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Cone type Phased Array Design for High Speed Hollow Axle ...For hollow axle inspection typically a...
Transcript of Cone type Phased Array Design for High Speed Hollow Axle ...For hollow axle inspection typically a...
ESIS TC24 Workshop: Integrity of Railway Structures
1 License: http://creativecommons.org/licenses/by-nd/3.0/
Cone type Phased Array Design for High
Speed Hollow Axle Inspection
Rainer BOEHM 1, Thomas HECKEL 1, Michel BLANKSCHÄN 1, Wolfgang SPRUCH 2, Toni BEGGEROW 2
1 Bundesanstalt für Materialforschung und -prüfung (BAM), Berlin, Germany 2 Büro für technische Diagnostik BTD, Brandenburg, Germany
Contact e-mail: [email protected]
Abstract
To increase inspection speed and inspection reliability the use of phased array system is a superior solution. Especially for shaft inspection phased array setups are commonly used. For hollow axle inspection typically a number conventional probes rotating through the axles drilling are applied, without demounting the axes and without dismantling the wheels and the brake discs. A new approach using a cone type array operated in immersion technique will allows to increase inspection speed and reduce the mechanical effort of the inspection system by rotating the sound field for the circumferential scan electronically. Only a linear movement of the probe is necessary to move the phased array cone forward and backwards inside the drilling. By applying additional focal laws the beam can be inclined exactly and be focused in the plane vertical to the specimen axis to concentrate the sound in the zones close to the external surface of the railway axle. The cone type phased array probe has been optimized to detect transversal flaws in and close to the outer surface of the hollow axle, whose surface lies in the radial-radial plane. The prototype probe system and its performance will be presented.
CONE TYPE PHASED ARRAY DESIGN FOR HIGH SPEED HOLLOW AXLE INSPECTION R. Boehm1, T. Heckel1, M. Blankschän1, W. Spruch2, T. Beggerow2 1 BAM, Bundesanstalt für Materialforschung und –prüfung, Berlin, Germany 2 BTD, Büro für Technische Diagnostik, Brandenburg, Germany
2017/09/26 – PRESENTATION
CONTENT
• Task • Principle of the scanning technique • Prior developments • New array design • Conclusion
Page 2 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
New Array Design for Electronic Rotation Scanning
TASK
Rail axle with longitudinal bore hole and test zones
Page 3 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
TASK
Orientation of transversal flaw in the radial – radial plane Page 4 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
bore hole
testregiontransversal flaw
PRINCIPLE OF THE SCANNING TECHNIQUE
Sketch of the cone shaped phased array for electronic rotation scan Page 5 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Kegelarray inmitten der Bohrung Ø 65 mm
Hohlwelle Flüssigkeit
Schallbündelrotation
Schwingerelemente Hohlwelle Axle Array Elements Fluid Axle
Conical array centered in the hole Electronic rotation
Bore hole Ø 65 mm
RESULTS OF PRIOR STUDIES
First cone array shown at ECNDT 2006 and Calculated sound fields Page 6 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Büro für Technische Diagnostik (BTD)
Testing zone
Calculated sound fieldsin the plane of incidence and
perpendicular thereto
Bore hole Ø = 30 mm
RESULTS OF PRIOR STUDIES
Page 7 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Cone array system encapsulated in an oil cavity for simultanious testing in foreward and backward direction; developed in the project WOLAXIM 2012
NEW DESIGN
Page 8 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Geometrical boundary conditions for the current task
Lower cone diameter ≥ 20 mm
Upper cone diameter ≤ 60 mm
Bore hole Ø = 65 mm
Cone angle = 2 b b depends on the angle of incidence
Element
Max. element length
SOUND FIELD SIMULATION
Page 9 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
The position of the array in the bore hole and the line of computation points circumferential at the outer surface of the axle with Ø = 175 mm
Bore hole Active elements
Position for calclation
Focal point (example)
SOUND FIELD SIMULATION, FOCUSING
Page 10 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Directivity of the array with 13 active elements from 108 in total
unfocusedNor
malize
damp
litude
Circumferencial angle position in °
1.0
0.8
0.6
0.4
0.2
0.0-50 -40 -30 -20 -10 0 10 20 30 40 50
Fluid
Sound beam
Axle
SOUND FIELD SIMULATION, FOCUSING
Page 11 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Directivity of the array with 13 active elements from 108 in total, focusing in circumferential direction, focus at the surface of the axle
Fluid
Sound beam
Axle
grating lobes
focussedNor
malize
damp
litude
Circumferencial angle position in °
1.0
0.8
0.6
0.4
0.2
0.0-50 -40 -30 -20 -10 0 10 20 30 40 50
-17 dB amp. -34 dB echo
SOUND FIELD SIMULATION, FOCUSING
Page 12 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Norma
lizeda
mplitu
de
Circumferencial angle position in °
1.0
0.8
0.6
0.4
0.2
0.0-50 -40 -30 -20 -10 0 10 20 30 40 50
grating lobes
Focal points at0°, 10°, 20° and 30°
Main beam
Grating lobe
1 µs
Pulses and spectra at 0° and -20° for the focal point at 0°, normalized amplitudes Amplitudes at different swivel angles in relation to the grating lobes
17 active el., bw = 1.6°13 active el., bw = 1.8°
9 active el., bw = 2.3°5 active el., bw = 3.8°
-5 -4 -3 -2 -1 0 1 2 3 4 5
Amplit
ude
Circumferencial angle position in °
1000800600400200
0
SOUND FIELD SIMULATION, NUMBER OF ELEMENTS
Page 13 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Directivity of single elements of an array with 17 active elements Amplitude and divergence angle bw with different numbers of active elements
Position = 1 3 5 7 9 11 13 15 17
Amplit
ude
Circumferencial angle position in °
100
80
60
40
20
0-50 -40 -30 -20 -10 0 10 20 30 40 50
1530 1170
810
450
SOUND FIELD SIMULATION, ROTATION SCAN
Page 14 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Rotation of the sound field by shifting the group of active elements and by focal law
1 el. shift, -3.33° Middle position
Norma
lizeda
mplitu
de
Circumferencial angle position in °
1.0
0.8
0.6
0.4
0.2
0.0-5 -4 -3 -2 -1 0 1 2 3 4 5
steering to -1.7° Middle position
Norma
lizeda
mplitu
de
Circumferencial angle position in °
1.0
0.8
0.6
0.4
0.2
0.0-5 -4 -3 -2 -1 0 1 2 3 4 5
1 el. shift, -3.33°
SOUND FIELD SIMULATION, FOCUSING II
Page 15 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Concave curved elements for focusing in the plane of incidence
00.10.20.30.40.50.60.70.80.9
1
6 10 14 18 22 26
Norm
alized
amplit
ude
Element length in mmunfocused focussed
SOUND FIELD SIMULATION, FOCUSING II
Page 16 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Concave curved elements for focusing in the plane of incidence
00.10.20.30.40.50.60.70.80.9
1
6 10 14 18 22 26
Norm
alized
amplit
ude
Element length in mmunfocused focussed02468
101214
6 10 14 18 22 26
Beam d
iverge
nce in °
Element length in mmunfocused focussed
SOUND FIELD SIMULATION, FOCUSING II
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Cross section of the beam at the axle surface focused and unfocused angle of incidence a in °46 44 42 40 38 36 34 32 30
mm-10 -8 -6 -4 -2 0 2 4 6 8 10
Plane elements
Curved elements 5 mm ≙ 2°
5 mm ≙ 2°
SOUND FIELD SIMULATION, FOCUSING II
Page 18 26. Sept., 2017 Cone type Phased Array Design for High Speed Hollow Axle Inspection ESIS TC24 Workshop, Integrity of Railway Structures, Wittenberge 2017
Cross section of the focused beam at the axle surface
2 mm
Cut of theplane of incidence
Line perpendicuar tothe plane of incidence
-3 dB-6 dB
-12 dB
Expected echo height
NEW DESIGNED PHASED ARRAY SYSTEM
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CONCLUSION Properties of the new cone type phased array, (earlyer versions) • Probe is optimized for a bore hole diameter of 65 mm • Higher frequency, 4 MHz (2.7 MHz) • Maximum cone diameter 60 mm (28 mm) • More elements, 108 (48) • Narrower elements, 1 mm (1.25 mm) • Longer elements, 25 mm (12 mm) • Focussing in the plane of incidence with curved elements • Nearly cycle shaped beam, or • adaptable beam divergence in circumferencial direction All this results in higher resolution and sensitivity
THANK YOU FOR YOUR ATTENTION QUESTIONS? [email protected] / www.bam.de
2017/09/26 This project has received funding from the Europeen Union‘s Horizon 2020 research and innovation program under grant agreement no 674231 RAAI