Sonic IR Thesis

1. Sonic IR Imaging on Bell Imact
Panels (Hat and I-Beam)
By: Justin Ar-Rasheed

2. Overview
• Behavior of Panels Observed
• Optimal Experimental Settings Tested
– Frequency
– Coupling Material
– Tip Size/Amplitude
• Additional Areas of Study
– Mode Pattern Vibration
– Automation

4. Legend:
< 1” Diameter, 9 Each
1.0” – 1.75” Diameter, 6 Each
1.75” - 2.65” Diameter, 4 Each
> 2.65” Diameter, 3 Each
0.170” Skin
0.096” Skin
Impact Panel for Wayne State University
60”
9/30/2011 Final Impact Plan - RJB

5. Hat Panel

6. Test Experiments
• Shoot gun on various locations of panel
• Analyze results and come up with hypothesis

7. Ultrasound
20KHz Handheld
20k LPt 20:0.5:902
40% Amplitude
800ms Pulse
Camera
30 Frames/s
IR Camera 8s
File
20K_handheld/40%_30fps_8s_01.fts
Panel mounted vertically

8. Ultrasound
40KHz Handheld
40k Lpe 40:0.5:4T
100% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
40k_handheld/100%_40fps_6s_02.fts

9. Ultrasound
40KHz Table Gun
40k Lpe 40:0.5:4T
100% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
40k_tableGun/40fra_6s_800ms_30lbs_coin.fts

10. Ultrasound
40KHz Handheld
40k Lpe 40:0.5:4T
100% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
40K_handheld/100%_40fps_6s_01_top.fts

11. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
Files
20PartitionShot/40%_Top33%_1.2s_40fps_6s
20PartitionShot/50%_Top_left_33%_800ms_40fps_6s_01
20PartitionShot/50%_Top_right_33%_800ms_40fps_6s01
Left
Middle
Right
Left Middle Right

12. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
Files
20PartitionShot/40%_Mid33%_1.2s_40fps_6s
20PartitionShot/50%_Mid_left_33%_800ms_40fps_6s_02
20PartitionShot/50%_Mid_right_33%_800ms_40fps_6s_02
Left
Middle
Right
Left Middle Right

13. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
Files
20PartitionShot/50%_bottom_left_33%_800ms_40fps_6
s_01
20PartitionShot/50%_bottom_right_33%_800ms_40fps
_6s_01
20PartitionShot/50%_Mid_left_33%_800ms_40fps_6s_0
2
Left
Middle
Right Left Middle Right

14. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
20PartitionShot

15. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
Bellimpactpanel03/Bottomhalfve
iw40fps_50%_800ms_6s_02
Panel mounted horizontally

16. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
Bellimpactpanel03/Fullveiw40fps_50%_8
00ms_6s_03

17. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
Bellimpactpanel03/Tophalfveiw40fps_50
%_800ms_6s_01

18. Experiment Setup:
20kHz Handheld (500W
from backside)
40 frames per second
Total 6 seconds
50% amplitude

19. Experimental Setup:
20kHz Handheld (500W)
40 frames per second
Total 6 seconds
50% amplitude

20. Experimental Setup:
20kHz Handheld(500W)
40 frames per second
Total 6 seconds
50% amplitude
File Name : 20K_handheld_Amp50_middle_GunHandI_LogoLeftBottom.bmp

21. Experimental Setup:
20kHz Handheld (500W)
40 frames per second
Total 6 seconds
60% amplitude
File Name : 20K_handheld_Amp60_middle_GunGandN_LogoLeftBottom.bmp

22. Experimental Setup:
20kHz Handheld (500W)
40 frames per second
Total 6 seconds
60% amplitude
File Name : 20K_handheld_Top_Amp60_GunOnTop_4inFromEdge.bmp

23. Experimental Setup:
20kHz Handheld(500w)
40 frames per second
Total 6 seconds
60% amplitude
File Name : 20K_handheld_Bottom_Amp60_GunOnBottom_2inFromEdge.bmp

25. Back View

26. Structure I - Beam Thin area Doublers Area
Size L M S L M S L M S
Front View(20k Table and
Handheld)
C,D,P,Q A G,F,N,M J,K,L I
Back View(20kTable and
Handheld)
R,O S
Never Seen
(Both 20k &40k)
B, E H

27. Frequency Experiments

28. 20k_Amp40%_without coin
20k_Amp40%_with coin

29. 40k_Amp40%_without coin
40k_Amp40%_with coin

30. 40k_Amp100%_without coin
40k_Amp100%_with coin

31. Preferred Frequency
20K

32. Small Tip Experiment
Coupling Materials and Tips

33. 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)

34. Coin + Business Card (20 lbs)
60% (4.56 RMS) 80% (6.27 RMS)

35. Coin + Cardboard (20 lbs)
60% (0.85 RMS) 80% (1.80 RMS)

36. Coin + Duct Tape (20 lbs)
60% (4.22 RMS) 80% (3.46 RMS)

37. Coin + Teflon (20 lbs)
60% (4.75 RMS)

38. Business Card (20 lbs)
60% (1.35 RMS) 80% (1.27 RMS)

39. Business Card (40 lbs)
60% (1.53 RMS) 80% (2.25 RMS)

40. Cardboard (20 lbs)
60% (0.64 RMS) 80% (0.76 RMS)

41. Cardboard (40 lbs)
60% (1.33 RMS) 80% (1.64 RMS)

42. Duct Tape (20 lbs)
60% (5.64 RMS) 80% (N/A RMS) (15 lbs)

43. Teflon (20 lbs)
40% (0.57 RMS)

44. Medium Tip Experiment
Coupling Materials and Tips

45. 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)

46. Coin + Duct Tape (40 lbs)
60% (0.67 RMS) 100% (0.96 RMS)

47. Coin + Duct Tape (60 lbs)
60% (0.85 RMS) 100% (0.84 RMS)

48. Coin + Teflon (40 lbs)
60% (0.75 RMS) 100% (1.15 RMS)

49. Coin + Teflon (20 lbs)
60% (0.19 RMS) 100% (5.95 RMS)

50. Business Card (40 lbs)
60% (0.84 RMS) 100% (1.53 RMS)

51. Cardboard (40 lbs)
60% (0.76 RMS) 100% (0.93 RMS)

52. Large Tip Experiment
Coupling Materials and Tips

53. 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)

54. Coin + Teflon (40 lbs)
60% (0.71 RMS) 100% (2.18 RMS)

55. Coin + Teflon (20 lbs)
60% (0.90 RMS) 100% (1.61 RMS)

56. Business Card (40 lbs)
60% (0.69 RMS) 100% (1.07 RMS)

57. Business Card (60 lbs)
60% (0.84 RMS) 100% (1.19 RMS)

58. Cardboard (40 lbs)
60% (0.29 RMS) 100% (0.44 RMS)

59. Cardboard (60 lbs)
60% (0.39 RMS) 100% (0.57 RMS)

60. Duct Tape (15 lbs)
60% (0.81 RMS) 100% (0.93 RMS)

61. Duct Tape (30 lbs)
60% (1.18 RMS) 100% (1.42 RMS)

62. Best Coupling Materials Setup
1. Business Card with Large tip
2. Cardboard with Large tip

63. Vibration Analysis
(Width-Wise)

64. I beam panel ; 20 kHz; 20lbs; Without coin;
Conclusion: I beam structure is very hard to vibrate effectively.
R1 Gun
V
R3
R2
Name of shot RMS of vilocity (mm/s)
Ref1 Vib Ref3 Ref2
02 52.69 47.61 19.07 45.99
03 63.02 54.45 16.67 35.12
04 77.46 36.31 23.62 42.52
05 70.66 31.48 20.70 36.18
07 75.92 37.96 24.51 44.71

65. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
bellimpactpanel03/ref2
Max Magnitude = 6.83 m/s RMS = 30.07mm/s

66. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
bellimpactpanel03/vib
Max Magnitude = 9.95 m/s RMS = 31.05mm/s

67. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
bellimpactpanel03/ref1
Max Magnitude = 31.63 m/s RMS = 84.55mm/s

68. Ultrasound
20KHz
20k LPt 20:0.5:902
50% Amplitude
800ms Pulse
Camera
40 Frames/s
IR Camera 6s
File
Bellimpactpanel03/ref3
Max Magnitude = 36.13 m/s RMS = 88.58m

69. 15 inches
J
G
N
R
B
Defect J shows up
Power Amplitude: 10%
Load: 25lbs
Input Frequency: 20kHz
RMS(Root Mean Square): 41.55mm/s

70. 15 inches
Defect N shows up
Power Amplitude: 20%
Load: 25lbs
Input Frequency: 20kHz
RMS(Root Mean Square): 117.7mm/s
J
G
N
R
B

71. 25 inches
Defect G shows up
Power Amplitude: 45%
Load: 25lbs
Input Frequency: 20kHz
RMS(Root Mean Square): 90.66mm/s
J
G
N
R
B

72. 25 inches
Defect R shows up
Power Amplitude: 45%
Load: 25lbs
Input Frequency: 20kHz
RMS(Root Mean Square): 44.08mm/s
J
G
N
R
B

73. 30 inches
Defect B shows up
Power Amplitude: 35%
Load: 25lbs
Input Frequency: 20kHz
RMS(Root Mean Square): 53.73mm/s
J
G
N
R
B

74. Vibration Analysis
(Length-wise)

75. 10 inches
180
160
140
120
100
80
60
40
20
0
Vibration Data in Thin Channel
0 10 20 30 40 50 60
Vibration Amplitude(mm/s)
Distance from Transducer (inches)
10% Amplitude
20% Amplitude
30% Amplitude
40% Amplitude
50% Amplitude
Transducer

76. 10 inches
Transducer
140
120
100
80
60
40
20
0
Vibration Data in Doubler Channel
0 10 20 30 40 50 60
Vibration Amplitude (mm/s)
Distance from Transducer (inches)
10% Amplitude
20% Amplitude
30% Amplitude
40% Amplitude
50% Amplitude

77. 4 4 8 10
Gun
I beam panel ; Center doubler channel; 20 kHz; 20lbs; Without coin;
Conclusion: Experiment is repeatable and vibration results show some periodicity property.

78. Gun
4 4 8 10
I beam panel ; 20 kHz; 20lbs; Without coin;
Conclusion: Experiment is repeatable and vibration results show some periodicity property.

79. Hat Pattern Consistency Test
(Vibration Study)

80. Mode Pattern
Left Gun Shot

81. Time Lapse
Left Gun Shot

82. Mode Pattern
Middle Gun Shot

83. Time Lapse
Middle Gun Shot

84. Mode Pattern
Right Gun Shot

85. Time Lapse
Right Gun Shot

86. Video

87. Consistency Test
Right Shot 1

88. Consistency Test
Right Shot 2

89. Consistency Test
Right Shot 3

90. Consistency Test
Right Shot 4

91. Consistency Test
Right Shot 6

92. Consistency Test
Right Shot 7

93. Consistency Test
Right Shot 8

94. Consistency Test
Right Shot 9

95. Mode Pattern Consistency
(Discard 3)
1 2 3 4 5 6 7
1 O O O O O
2 O O O O O O
3
4 O O O O O O O
5 O O O O O O
6 O O O O O O O
7 O O O O O O
8 O O O O O
9 O O O O O O O
10 O O O O O O
11 O O O O O O O
12 O O O O O O
13 O O O O O O O
1 2 3 4 5 6 7 8 9 10 11 12 13
5 6 0 7 6 7 6 5 7 6 7 6 7

97. Vibrometer Test
OFV-551 Vib
Distance (mm) RMS (mm/s) Signal Level Stability
135 2.60 1.00 High
339 2.60 1.00 High
543 2.60 1.00 High
747 2.60 1.00 High
951 2.59 1.00 High
237 2.60 1.00 High
441 2.60 1.00 High
645 2.60 1.00 Low
849 2.60 1.00 High
1053 2.60 0.90 Low
Average 2.60 0.99 High
OFV-511 Ref3
Distance (mm) RMS (mm/s) Signal Level Stability
232 2.58 0.85 No
437 2.56 0.70 No
642 2.56 0.30 No
847 2.55 0.35 No
1052 2.56 0.00 No
335 2.56 0.60 No
540 Error 0.35 No
745 2.56 0.40 No
950 2.55 0.45 No
1155 2.53 0.40 No
Average 2.56 0.44 No

98. Defects 1 & 2
1.2
1
0.8
0.6
0.4
0.2
0
Source, 1 and 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
RMS
Trial #
1
2
Source

99. Defects 4 & 11
2.5
2
1.5
1
0.5
0
Source, 4 and 11
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Axis Title
Axis Title
4
11
Source

100. Defects 5 & 10
2.5
2
1.5
1
0.5
0
Source, 5 and 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
RMS (m/s)
Trial #
Source
10
5

101. Defects 6 & 13
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
Source, 6 and 13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
RMS (m/s)
Trial #
6
13
Source

102. Defects 7 & 12
2
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
Source, 7 and 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
RMS (m/s)
Trial #
7
12
Source

103. Defects 8 & 9
2
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
Source, 8 and 9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
RMS
Trial #
8
9
Source

104. New Approach
• Fixed Camera
• Enables Image Processing

105. High Vibration

106. Steps
• Fixed Camera Images
• Convert to Binary
• Image Registration (Optional)
• Binary Operation
• Point selection

108. Registration

109. Binary Operation

110. Selected Points

111. Results
1 2 3 4 5 6
Point 0.45 0.14 0.18 0.10 0.10 0.14
Source 2.29 2.25 2.32 2.49 2.43 2.38
Ratio 0.20 0.06 0.08 0.04 0.04 0.06

112. Low Vibration

113. Low Vibration

114. Results
1 2 3 4 5 6
Point 0.09 0.08 0.04 0.06 0.09 0.06
Source 2.08 2.28 2.00 1.86 2.50 2.22
Ratio 0.04 0.04 0.02 0.03 0.04 0.03

115. Results
High
1 2 3 4 5 6
Point 0.45 0.14 0.18 0.10 0.10 0.14
Source 2.29 2.25 2.32 2.49 2.43 2.38
Ratio 0.20 0.06 0.08 0.04 0.04 0.06
Low
1 2 3 4 5 6
Point 0.09 0.08 0.04 0.06 0.09 0.06
Source 2.08 2.28 2.00 1.86 2.50 2.22
Ratio 0.04 0.04 0.02 0.03 0.04 0.03

116. Conclusion
• High density granule areas indicate low
vibration
• Low density granule areas indicate high
vibration

117. TT-Plot Automation
.

118. Hat Defect Locations

119. Legend:
< 1” Diameter, 9 Each
1.0” – 1.75” Diameter, 6 Each
1.75” - 2.65” Diameter, 4 Each
> 2.65” Diameter, 3 Each
0.170” Skin
0.096” Skin
Impact Panel for Wayne State University
60”
9/30/2011 Final Impact Plan - RJB

120. TT-Plot on Hat

121. Sample of TT-Plot from
Defect J
Video = V
Frames = F1…Fn
F1…Fn ∈ V
Pixels = P1,1…Pn,n
TT-Plot = P for all F
Defect J = J (White)
J = {P}
J ⊆ F
TT-Plot
Threshold Sampling

122. TT-Plot for Frame Subset (Pixels) for all
Video
0 20 40 60 80 100 120 140 160 180 200
1
0.95
0.9
0.85
0.8
0.75
0.7
0.65
0.6
0.55
All Defects in Neighborhood + Error
Pixel Value
Frame

123. Min and Max Graphs for TT-Plot
0 20 40 60 80 100 120 140 160 180 200
1.2
1.1
1
0.9
0.8
0.7
0.6
0.5
Max and Min Defect in Neighborhood
Pixel Value
Frame

124. Scanned Matching TT-Plots that fall
between Min and Max TT-Plots

125. Repeated for Defect F

126. TT-Plots and Min/Max
0 20 40 60 80 100 120 140 160 180 200
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
All Defects in Neighborhood + Error
Pixel Value
Frame
0 20 40 60 80 100 120 140 160 180 200
1.1
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
Max and Min Defect in Neighborhood
Pixel Value
Frame

127. Matching TT-Plots

128. Combined Matching TT-Plots

129. Sample of TT-Plots on defect J
with subtraction

130. TT-Plots and Min/Max
0 20 40 60 80 100 120 140 160 180 200
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
All Defects in Neighborhood
Pixel Value
Frame
0 20 40 60 80 100 120 140 160 180 200
1.2
1
0.8
0.6
0.4
0.2
0
-0.2
Max and Min Defect in Neighborhood + 9% Error
Pixel Value
Frame

131. Scanned Matching TT-Plots that fall
between Min and Max TT-Plots

132. 4 Point Smooth, 4% Error, 31%
Threshold
6 Point Smooth, 6% Error, 31%
Threshold

133. 4 Point Smooth, 7% Error, 31%
Threshold
6 Point Smooth, 7% Error, 31%
Threshold

134. 4 Point Smooth, 4% Error, 27%
Threshold
6 Point Smooth, 4% Error, 27%
Threshold

135. With and Without TT-Plot Automation
Before After

136. Conclusion
• Shows possibility of automatic defect
detection
• Does not support hypothesis that depth of
defect is directly proportional to how slow it
shows up on camera

137. Final Conclusion
• Behavior of Panels Observed
• Optimal Experimental Settings Tested
– Frequency
– Coupling Material
– Tip Size/Amplitude
• Additional Areas of Study
– Mode Pattern Vibration
– Automation

138. Future Work
• Further study on mode pattern
• Further study on TT-Plot shape of
defects/depth of defects