosure, wherein the enclosure further includes:

(i) at least one input for connecting to the at least one matrix phased array probe;

(ii) ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input;

(iii) at least one data processor running software that includes at least one algorithm for processing data received from the probe and generating discrete specifications of evaluated welds, wherein the discrete specifications further include pass indications or fail indications regarding weld acceptability; and

(iv) at least one output for outputting the discrete specifications of the evaluated welds.

2. The system of claim 1 , wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals.

3. The system of claim 2 , wherein activating each subgroup independently of the other subgroups and at different time intervals for each of the transducer elements in the subgroup provides signal focusing and steering capability.

4. The system of claim 1 , wherein the ultrasonic phased array transmitting and receiving circuitry further includes 64-channel phased array circuitry with 16-channel simultaneous multiplexing capability.

5. The system of claim 1 , wherein the software further includes inputs that permit calibration of the system by using the matrix phased array probe to initially scan a weld joint of known diameter and then adjust system gating ratios accordingly.

6. The system of claim 1 , wherein the robot or other mechanical actuator is operative to move the probe through a predetermined range of positions, and wherein the predetermined range of positions is operative to facilitate production of high-integrity scans of welds being characterized.

7. The system of claim 1 , wherein the robot or other mechanical actuator includes a slide, and wherein the slide provides compliance for accommodating variations in shape and location of welded parts, and further wherein the compliance allows the probe to be applied to a weld surface to be inspected with a predetermined force that is constant across a predetermined range of displacements.

8. The system of claim 1 , wherein the at least one matrix phased array probe is operative to determine physical characteristics of a weld being examined, and wherein the physical characteristics include measured weld diameter at various locations within the weld, total area of weld penetration, weld perimeter, weld shape, or combinations thereof.

9. The system of claim 1 , wherein the at least one matrix phased array probe is operative to measure normality to workpiece surface based on the reflections of the ultrasonic signals at disparate elements within the probe.

10. The system of claim 1 , wherein the tip of the probe is pre-filled with a couplant, and wherein the pre-filled tip further includes a quick-connect disconnect mechanism for rapidly detaching and reattaching the tip to the probe.

11. The system of claim 10 , wherein the software generates notifications when the tip of the probe requires replacement.

12. A system for non-destructively evaluating spot welds, comprising:

(a) at least one matrix phased array probe, wherein the matrix phased array probe includes:

(i) a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and receive reflections thereof, and wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals; and

(ii) a combination of materials for allowing the probe to conform to a contoured surface of a spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on a tip of the probe and a fluid filled chamber or solid sound delay material disposed between the membrane and the array;

(b) a fixture adapted to be mounted on a robot or other mechanical actuator, wherein the fixture is further adapted to retain the at least one matrix phased array probe, wherein the robot or other mechanical actuator is operative to move the probe through a predetermined range of positions, and wherein the predetermined range of positions is operative to facilitate production of high-integrity scans of welds being characterized; and

(c) an enclosure, wherein the enclosure further includes:

(i) at least one input for connecting to the at least one matrix phased array probe;

(ii) ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input;

(iii) at least one data processor running software that includes at least one algorithm for processing data received from the probe and generating discrete specifications of evaluated welds, wherein the discrete specifications further include pass indications or fail indications regarding weld acceptability; and

(iv) at least one output for outputting the discrete specifications of the evaluated welds.

13. The system of claim 12 , wherein activating each subgroup independently of the other subgroups and at different time intervals for each of the transducer elements in the subgroup provides signal focusing and steering capability.

14. The system of claim 12 , wherein the ultrasonic phased array transmitting and receiving circuitry further includes 64-channel phased array circuitry with 16-channel simultaneous multiplexing capability.

15. The system of claim 12 , wherein the software further includes inputs that permit calibration of the system by using the matrix phased array probe to initially scan a weld joint of known diameter and then adjust system gating ratios accordingly.

16. The system of claim 12 , wherein the robot or other mechanical actuator includes a slide, and wherein the slide provides compliance for accommodating variations in shape and location of welded parts, and further wherein the compliance allows the probe to be applied to a weld surface to be inspected with a predetermined force that is constant across a predetermined range of displacements.

17. The system of claim 12 , wherein the at least one matrix phased array probe is operative to determine physical characteristics of a weld being examined, and wherein the physical characteristics include measured weld diameter at various locations within the weld, total area of weld penetration, weld perimeter, weld shape, or combinations thereof.

18. The system of claim 12 , wherein the at least one matrix phased array probe is operative to measure normality to workpiece surface based on the reflections of the ultrasonic signals at disparate elements within the probe.

19. The system of claim 12 , wherein the tip of the probe is pre-filled with a couplant, and wherein the pre-filled tip further includes a quick-connect disconnect mechanism for rapidly detaching and reattaching the tip to the probe.

20. The system of claim 19 , wherein the software generates notifications when the tip of the probe requires replacement.

21. A system for non-destructively evaluating spot welds, comprising:

(a) at least one matrix phased array probe, wherein the matrix phased array probe includes:

(i) a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and receive reflections thereof; and wherein the transducer elements are further arranged into discrete subgroups, and wherein each subgroup may be activated independently of the other subgroups and at different time intervals; and

(ii) a combination of materials for allowing the probe to conform to a contoured surface of a spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on a tip of the probe and a fluid filled chamber or solid sound delay material disposed between the membrane and the array, and wherein the tip of the probe is pre-filled with a couplant, and further includes a quick-connect disconnect mechanism for rapidly detaching and reattaching the tip to the probe; and

(b) a fixture adapted to be mounted on a robot or other mechanical actuator, wherein the fixture is further adapted to retain the at least one matrix phased array probe, wherein the robot or other mechanical actuator is operative to move the probe through a predetermined range of positions, and wherein the predetermined range of positions is operative to facilitate production of high-integrity scans of welds being characterized; and

(c) an enclosure, wherein the enclosure further includes:

(i) at least one input for connecting to the at least one matrix phased array probe;

(ii) ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input;

(iii) at least one data processor running software that includes at least one algorithm for processing data received from the probe and generating discrete specifications of evaluated welds, wherein the discrete specifications further include pass indications or fail indications regarding weld acceptability; and

(iv) at least one output for outputting the discrete specifications of the evaluated welds.

22. The system of claim 21 , wherein activating each subgroup independently of the other subgroups and at different time intervals for each of the transducer elements in the subgroup provides signal focusing and steering capability.

23. The system of claim 21 , wherein the ultrasonic phased array transmitting and receiving circuitry further includes 64-channel phased array circuitry with 16-channel simultaneous multiplexing capability.

24. The system of claim 21 , wherein the software further includes inputs that permit calibration of the system by using the matrix phased array probe to initially scan a weld joint of known diameter and then adjust system gating ratios accordingly.

25. The system of claim 21 , wherein the robot or other mechanical actuator includes a slide, and wherein the slide provides compliance for accommodating variations in shape and location of welded parts, and further wherein the compliance allows the probe to be applied to a weld surface to be inspected with a predetermined force that is constant across a predetermined range of displacements.

26. The system of claim 21 , wherein the at least one matrix phased array probe is operative to determine physical characteristics of a weld being examined, and wherein the physical characteristics include measured weld diameter at various locations within the weld, total area of weld penetration, weld perimeter, weld shape, or combinations thereof.

27. The system of claim 21 , wherein the at least one matrix phased array probe is operative to measure normality to workpiece surface based on the reflections of the ultrasonic signals at disparate elements within the probe.

28. The system of claim 21 , wherein the software generates notifications when the tip of the probe requires replacement.

29. The system of claim 21 , further comprising at least one remote monitor for displaying color coded ultrasonic C-scan images of the welds being characterized, in real time.

30. The system of claim 29 , wherein the color coded ultrasonic C-scan images further include an average diameter of weld nugget and a fused area for each of the welds being characterized.