1. 1. Sonic IR Imaging on Bell ImactPanels (Hat and I-Beam)By: Justin Ar-Rasheed
2. 2. Overview Behavior of Panels Observed Optimal Experimental Settings Tested Frequency Coupling Material Tip Size/Amplitude Additional Areas of Study Mode Pattern Vibration Automation
3. 3. Legend:< 1 Diameter, 9 Each1.0 1.75 Diameter, 6 Each1.75 - 2.65 Diameter, 4 Each> 2.65 Diameter, 3 Each0.170 Skin0.096 SkinImpact Panel for Wayne State University609/30/2011 Final Impact Plan - RJB
4. 4. Hat Panel
5. 5. Test Experiments Shoot gun on various locations of panel Analyze results and come up with hypothesis
6. 6. Ultrasound20KHz Handheld20k LPt 20:0.5:90240% Amplitude800ms PulseCamera30 Frames/sIR Camera 8sFile20K_handheld/40%_30fps_8s_01.ftsPanel mounted vertically
7. 7. Ultrasound40KHz Handheld40k Lpe 40:0.5:4T100% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFile40k_handheld/100%_40fps_6s_02.fts
8. 8. Ultrasound40KHz Table Gun40k Lpe 40:0.5:4T100% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFile40k_tableGun/40fra_6s_800ms_30lbs_coin.fts
9. 9. Ultrasound40KHz Handheld40k Lpe 40:0.5:4T100% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFile40K_handheld/100%_40fps_6s_01_top.fts
10. 10. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFiles20PartitionShot/40%_Top33%_1.2s_40fps_6s20PartitionShot/50%_Top_left_33%_800ms_40fps_6s_0120PartitionShot/50%_Top_right_33%_800ms_40fps_6s01LeftMiddleRightLeft Middle Right
11. 11. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFiles20PartitionShot/40%_Mid33%_1.2s_40fps_6s20PartitionShot/50%_Mid_left_33%_800ms_40fps_6s_0220PartitionShot/50%_Mid_right_33%_800ms_40fps_6s_02LeftMiddleRightLeft Middle Right
12. 12. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFiles20PartitionShot/50%_bottom_left_33%_800ms_40fps_6s_0120PartitionShot/50%_bottom_right_33%_800ms_40fps_6s_0120PartitionShot/50%_Mid_left_33%_800ms_40fps_6s_02LeftMiddleRight Left Middle Right
13. 13. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFile20PartitionShot
14. 14. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFileBellimpactpanel03/Bottomhalfveiw40fps_50%_800ms_6s_02Panel mounted horizontally
15. 15. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFileBellimpactpanel03/Fullveiw40fps_50%_800ms_6s_03
16. 16. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFileBellimpactpanel03/Tophalfveiw40fps_50%_800ms_6s_01
17. 17. Experiment Setup:20kHz Handheld (500Wfrom backside)40 frames per secondTotal 6 seconds50% amplitude
18. 18. Experimental Setup:20kHz Handheld (500W)40 frames per secondTotal 6 seconds50% amplitude
19. 19. Experimental Setup:20kHz Handheld(500W)40 frames per secondTotal 6 seconds50% amplitudeFile Name : 20K_handheld_Amp50_middle_GunHandI_LogoLeftBottom.bmp
20. 20. Experimental Setup:20kHz Handheld (500W)40 frames per secondTotal 6 seconds60% amplitudeFile Name : 20K_handheld_Amp60_middle_GunGandN_LogoLeftBottom.bmp
21. 21. Experimental Setup:20kHz Handheld (500W)40 frames per secondTotal 6 seconds60% amplitudeFile Name : 20K_handheld_Top_Amp60_GunOnTop_4inFromEdge.bmp
22. 22. Experimental Setup:20kHz Handheld(500w)40 frames per secondTotal 6 seconds60% amplitudeFile Name : 20K_handheld_Bottom_Amp60_GunOnBottom_2inFromEdge.bmp
23. 23. Back View
24. 24. Structure I - Beam Thin area Doublers AreaSize L M S L M S L M SFront View(20k Table andHandheld)C,D,P,Q A G,F,N,M J,K,L IBack View(20kTable andHandheld)R,O SNever Seen(Both 20k &40k)B, E H
25. 25. Frequency Experiments
26. 26. 20k_Amp40%_without coin20k_Amp40%_with coin
27. 27. 40k_Amp40%_without coin40k_Amp40%_with coin
28. 28. 40k_Amp100%_without coin40k_Amp100%_with coin
29. 29. Preferred Frequency20K
30. 30. Small Tip ExperimentCoupling Materials and Tips
31. 31. Small Tip Experiment Coin + Business Card (20 lbs) Coin + Cardboard (20 lbs) Coin + Duct Tape (20 lbs) Coin + Teflon (20 lbs) Business Card (20 lbs) (40 lbs) Cardboard (20 lbs) (40 lbs) Duct Tape (20 lbs) Teflon (20 lbs)
32. 32. Coin + Business Card (20 lbs)60% (4.56 RMS) 80% (6.27 RMS)
33. 33. Coin + Cardboard (20 lbs)60% (0.85 RMS) 80% (1.80 RMS)
34. 34. Coin + Duct Tape (20 lbs)60% (4.22 RMS) 80% (3.46 RMS)
35. 35. Coin + Teflon (20 lbs)60% (4.75 RMS)
36. 36. Business Card (20 lbs)60% (1.35 RMS) 80% (1.27 RMS)
37. 37. Business Card (40 lbs)60% (1.53 RMS) 80% (2.25 RMS)
38. 38. Cardboard (20 lbs)60% (0.64 RMS) 80% (0.76 RMS)
39. 39. Cardboard (40 lbs)60% (1.33 RMS) 80% (1.64 RMS)
40. 40. Duct Tape (20 lbs)60% (5.64 RMS) 80% (N/A RMS) (15 lbs)
41. 41. Teflon (20 lbs)40% (0.57 RMS)
42. 42. Medium Tip ExperimentCoupling Materials and Tips
43. 43. Medium Tip Experiment Coin + Duct Tape (40 lbs) Coin + Duct Tape (60 lbs) Coin + Teflon (40 lbs) Coin + Teflon (20 lbs) Business Card (40 lbs) Cardboard (40 lbs) Duct Tape (40 lbs)
44. 44. Coin + Duct Tape (40 lbs)60% (0.67 RMS) 100% (0.96 RMS)
45. 45. Coin + Duct Tape (60 lbs)60% (0.85 RMS) 100% (0.84 RMS)
46. 46. Coin + Teflon (40 lbs)60% (0.75 RMS) 100% (1.15 RMS)
47. 47. Coin + Teflon (20 lbs)60% (0.19 RMS) 100% (5.95 RMS)
48. 48. Business Card (40 lbs)60% (0.84 RMS) 100% (1.53 RMS)
49. 49. Cardboard (40 lbs)60% (0.76 RMS) 100% (0.93 RMS)
50. 50. Large Tip ExperimentCoupling Materials and Tips
51. 51. Large Tip Experiment Coin + Duct Tape (40 lbs) Coin + Teflon (20 lbs) Business Card (40 lbs) (60 lbs) Cardboard (40 lbs) (60 lbs) Duct Tape (15 lbs) (30 lbs)
52. 52. Coin + Teflon (40 lbs)60% (0.71 RMS) 100% (2.18 RMS)
53. 53. Coin + Teflon (20 lbs)60% (0.90 RMS) 100% (1.61 RMS)
54. 54. Business Card (40 lbs)60% (0.69 RMS) 100% (1.07 RMS)
55. 55. Business Card (60 lbs)60% (0.84 RMS) 100% (1.19 RMS)
56. 56. Cardboard (40 lbs)60% (0.29 RMS) 100% (0.44 RMS)
57. 57. Cardboard (60 lbs)60% (0.39 RMS) 100% (0.57 RMS)
58. 58. Duct Tape (15 lbs)60% (0.81 RMS) 100% (0.93 RMS)
59. 59. Duct Tape (30 lbs)60% (1.18 RMS) 100% (1.42 RMS)
60. 60. Best Coupling Materials Setup1. Business Card with Large tip2. Cardboard with Large tip
61. 61. Vibration Analysis(Width-Wise)
62. 62. I beam panel ; 20 kHz; 20lbs; Without coin;Conclusion: I beam structure is very hard to vibrate effectively.R1 GunVR3R2Name of shot RMS of vilocity (mm/s)Ref1 Vib Ref3 Ref202 52.69 47.61 19.07 45.9903 63.02 54.45 16.67 35.1204 77.46 36.31 23.62 42.5205 70.66 31.48 20.70 36.1807 75.92 37.96 24.51 44.71
63. 63. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFilebellimpactpanel03/ref2Max Magnitude = 6.83 m/s RMS = 30.07mm/s
64. 64. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFilebellimpactpanel03/vibMax Magnitude = 9.95 m/s RMS = 31.05mm/s
65. 65. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFilebellimpactpanel03/ref1Max Magnitude = 31.63 m/s RMS = 84.55mm/s
66. 66. Ultrasound20KHz20k LPt 20:0.5:90250% Amplitude800ms PulseCamera40 Frames/sIR Camera 6sFileBellimpactpanel03/ref3Max Magnitude = 36.13 m/s RMS = 88.58m
67. 67. 15 inchesJGNRBDefect J shows upPower Amplitude: 10%Load: 25lbsInput Frequency: 20kHzRMS(Root Mean Square): 41.55mm/s
68. 68. 15 inchesDefect N shows upPower Amplitude: 20%Load: 25lbsInput Frequency: 20kHzRMS(Root Mean Square): 117.7mm/sJGNRB
69. 69. 25 inchesDefect G shows upPower Amplitude: 45%Load: 25lbsInput Frequency: 20kHzRMS(Root Mean Square): 90.66mm/sJGNRB
70. 70. 25 inchesDefect R shows upPower Amplitude: 45%Load: 25lbsInput Frequency: 20kHzRMS(Root Mean Square): 44.08mm/sJGNRB
71. 71. 30 inchesDefect B shows upPower Amplitude: 35%Load: 25lbsInput Frequency: 20kHzRMS(Root Mean Square): 53.73mm/sJGNRB
72. 72. Vibration Analysis(Length-wise)
73. 73. 10 inches180160140120100806040200Vibration Data in Thin Channel0 10 20 30 40 50 60Vibration Amplitude(mm/s)Distance from Transducer (inches)10% Amplitude20% Amplitude30% Amplitude40% Amplitude50% AmplitudeTransducer
74. 74. 10 inchesTransducer140120100806040200Vibration Data in Doubler Channel0 10 20 30 40 50 60Vibration Amplitude (mm/s)Distance from Transducer (inches)10% Amplitude20% Amplitude30% Amplitude40% Amplitude50% Amplitude
75. 75. 4 4 8 10GunI beam panel ; Center doubler channel; 20 kHz; 20lbs; Without coin;Conclusion: Experiment is repeatable and vibration results show some periodicity property.
76. 76. Gun4 4 8 10I beam panel ; 20 kHz; 20lbs; Without coin;Conclusion: Experiment is repeatable and vibration results show some periodicity property.
77. 77. Hat Pattern Consistency Test(Vibration Study)
78. 78. Mode PatternLeft Gun Shot
79. 79. Time LapseLeft Gun Shot
80. 80. Mode PatternMiddle Gun Shot
81. 81. Time LapseMiddle Gun Shot
82. 82. Mode PatternRight Gun Shot
83. 83. Time LapseRight Gun Shot
84. 84. Video
85. 85. Consistency TestRight Shot 1
86. 86. Consistency TestRight Shot 2
87. 87. Consistency TestRight Shot 3
88. 88. Consistency TestRight Shot 4
89. 89. Consistency TestRight Shot 6
90. 90. Consistency TestRight Shot 7
91. 91. Consistency TestRight Shot 8
92. 92. Consistency TestRight Shot 9
93. 93. Mode Pattern Consistency(Discard 3)1 2 3 4 5 6 71 O O O O O2 O O O O O O34 O O O O O O O5 O O O O O O6 O O O O O O O7 O O O O O O8 O O O O O9 O O O O O O O10 O O O O O O11 O O O O O O O12 O O O O O O13 O O O O O O O1 2 3 4 5 6 7 8 9 10 11 12 135 6 0 7 6 7 6 5 7 6 7 6 7
94. 94. Vibrometer TestOFV-551 VibDistance (mm) RMS (mm/s) Signal Level Stability135 2.60 1.00 High339 2.60 1.00 High543 2.60 1.00 High747 2.60 1.00 High951 2.59 1.00 High237 2.60 1.00 High441 2.60 1.00 High645 2.60 1.00 Low849 2.60 1.00 High1053 2.60 0.90 LowAverage 2.60 0.99 HighOFV-511 Ref3Distance (mm) RMS (mm/s) Signal Level Stability232 2.58 0.85 No437 2.56 0.70 No642 2.56 0.30 No847 2.55 0.35 No1052 2.56 0.00 No335 2.56 0.60 No540 Error 0.35 No745 2.56 0.40 No950 2.55 0.45 No1155 2.53 0.40 NoAverage 2.56 0.44 No
95. 95. Defects 1 & 21.210.80.60.40.20Source, 1 and 21 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25RMSTrial #12Source
96. 96. Defects 4 & 112.521.510.50Source, 4 and 111 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25Axis TitleAxis Title411Source
97. 97. Defects 5 & 102.521.510.50Source, 5 and 101 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25RMS (m/s)Trial #Source105
98. 98. Defects 6 & 131.61.41.210.80.60.40.20Source, 6 and 131 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25RMS (m/s)Trial #613Source
99. 99. Defects 7 & 1221.81.61.41.210.80.60.40.20Source, 7 and 121 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25RMS (m/s)Trial #712Source
100. 100. Defects 8 & 921.81.61.41.210.80.60.40.20Source, 8 and 91 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25RMSTrial #89Source
101. 101. New Approach Fixed Camera Enables Image Processing
102. 102. High Vibration
103. 103. Steps Fixed Camera Images Convert to Binary Image Registration (Optional) Binary Operation Point selection
104. 104. Registration
105. 105. Binary Operation
106. 106. Selected Points
107. 107. Results1 2 3 4 5 6Point 0.45 0.14 0.18 0.10 0.10 0.14Source 2.29 2.25 2.32 2.49 2.43 2.38Ratio 0.20 0.06 0.08 0.04 0.04 0.06
108. 108. Low Vibration
109. 109. Low Vibration
110. 110. Results1 2 3 4 5 6Point 0.09 0.08 0.04 0.06 0.09 0.06Source 2.08 2.28 2.00 1.86 2.50 2.22Ratio 0.04 0.04 0.02 0.03 0.04 0.03
111. 111. ResultsHigh1 2 3 4 5 6Point 0.45 0.14 0.18 0.10 0.10 0.14Source 2.29 2.25 2.32 2.49 2.43 2.38Ratio 0.20 0.06 0.08 0.04 0.04 0.06Low1 2 3 4 5 6Point 0.09 0.08 0.04 0.06 0.09 0.06Source 2.08 2.28 2.00 1.86 2.50 2.22Ratio 0.04 0.04 0.02 0.03 0.04 0.03
112. 112. Conclusion High density granule areas indicate lowvibration Low density granule areas indicate highvibration
113. 113. TT-Plot Automation.
114. 114. Hat Defect Locations
115. 115. Legend:< 1 Diameter, 9 Each1.0 1.75 Diameter, 6 Each1.75 - 2.65 Diameter, 4 Each> 2.65 Diameter, 3 Each0.170 Skin0.096 SkinImpact Panel for Wayne State University609/30/2011 Final Impact Plan - RJB
116. 116. TT-Plot on Hat
117. 117. Sample of TT-Plot fromDefect JVideo = VFrames = F1FnF1Fn VPixels = P1,1Pn,nTT-Plot = P for all FDefect J = J (White)J = {P}J FTT-PlotThreshold Sampling
118. 118. TT-Plot for Frame Subset (Pixels) for allVideo0 20 40 60 80 100 120 140 160 180 20010.950.90.850.80.750.70.650.60.55All Defects in Neighborhood + ErrorPixel ValueFrame
119. 119. Min and Max Graphs for TT-Plot0 20 40 60 80 100 120 140 160 180 2001.21.110.90.80.70.60.5Max and Min Defect in NeighborhoodPixel ValueFrame
120. 120. Scanned Matching TT-Plots that fallbetween Min and Max TT-Plots
121. 121. Repeated for Defect F
122. 122. TT-Plots and Min/Max0 20 40 60 80 100 120 140 160 180 20010.90.80.70.60.50.40.30.2All Defects in Neighborhood + ErrorPixel ValueFrame0 20 40 60 80 100 120 140 160 180 2001.110.90.80.70.60.50.40.30.20.1Max and Min Defect in NeighborhoodPixel ValueFrame
123. 123. Matching TT-Plots
124. 124. Combined Matching TT-Plots
125. 125. Sample of TT-Plots on defect Jwith subtraction
126. 126. TT-Plots and Min/Max0 20 40 60 80 100 120 140 160 180 20010.90.80.70.60.50.40.30.20.10All Defects in NeighborhoodPixel ValueFrame0 20 40 60 80 100 120 140 160 180 2001.210.80.60.40.20-0.2Max and Min Defect in Neighborhood + 9% ErrorPixel ValueFrame
127. 127. Scanned Matching TT-Plots that fallbetween Min and Max TT-Plots
128. 128. 4 Point Smooth, 4% Error, 31%Threshold6 Point Smooth, 6% Error, 31%Threshold
129. 129. 4 Point Smooth, 7% Error, 31%Threshold6 Point Smooth, 7% Error, 31%Threshold
130. 130. 4 Point Smooth, 4% Error, 27%Threshold6 Point Smooth, 4% Error, 27%Threshold
131. 131. With and Without TT-Plot AutomationBefore After
132. 132. Conclusion Shows possibility of automatic defectdetection Does not support hypothesis that depth ofdefect is directly proportional to how slow itshows up on camera
133. 133. Final Conclusion Behavior of Panels Observed Optimal Experimental Settings Tested Frequency Coupling Material Tip Size/Amplitude Additional Areas of Study Mode Pattern Vibration Automation
134. 134. Future Work Further study on mode pattern Further study on TT-Plot shape ofdefects/depth of defects