Patent US5654977A successfully refreshed from Google Patents.
US5654977A
Expired / Lapsed
US
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Method and apparatus for real time defect inspection of metal at elevated temperature
Assignee: TDY Industries LLC
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Filing: 1995-02-02
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Granted: 1997-08-05
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Expires: 2015-02-02
Abstract
Abstract A system for detecting, in real time, the existence, depth, extent, and type of a defect in an above ambient temperature object which has been formed by working or other heat input. Such defect detection is performed by analyzing IR emissions from the product, and from a defect site in particular, in order to assess the characteristics of the detected defect. The defect observables are then compared with known defect training data in order to characterize the defect as to type, depth and extent.
Inventors
- 👤 John W. Morris
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 16:45
CPC Classifications
G; G01; G01N; G01N25/00; G01N25/72; G01N33/00; G01N33/20; G01N33/204; G01N33/2045
Claims Analysis
Total Claims: 67
Claim 1
Independent Claim
188 words
An apparatus for inspecting an object in real time to determine an existence of a defect in the object, said apparatus comprising: an IR detection device directed at a focal region on the object in order to detect IR radiation emitted from the focal region, said detection device outputting detection signals corresponding to the focal region which signals include temperature; a means for advancing the object to inspect another contiguous focal region on the object; computing means for maintaining a running average of detected temperatures and calculating a deviation threshold corresponding to said running average; and a memory containing pre-stored known defect profiles; said computing means determines the existence of the defect when a detected temperature exceeds said deviation threshold; said computing means determines a defect depth when the defect exists by analysis of a temperature gradient between detection signals in a particular focal region; said computing means determines a defect type by tracking the defect after the defect is detected and mapping the existence of the defect through contiguous focal regions to generate a defect signature pattern and comparing the signature with said pre-stored known defect profiles.
Claim 2
Independent Claim
188 words
An apparatus for inspecting an object in real time to determine an existence of a defect in the object, said apparatus comprising: an IR detection device directed at a focal region on the object in order to detect IR radiation emitted from the focal region, said detection device outputting detection signals corresponding to the focal region which signals include temperature; a means for advancing the object to inspect another contiguous focal region on the object; computing means for maintaining a running average of detected temperatures and calculating a deviation threshold corresponding to said running average; and a memory containing pre-stored known defect profiles; said computing means determines the existence of the defect when a detected temperature exceeds said deviation threshold; said computing means determines a defect depth when the defect exists by analysis of a temperature gradient between detection signals in a particular focal region; said computing means determines a defect type by tracking the defect after the defect is detected and mapping the existence of the defect through contiguous focal regions to generate a defect signature pattern and comparing the signature with said pre-stored known defect profiles.
Claim 3
Dependent Claim
24 words
An apparatus as claimed in claim 1 wherein, said IR detection device is an IR camera having at least one linear focal plane array.
Claim 4
Dependent Claim
33 words
An apparatus as claimed in claim 1 wherein, said means for advancing the focal region relative to the object is a system which forms the focal regions prior to inspection of said object.
Claim 5
Dependent Claim
38 words
An apparatus as claimed in claim 1 wherein, said means for advancing the focal region relative to said object is an arrangement for moving said IR detection device over an object to be inspected which object is stationary.
Claim 6
Dependent Claim
31 words
An apparatus as claimed in claim 1 wherein, said means for advancing the focal region relative to the object is a movable optic arrangement which is capable of directing IR radiation.
Claim 7
Dependent Claim
18 words
An apparatus as claimed in claim 1 wherein, said computing means includes a computer which utilizes parallel processing.
Claim 8
Dependent Claim
16 words
An apparatus as claimed in claim 1 wherein, said computing means includes a programmable gate array.
Claim 9
Dependent Claim
18 words
An apparatus as claimed in claim 1 wherein, said computing means further includes an analog to digital converter.
Claim 10
Dependent Claim
21 words
An apparatus as claimed in claim 1 wherein, the object is formed metal having a temperature higher than an ambient temperature.
Claim 11
Dependent Claim
25 words
An apparatus as claimed in claim 1 wherein, a plurality of IR detection devices are utilized in order to provide enhanced inspection of the object.
Claim 12
Dependent Claim
24 words
An apparatus as claimed in claim 10 wherein, said IR detection devices are arranged in order to inspect an entire perimeter of the object.
Claim 13
Dependent Claim
19 words
An apparatus as claimed in claim 1 wherein, said IR detection device further detects spatial characteristics of the object.
Claim 14
Dependent Claim
33 words
An apparatus as claimed in claim 1 wherein, a shape of the object is selected from a group consisting of a bar, a beam, a rod, a wire, a sheet, and a plate.
Claim 15
Dependent Claim
15 words
An apparatus as claimed in claim 1 wherein, said apparatus further includes a calibration element.
Claim 16
Dependent Claim
28 words
An apparatus as claimed in claim 1 wherein, said apparatus further includes a guide for maintaining said object proximal to a focal area of said IR detection device.
Claim 17
Dependent Claim
22 words
An apparatus as claimed in claim 1 wherein, said IR detection device includes a mirror and optics for directing said IR radiation.
Claim 18
Independent Claim
132 words
An apparatus for inspecting an object in real time to determine an existence of a defect in the object, said apparatus comprising: an IR detection device directed at a focal region on the object in order to detect IR radiation emitted from the focal region, said detection device outputting detection signals corresponding to the focal region which signals include temperature; a means for advancing the object to inspect another contiguous focal region on the object; transverse data processing means for processing detection signals from said focal region and generating transverse scan data corresponding to said focal region: longitudinal data processing means for compiling and correlating contiguous transverse scan data to generate an object profile; computing means having a memory for comparing said object profile with know defect profiles stored in said memory.
Claim 19
Independent Claim
132 words
An apparatus for inspecting an object in real time to determine an existence of a defect in the object, said apparatus comprising: an IR detection device directed at a focal region on the object in order to detect IR radiation emitted from the focal region, said detection device outputting detection signals corresponding to the focal region which signals include temperature; a means for advancing the object to inspect another contiguous focal region on the object; transverse data processing means for processing detection signals from said focal region and generating transverse scan data corresponding to said focal region: longitudinal data processing means for compiling and correlating contiguous transverse scan data to generate an object profile; computing means having a memory for comparing said object profile with know defect profiles stored in said memory.
Claim 20
Dependent Claim
24 words
An apparatus as claimed in claim 17 wherein, said IR detection device is an IR camera having at least one linear focal plane array.
Claim 21
Dependent Claim
33 words
An apparatus as claimed in claim 17 wherein, said means for advancing the focal region relative to the object is a system which forms the focal regions prior to inspection of said object.
Claim 22
Dependent Claim
38 words
An apparatus as claimed in claim 17 wherein, said means for advancing the focal region relative to said object is a system for moving the IR detection device over the object to be inspected which object is stationary.
Claim 23
Dependent Claim
31 words
An apparatus as claimed in claim 17 wherein, said device for advancing the focal region relative to the object is a movable optic arrangement which is capable of directing IR radiation.
Claim 24
Dependent Claim
23 words
An apparatus as claimed in claim 17 wherein, said transverse and said longitudinal data processing means include a computer which utilizes parallel processing.
Claim 25
Dependent Claim
21 words
An apparatus as claimed in claim 17 wherein, said transverse and said longitudinal data processing means include a programmable gate array.
Claim 26
Dependent Claim
18 words
An apparatus as claimed in claim 17 wherein, said computing means further includes an analog to digital convertor.
Claim 27
Dependent Claim
14 words
An apparatus as claimed in claim 17 wherein, said computing means is a computer.
Claim 28
Dependent Claim
21 words
An apparatus as claimed in claim 17 wherein, the object is formed metal having a temperature higher than an ambient temperature.
Claim 29
Dependent Claim
33 words
An apparatus as claimed in claim 26 wherein, a shape of the object is selected from the group consisting of a bar, a beam, a rod, a wire, a sheet and a plate.
Claim 30
Dependent Claim
25 words
An apparatus as claimed in claim 17 wherein, a plurality of IR detection devices are utilized in order to provide enhanced inspection of the object.
Claim 31
Dependent Claim
24 words
An apparatus as claimed in claim 28 wherein, said IR detection devices are arranged in order to inspect an entire perimeter of said object.
Claim 32
Dependent Claim
19 words
An apparatus as claimed in claim 17 wherein, said IR detection device further detects spatial characteristics of the object.
Claim 33
Dependent Claim
15 words
An apparatus as claimed in claim 17 wherein, said apparatus further includes a calibration element.
Claim 34
Dependent Claim
26 words
An apparatus as claimed in claim 17 wherein, said apparatus further includes a guide for maintaining the object within a focal area of the IR detector.
Claim 35
Dependent Claim
22 words
An apparatus as claimed in claim 17 wherein, said IR detection device includes a mirror and optics for directing said IR radiation.
Claim 36
Independent Claim
107 words
An apparatus for inspecting an object in real time to determine an existence of a defect in the object, said apparatus comprising: an IR detection device directed at a focal region on the object in order to detect IR radiation emitted from the focal region, said detection device outputting detection signals corresponding to the focal region which signals include temperature; a means for advancing the object to inspect another contiguous focal region on the object; data processing means for processing detection signals from contiguous focal regions into an object profile; computing means having a memory for comparing said object profile with defect profiles stored in said memory.
Claim 37
Independent Claim
107 words
An apparatus for inspecting an object in real time to determine an existence of a defect in the object, said apparatus comprising: an IR detection device directed at a focal region on the object in order to detect IR radiation emitted from the focal region, said detection device outputting detection signals corresponding to the focal region which signals include temperature; a means for advancing the object to inspect another contiguous focal region on the object; data processing means for processing detection signals from contiguous focal regions into an object profile; computing means having a memory for comparing said object profile with defect profiles stored in said memory.
Claim 38
Dependent Claim
24 words
An apparatus as claimed in claim 34 wherein, said IR detection device is an IR camera having at least one linear focal plane array.
Claim 39
Dependent Claim
33 words
An apparatus as claimed in claim 34 wherein, said device for advancing the focal region relative to the object is a system which forms the focal regions prior to inspection of the object.
Claim 40
Dependent Claim
38 words
An apparatus as claimed in claim 34 wherein, said device for advancing the focal region relative to the object is a system for moving said IR detection device over the object to be inspected which object is stationary.
Claim 41
Dependent Claim
31 words
A apparatus as claimed in claim 34 wherein, said device for advancing the focal region relative to the object is a movable optic arrangement which is capable of directing IR radiation.
Claim 42
Dependent Claim
19 words
An apparatus as claimed in claim 34 wherein, said data processing means includes a computer which utilizes parallel processing.
Claim 43
Dependent Claim
17 words
An apparatus as claimed in claim 34 wherein, said data processing means includes a programmable gate array.
Claim 44
Dependent Claim
18 words
An apparatus as claimed in claim 34 wherein, said computing means further includes an analog to digital converter.
Claim 45
Dependent Claim
14 words
An apparatus as claimed in claim 34 wherein, said computing means includes a computer.
Claim 46
Dependent Claim
21 words
An apparatus as claimed in claim 34 wherein, the object is formed metal having a temperature higher than an ambient temperature.
Claim 47
Dependent Claim
33 words
An apparatus as claimed in claim 43 wherein, a shape of the object is selected from the group consisting of a bar, a beam, a rod, a wire, a sheet and a plate.
Claim 48
Dependent Claim
25 words
An apparatus as claimed in claim 34 wherein, a plurality of IR detection devices are utilized in order to provide enhanced inspection of the object.
Claim 49
Dependent Claim
24 words
An apparatus as claimed in claim 45 wherein, said IR detection devices are arranged in order to inspect an entire perimeter of the object.
Claim 50
Dependent Claim
19 words
An apparatus as claimed in claim 34 wherein, said IR detection device further detects spatial characteristics of the object.
Claim 51
Dependent Claim
15 words
An apparatus as claimed in claim 34 wherein, said apparatus further includes a calibration element.
Claim 52
Dependent Claim
27 words
An apparatus as claimed in claim 34 wherein, said apparatus further includes a guide for maintaining the object proximal to a focal area of said IR detector.
Claim 53
Dependent Claim
22 words
An apparatus as claimed in claim 34 wherein, said IR detection device includes a mirror and optics for directing said IR radiation.
Claim 54
Independent Claim
145 words
A method for inspecting an object in real time to determine an existence of a defect in the object, said method comprising the steps of: detecting IR radiation emitted by the object at a focal region; outputting detection signals corresponding to said focal region which detection signals include temperature; advancing said focal region relative to the object to the next contiguous focal region; maintaining a running average of detected temperatures and calculating a deviation threshold corresponding to said running average; indicating defect detection when a detected temperature exceeds said deviation threshold; determining a defect depth by assessing temperature gradient between detection signals for a particular focal region; identifying a defect by opening a tracking file when the defect is detected and mapping the defect through contiguous focal regions to generate a defect signature and comparing said defect signature with known defect profiles stored in memory.
Claim 55
Independent Claim
145 words
A method for inspecting an object in real time to determine an existence of a defect in the object, said method comprising the steps of: detecting IR radiation emitted by the object at a focal region; outputting detection signals corresponding to said focal region which detection signals include temperature; advancing said focal region relative to the object to the next contiguous focal region; maintaining a running average of detected temperatures and calculating a deviation threshold corresponding to said running average; indicating defect detection when a detected temperature exceeds said deviation threshold; determining a defect depth by assessing temperature gradient between detection signals for a particular focal region; identifying a defect by opening a tracking file when the defect is detected and mapping the defect through contiguous focal regions to generate a defect signature and comparing said defect signature with known defect profiles stored in memory.
Claim 56
Dependent Claim
21 words
A method as claimed in claim 51 wherein, said method further includes converting said detection signals into digital transverse scan data.
Claim 57
Dependent Claim
31 words
A method as claimed in claim 52 wherein, said method further involves spatially aligning consecutive transverse scan data in a direction of relative motion between an IR detector and the object.
Claim 58
Dependent Claim
32 words
A method as claimed in claim 51 wherein, said method further includes determining an extent of the defect by measuring a number and arrangement of pixels which make up said defect signature.
Claim 59
Dependent Claim
30 words
A method as claimed in claim 52 wherein, said method further comprises: opening the tracking file when a defect is detected; and mapping the defect in subsequent transverse scan data.
Claim 60
Dependent Claim
40 words
A method as claimed in claim 51 wherein, said method further comprises: entering a learning mode when a particular detected defect fails to match known defect profiles stored in memory; and storing characteristics of the particular detected defect in memory.
Claim 61
Dependent Claim
19 words
A method as claimed in claim 51 wherein, said method further comprises: performing noise reduction on said detected signals.
Claim 62
Independent Claim
146 words
A method for inspecting an object in real time to determine an existence of a defect in the object, said method comprising the steps of: detecting IR radiation emitted by the object at a focal region; outputting detection signals corresponding to said focal region which detection signals include temperature; generating transverse scan data by converting said detection signals into digital data; advancing said focal region relative to the object to a next contiguous focal region; compiling and correlating contiguous transverse scan data in order to generate an object signature; maintaining a running average of detected temperatures and calculating a deviation threshold corresponding to said running average; indicating defect detection when a detected temperature exceeds said deviation threshold; determining defect depth by analyzing temperature gradient between detection signals for a particular focal region; identifying the defect by comparing said signature with known defect profiles stored in memory.
Claim 63
Independent Claim
146 words
A method for inspecting an object in real time to determine an existence of a defect in the object, said method comprising the steps of: detecting IR radiation emitted by the object at a focal region; outputting detection signals corresponding to said focal region which detection signals include temperature; generating transverse scan data by converting said detection signals into digital data; advancing said focal region relative to the object to a next contiguous focal region; compiling and correlating contiguous transverse scan data in order to generate an object signature; maintaining a running average of detected temperatures and calculating a deviation threshold corresponding to said running average; indicating defect detection when a detected temperature exceeds said deviation threshold; determining defect depth by analyzing temperature gradient between detection signals for a particular focal region; identifying the defect by comparing said signature with known defect profiles stored in memory.
Claim 64
Dependent Claim
18 words
A method as claimed in claim 58 wherein, said method further involves spatially aligning consecutive transverse scan data.
Claim 65
Dependent Claim
30 words
A method as claimed in claim 58 wherein, said method further comprises: opening the tracking file when a defect is detected; and mapping the defect in subsequent transverse scan data.
Claim 66
Dependent Claim
40 words
A method as claimed in claim 58 wherein, said method further comprises: entering a learning mode when a particular detected defect fails to match known defect profiles stored in memory; and storing characteristics of the particular detected defect in memory.
Claim 67
Dependent Claim
19 words
A method as claimed in claim 58 wherein, said method further comprises: performing noise reduction on said detected signals.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2000-08-04 | 2001-02-03 | 2001-08-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-08-04 | 2005-02-03 | 2005-08-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-08-04 | 2009-02-03 | 2009-08-05 | $7700.00 | Window Closed / Lapsed |