Real Time Ultrasound Camera for Industrial Applications

Bob LasserImperium, Inc.Beltsville, MD

Imperium

Formed in 1996 Focused solely on ultrasound camera

technology In development for 10 years, now

selling commercially Implement for different embodiments

of ultrasound camera

Sampling of Customers

Lack of trained NDT personnelLack of trained NDT personnel Prevalence towards portable devicesPrevalence towards portable devices Strong interest in imagingStrong interest in imaging Time and cost pressures Time and cost pressures

Industry Needs for New NDT Device

A-scan, B-scan, C-scan

A-scan to B-scan

Defect

B-scan versus C-scan

Defect

Defect

Ultrasound Camera

Developed to make ultrasonic testing simple High resolution Real time C-scan Large areas can be covered quickly Video presentation Free of artifacts, distortion Most imaging between 500 KHz and 10 MHz Same applications as conventional UT, only

higher resolution

Imperium’s Patented ArchitectureApplies optical imaging techniques to ultrasound

Optical Sensor (CCD) Lens

Ultrasonic Sensor (2) F1 Acoustic LensAcoustic Flashlight

Flash

Note: CCD means Charged Coupled Device

Optical Architecture:

Ultrasonic Architecture:

C-scan: Pitch Catch

Source Lens set

Array

Target

Sound Sound TransmitterTransmitter

ArrayArray

VideoVideo

LensLens

TargetTarget

Subsurface Subsurface faultfault

Pulse Echo – 50/50 Beamsplitter

Pulse echo image of quarter

Acoustic Acoustic beamsplitterbeamsplitter

WaterWater

Imaging Array

Piezoelectric Layer

Pre-amp/ detection

Signal Conditioning

Multiplexing

Pin Grid ArrayPackage

Ultrasound (piezoelectric)

material Read out

integrated circuit(ROIC)

Wire bonds

14,400 pixels

Handheld C-scan Camera

Graphical User Interface

Acoustocam i600 Camera

Introduced in 2010 1.5 lbs. versus 4 lbs. (i500) 80% less parts Robust design LCD removed Easily changed transducers

Internal Inserts – 5 MHz

One inch

C-scan Imagery: Front of Quarter

Single camera with array: 120 x 120 Distance to target: 4” Field of view: 1” Frequency: 7 MHz Wavelength: 0.20 mm Resolution: 1”/120 pixels = 0.008” or 0.21 mm

Grid Lines/Sizing

Time Corrected Gain

TCG off TCG on Threshold Crossed

Range Gating for Depth: Pick the C-scan plane of interest

Petrochemical Implementation

Petrochemical Applications

Corrosion mapping Pipes, storage tanks

Crack detection

Need simple, inexpensive easy to use device

Minimal training Portable Wireless monitoring

Scanning & Stitching

Make large mosaic images from smaller ones Capture both C-scan and thickness Uses encoder attached to side of camera

Stitching Algorithm

12

12

Individual Images

Stitched Image

Variable Weighting In Overlapped Area

Stitching Algorithm

1 2

70% Image 230% Image 1

70% Image 130% Image 2

50% Image 250% Image 1

Steel Imaging

Ultrasound video: 3.5 MHz, 1” field of view

Optical image

Mosaic Imaging : Creating Large Images From Smaller Ones

Corrosion Mapping

C-scan Optical

Lack of trained NDI personnelLack of trained NDI personnel Better quality control of NDI activitiesBetter quality control of NDI activities Use by non-certified personnelUse by non-certified personnel SIMPLE, SIMPLE, SIMPLESIMPLE, SIMPLE, SIMPLE Remotely monitored in real timeRemotely monitored in real time WirelessWireless Boeing approval spring 2011Boeing approval spring 2011

Boeing Remote NDI Program

Remote Wireless NDI Program

C-scan, A-scan, Audio, Video of inspection

Audio, Control of camera

Remote NDI Demonstration

Global Inspection Product Development Award