Convex ultrasonic sensor for weld inspection
A system and a method embodiment or automatic inspection of branch wells is provided. An exemplary system includes a scanning head including an ultrasonic probe, wherein the ultrasonic probe includes a convex crystal. A track is mounted to a branch pipe welded to a main pipe, wherein the scanning head mounts to the track, and wherein the scanning head moves the ultrasonic probe along the track. The system includes a controller configured to display an image based on data provided from the ultrasonic probe.
1. A system for automatic inspection of branch welds, comprising:
a scanning head comprising an ultrasonic probe, wherein the ultrasonic probe comprises a convex crystal;
a track mounted to a branch pipe welded to a main pipe, wherein the scanning head mounts to the track, and wherein the scanning head moves the ultrasonic probe along the track; and
a controller configured to display an image based on data provided from the ultrasonic probe.
2. The system of claim 1 , wherein the convex crystal has a conical beam comprising a focal point behind the surface of the convex crystal.
3. The system of claim 1 , wherein the track comprises a rack gear configured to couple to a pinion gear on the scanning head.
4. The system of claim 3 , wherein the scanning head comprises a motor coupled to the pinion gear to move the scanning head along the rack gear of the track.
5. The system of claim 1 , wherein the scanning head comprises a magnet to hold the scanning head to the branch pipe.
6. The system of claim 1 , wherein the scanning head comprises a radio communications device to couple the ultrasonic probe to the controller.
7. The system of claim 1 , wherein the scanning head comprises a memory to store ultrasonic data from the ultrasonic probe.
8. The system of claim 7 , wherein the controller couples to the memory to download the ultrasonic data from the ultrasonic probe.
9. The system of claim 1 , wherein the controller comprises:
a processor;
a sensor interface coupled to the ultrasonic probe;
a controller interface coupled to the scanning head; and
a data store, wherein the data store comprises instructions that, when executed, direct the processor to:
obtain control inputs from a user;
control the scanning head to move the ultrasonic probe along the track;
collect ultrasonic data from the ultrasonic probe;
store the ultrasonic data; and
generate the image from the ultrasonic data.
10. The system of claim 9 , wherein the data store comprises instructions that, when executed, direct the processor to obtain the ultrasonic data from a memory in the scanning head.
11. The system of claim 9 , wherein the data store comprises instructions that, when executed, direct the processor to highlight potential weld defects in the image.
12. The system of claim 9 , wherein the controller comprises a radio frequency (RF) interface to couple to the scanning head.
13. The system of claim 12 , wherein the RF interface comprises a Wi-Fi interface system.
14. The system of claim 12 , wherein the data store comprises instructions, that when executed, direct the processor to communicate with external networks.
15. A method for automatic inspection of a branch weld, comprising:
mounting a scanner track along an outer circumference of a branch pipe, welded to a main pipe;
mounting a scanning head on the scanner track, wherein the scanning head comprises an ultrasonic probe comprising a convex crystal;
scanning along the outer circumference of the branch pipe to collect ultrasonic data;
analyzing the ultrasonic data to generate an image; and
determining if defects in the branch weld are present based on the image.
16. The method of claim 15 , comprising mounting the scanner track in a circular pattern around the outer circumference of the branch pipe.
17. The method of claim 15 , comprising mounting the scanner track parallel to the branch weld.
18. The method of claim 15 , comprising applying an acoustic coupling fluid to the branch pipe under the scanning head.
19. The method of claim 15 , comprising storing the ultrasonic data in a memory in the scanning head.
20. The method of claim 19 , comprising generating the image from the ultrasonic data stored in the memory.