ICT R&D Project Fourth Quarter Report
Contents
1. 3 2014 NDI Center PNEC NUS me evident from the figure shown above the calibration file amp raw data directory need to be loaded in order to activate the Eddy Current GUI Clicking on the Select Calibration File button opens up a window which allows the user to select a dat file EJ ANDT_GULUT a h Elax eci IR Ss PLA gt ANDT_GUI 20140310 eE Data files I s Search Data fies A i hepa PEPEE X New folder d Favorites Name Date modified MB Desktop _ Ldat 1 1 200512 10AM DAT File i Downloads L 2dat 1 1 200512 09AM DAT File Dropbox 3 dat 1 1 200512 09AM DAT File El Recent Places 4 dat 1 1 20051240AM DAT Fil X Data Cursor Libraries Documents a Music E Pictures E Videos l Homegroup Defining futures 2014 NDT Center PNEC NUST Select the file and click open Next click the Select Raw Data Directory button Another window will appear from which the user can select the folder to which the data will be directed EJ ANDTGULUT _ Ti 2 N r Directory to Natig G Sp gt ANDT_GUI 20140310 MNKUT n gt Lo xs Data_files d Organize New folder Jz v Fs z 7 y d Fr Favorites Name Date modified Type m Tii No it natch ch sb Downloads 3 Dropbox E Recent Places Z Libraries Documents a Music E Pict2. C Users Salar Desktop ANDT_GUI 20140310 ET Data_files 100K C Users Salar Desktop ANDT_GUI 20140310 ET Data_files 200k Inductive Reactance ie 50 100 150 Resistance R 2014 NDT Center PNEC NUS I The buttons and there functions are as stated i Magnitude button The magnitude button shows the image of calibrated impedance magnitude The image comprises of various colors ranged from blue to red Red means maximum deflection in the area from the probe and blue indicates no deflection Deflection occurs due to the cracks land marks and noise in the signal The colors in between blue and red indicates EH Aerospace NOT GUT Wings ETI lie TE _ D a oH Aerospace NDT x BiP IA National ICT Flaw Detection Software Pat EAE R amp D Fund _ e z neoa C Users Salar Desktop ANDT_GUI 20140310 ET Data_files 100K C Users Salar Desktop ANDT_GUI 20140310 ET Data_files 200k Imagesc plot of Calibrated Magnitude Rows wn 0 500 1000 1500 2000 2500 3000 3500 4oooVoltage indices 2014 NDT Center PNEC NUS I ii Histogram button The histogram button displays the probability distribution of pixel values in an image in the form of a bar plot It bins the elements of image into 100 equally spaced containers and returns the number of elements in each con
3. Figure 39 Modulated Gaussian pulse Presently we are concentrating on designing exciter circuit using modulation approach A Gaussian pulse will be generated using Zigbee motes integrated Digital to Analog Converter DAC which will then be multiplied with an oscillator circuit using AD633 multiplier IC This is because the on board DAC is incapable of generating signals of the order of hundreds of kHz however it can easily generate Gaussian pulses which can be re programmed easily as well AD633 has been theoretically and practically tested for multiple frequencies This approach is represented in Figure 40 Output DAC of Wireless sensing Motes 300 Khz amplitude modulated generate envelope gaussian pulse Figure 40 Generation of modulated Gaussian pulse Modulation approach 4 3 3 Wireless Sensor Networks After completion of prior objectives discussed in previous reports we commenced the task of increasing the data sampling rate to 200 kilo samples per second In consideration of Aliasing and ADC sampling issues we did not jump to increasing the sampling rate form 5 kHz to 200 kHz directly but decided to do this in discrete steps increasing it 2 times then 4 times and so on up till 200 kHz Data sampled by this technique will be transmitted to a base station mote however before moving onto this task the team decided to test ADC operations in WSN so that any sampling issues with ADCs in mot
4. Inductive loads The above two waveforms in Figure 23 indicate output voltage current for resistive and inductive loads One can see reasonably stable waveforms with only slight noise in the output of inductive load But that could be fixed using a simple passive filter The problem was that the voltage level at output was very low which would have been difficult to detect practically Also the IC had a problem of quickly getting heated up As a result of this the students burnt two such ICs due to problem of voltage spikes from inductor coil and heating up of the component 4 1 2 2 OPA548 amp Howland Protection The Howland design finalized for this purpose is the most efficient one and so the students carefully picked up a similar IC but one with better heat sinking and voltage levels They finalized the OPA548 due to its following advantages 1 High current output of 5A 2 Adjustable current limit 3 Mosfet packaging This IC was also ordered and procured from USA along with the precision resistors Meanwhile the students have been working on better heat sinking techniques as well as looking for solutions to protect the IC from inductive kickbacks For this purpose the RC Snubber circuit has been finalized The results of adding a snubber circuit in parallel to the load on simulation can be seen in Figure 24 T pea o Fr Oscilloscope XSC1 Ea Time Channel_A Channel_B 19 019 ms 9 655 mV 2 62
5. Mouse Button Elapsed time Mouse Button Elapsed time Mouse Button Elapsed time Mouse Button Elapsed time Mouse Button Elapsed time Mouse Button Elapsed time Mouse Button Down at X 47 482720 is 24 841350 seconds Down at X 47 495690 is 24 853081 seconds Down at X 47 508661 is 24 864900 seconds Down at X 47 521632 is 24 876882 seconds Down at X 47 534603 is 24 895745 seconds Down at X 47 547573 is 24 907785 seconds Down at X 47 547573 is 24 919813 seconds Down at X 47 560544 is 24 931571 seconds Down at X 47 560544 is 24 943375 seconds Down at X 47 573515 is 24 954834 seconds Down at X 47 573515 is 25 101289 seconds Down at X 47 586485 is 27 725992 seconds Down at X 42 164728 733630 746139 758647 771156 796173 T9613 808682 821191 833699 833699 846208 846208 145029 Figure 35 Real time data acquisition displayed on command window 2 Pointer ballistics problem was also solved Pointer Ballistics refers to the error caused due to difference in mouse and cursor velocities with different mouse accelerations Actually a non linear relationship is maintained by the operating system between the two velocities to ease pointer perception for the user This is shown in Figure 36 But to make this relationship linear a registry setting relating to mouse cursors is modified by the software Linear pointer velocity in
6. 18 Pe age 1 1 PO e E E N 19 Pouc 10 SEET eC UM POU 5c sco ssevicado ennaseostcoseeoeect noaorentaedowcnadeanerosneoeect r NET EOE EE 19 Powe 5 Dne Cy NO e 20 Figure 18 a is of Healthy location b is of Cracked Location of 3 mm dia c is of Cracked Location of 4 mm dia and d is of Crack location Of 5 mm d1a cee eecceeecceeceeeeseeeseeeseees 21 Figure 19 Eddy Current Probes hand wounded cccecccccccccccceceeeeeeeeeeeeeeeeeeceeeeeeeeeeeeenaaaas 22 Figure 20 ET TAS CMS alois E E deed einteepeenionaydaceustdaunnceeaneeueceepees 23 Figure 21 OPA564 Based Howland pump cccccssesssseccecccceeeessseecceececeaeeeeseeccceeeseaaaeseeeeeees 23 Figure 22 OPA564 through hole Adapter amp Circuit ccccccccssssessseceecceceaeeeessecceeeeeeaaaaeseeeeeees 24 Figure 23 OPA564 Howland results Resistive amp Inductive loads cc eeeecseccceeeeeeseeeeeeeeees 24 Figure 24 Inductive Load without Snubbet cccccceececceecccceeeeeeeeeeeeeeseeeeeeeeeceeeceeeeeeeeaqaaaas 25 Figure 23 Inductive Load witi SMUD DEI sa iscoriesd ccwttencesautaatasdicaatentensecoutuedneqsautoatesdinauatnecvcesivedse 26 Figure 26 Eddy Current Probes machine wounded eeesesssesssssssssseeerererrssessssssssssssseeeeerereeees 26 Figure 27 Demodulated Output from Phase Locked Loop PLL ccccccceeceeccceceeeeeeeeeeeeees 2i Figure 28 Output ol XOR Galeses iiini rE NE san EN O S E SE SA EEE E
7. 30 4 21 Previous Work Approach esscsssrscsisesisisrisonisuiinai eeann isea a s 31 4 2 2 Final Approach for ET Position Sensor cc cceccccccececcceeessseeeeceeeeceeeaeseeeeeeeeeeaaas 31 do ONULT T WING gasses esc aec A ecco E E E E 34 dad ERN OP e r e U a E E E 34 aS Ma 2 2 Ua E E E E E E E A E E ee 34 Mies Wireless SENSOR NCI Oli Sesser renen neee ra EE TE EEEE ET EEN 35 APO A e E E E E E E E E E 38 Table of Figures Figure Typical flow through figures for the ANDT FDS GULl eseeesssssssssssssssssseeereeeeesssssssss 9 Figure 2 Background image incorporated in every figure of the ANDT FDS GUI 10 Figure 3 Text from previous figure as an example of inter figure communication 11 Figure 4 ET GUI Figure with buttons disabled until input files are selected eee 12 Figure 5 ET GUI figure showing Thresholded dato cccccnnseseeeeeeeeeeeeeecceeeeeeeeeeeseaaaeas 12 Figure 6 Image plot of Calibrated Magnitude 20 0 0 cccceccccccccccccccceeeeeeeeesseeseeeeeeeceeeceeeeeeeeaaaaeas 13 TOUTS Histogram of Imag eisie TE EE E EEEE 14 Figure 8 Image after Adaptive Thresholding Algorithm cc cceesssseeeeseeeeeeeceeeeeeeeeeeenaaaees 15 Figure o Imane Wl ete Cre GIS ORS sereas ren E EE N 15 Ficu 1O Cree CALE Repol erra E EEE 16 Figure L UT GUL Figure showings A SCANS ces scsastans ecctee ien E EAEN 17 Poor AS A esa ta est cece E E E E E catapenneteemmencees 17 Pae Me D ooi E E 18 A CN E E T E E E EE E EEA
8. BY OGN GARNIT WEEGGRROGDRY ee ey 1 BS ZHz 2 99 SHHz Duty Cycie PAIL 33 65 o Ne 49 30 Yay Rise Time i 317 Bus 2 2 616ms Soom Sms 0 CH EDGE JDC eet 1 0 99 8676Hz 0 Figure 27 Demodulated Output from Phase Locked Loop PLL 4 1 5 Demodulation using XOR Logic Gate As a result the students had to find some other means of detecting the phase shift obtained between the two signals input and output The XOR gate was finalized which is a logic gate that produces a high output only when one of the inputs is high In our case the input and output signals are 180 degrees out of phase Hence the XOR produces high output for every part of the cycle as the inputs are different except at zero crossing and its results can be seen below in Figure 28 POPPE Pe eee pear pare a pana ade d MEP ese hee aamen meio gt Pre rarer re IAAI tao bbeo jor vannene F pappe eih Figure 28 Output of XOR Gate The result of this XOR was a square wave whose pulse width changed when the probe was moved from air close to the test specimen and then over the crack and non crack 4 1 6 Filtering for required signal The next step was to filter this output to get a dc signal whose voltage level would vary as the phase would change There are two filtering techniques available 1 Passive RC filter 2 Active filter Initially the students designed and developed a passive RC circuit The results of which can be seen below in
9. ET and UT GUI figure commands in further detail 3 4 The ET GUI The ET GUI is developed for diagnosing and profiling flaws using Eddy current testing Figure 5 shows the ET GUI figure showing thresholded data nap FT GU Laing Deary T Se cA Aerospace NET iniaa IET Flaw Detection Soliwere L u Figure 5 ET GUI figure showing Thresholded data Important Buttons Commands for the ET GUI are detailed as follows 3 4 1 Magnitude Button The magnitude button shows the image of calibrated impedance magnitude as shown in Figure 6 The impedance has been calculated by extracting real and imaginary parts from the raw data of particular area The calibration has been done using two calibration parameters 1 e rotation matrix and scaling factor The image shown has comprises of various colors ranges from blue to red The part which is in red means maximum deflection in that area from the probe and blue color indicates no deflection The deflection occurs due to the cracks land marks and noise in the signal The colors in between blue and red indicates the strengths of different deflected signal Imagesec plot of hMlagnitude 400 1000 1800 2000 2500 3000 34500 Voltage Indices Figure 6 Image plot of Calibrated Magnitude 3 4 2 Histogram Button The histogram button displays the probability distribution of pixel values in an image in the form of bar plot as shown in Figure 7 It bins the elements of image into 100 equally spaced con
10. Places __ 4 dat 3 25 2013 8 33 AM DAT File _ 5 dat 3 25 2013 8 34 AM DAT File 3 Libraries 6 dat 3 25 2013 8 35AM DAT File C Documents _ 7 dat 3 25 2013 8 35AM DAT File a Music A 8 dat 3 25 2013836 AM DAT File E Pictures E Videos _ 9 dat 3 25 2013 8 37 AM DAT File a Homegroup File name 1 dat Defining futures 2014 NDT Center PNEC NUS Select the file and click open Next click the Select Raw Data Directory button Another window will appear from which the user can select the folder to which the data will be directed E Aerospace NDT GUI Wings ET c D Es PIA Great People to Fiy VWwithr Name Ur Favorites Date modified E Desktop ib Downloads Dropbox Recent Places No items match your search Sy Libraries E Documents a Music E Pictures E Videos 28 Homegroup Nia m mpe 5 m r Folder 200k Defining futures 2014 NDT Center PNEC NUS Click Select Folder After the file and the folder have been selected the user can click the Load button to load the selected data and enable the other buttons The user can now access the various buttons present The impedance plot of raw data is displayed by default Bh Arosa NOT GU Wins TR ii _ Se Aerospace NDT z pz P IA National ICT Flaw Detection Software ee es Goes R amp D Fund Ets
11. purpose was procured by the end of 3 quarter The design for OPA564 finalized is shown on the right in Figure 21 Figure 21 OPA564 Based Howland pump This is known as the Howland current pump which was tried on hardware and accurate results were achieved But before the students could start working with the IC they had to design and develop an adapter to convert the SMD package into DIP package This was a critical task as there was a power pad provided at the bottom of the IC for heat sinking and that was to be soldered with the PCB The soldering of an SMD IC is already difficult and with this added requirement the students had to design a suitable design that was both sufficient and easy to develop The results of the adapter and the circuit PCB can be seen in Figure 22 This circuit offered a sufficient current at output Also the load changes did not affect the current from the op amp The results are also shown below in Figure 23 Figure 22 OPA564 through hole Adapter amp Circuit Precision resistors of tolerance 0 1 were still awaited hence this circuit was designed using local precision resistors with tolerance 1 But even then a reasonably stable waveform was achieved GY InSTEK we 8 000s A S ag l _Measure AAN M A A N 4 A Nx sednu l i rl ja Vavg WV VV y Vh 2 4 99 Frequency 1 1 883kH2 ie Fi I 4 lim Figure 23 OPA564 Howland results Resistive amp
12. the potential interested regions in the image To find potential region of interest a morphological operation has to be performed Morphological image processing pursues the goals of removing these imperfections by accounting for the form and structure of the image l 2 Aerospac t F r e NDT GUI Wings ET HE ARE a ie ae a Aerospace NDT National ICT Flaw Detection Software R amp und ISPIA Imagesc plot of Magnitude after thresholding and ROI Detection 0 500 1000 1500 2000 2500 3000 3500 indices Rows D N J B on n Ns oO Ww 2014 NDT Center PNEC NUS I v Report button The report button displays the final report which gives adequate detail about the effected regions Generated report saves as a text format and place in the current folder The first column represents the location of potential regions in terms of rows and columns The features such as maximum reactance maximum magnitude phase at 200 kHz and phase at 100 kHz are extracted from defined location The values of the extracted features are placed in third column Classification of the ROI is done using heuristically defined rule and result is shown in the last column 1 e either the detected ROI contains DEFECT or NO DEFECT b Ultrasonic ANDT_GULUT Aerospace NDOO poss Flaw Detection Software Data Cursor Ma NUST Defining futures
13. 1V Reverse 19 019 ms 9 655 mV 2 621V 0 000 s 0 000 V 0 000 V Save Ext trigger Channel A Channel B Trigger us Div Scale 5 V Div Scale 100 v Div Edge F a B Ext 0 Y pos Div 1 Y pos Div 2 Leve 9 V B A a ac o DC ac ol pcl Single Normal Auto None 4 Figure 24 Inductive Load without Snubber i lt iri ae Time Channel_A Channel_B F aS 25 535ms 202 648 mV 2 058 V everse 25 535ms 202 648 mV 2 058 V T2 T1 0 000 s 0 000 V 0 000 V ee Timebase Channel A Channel B Trigger Scale 5 V Div Scale htkv Ow _ edge F E A 8 Ext Y pos Div 1 Y pos Div 2 Leve o V ac o Dc ac ol pc Singe Normal Auto None Figure 25 Inductive Load with Snubber As seen from the two figures above the voltage spikes during turn on and turn off period of the circuit using inductive load were significantly reduced in terms of voltage level by using an RC snubber of appropriate value 4 1 3 Eddy Current Probe Design amp Development The next phase of ET Probe design is the fabrication of a coil of sufficient inductance which is able to produce a magnetic field to generate eddy currents in the test specimen and large enough to show change in phase when passed over a crack flaw Some probes were designed and developed but because they were hand wounded the winding was coming off amp hence accurate results
14. 1s greater as compared to other students The students listed above have been hired for fourth quarter only Their continuous hiring is dependent on their performance in the project The leadership assignment may also be changed based on performance and commitment to the project The groups may be further divided into sub groups that will accomplish a specific task These groups may also be populated by students not taking any grant from the project for instance they may be working for their FYP or involved voluntarily Current groups or sub groups involved in different activities are as under 1 Oscillator and Excitation for Eddy Current Testing ET a Sumayya Abbas b Salar Bin Javaid Group Leader Coordinator for ET 2 Eddy Current Probe Design a Shayan Ahmed FYP b Mansoor Malik 3 Data Acquisition and Flaw Profiling for ET a Uzair Gilani FYP b Iqra Sajid FYP 4 Guided Wave Ultrasonic Testing GWUT a Taha Saeed Khan Group Leader Coordinator for UT 5 GWUT on WSN a Taha Saeed Khan b Umair Asif Shamsi c Sulaiman Rais 6 Position Sensor for ET with GUI a Talha Waqar Khan b Uzair Gillani 7 Development of GUI with RA a Salar bin Javed b Talha Waqar Khan c Taha Saeed Khan For each group there is at least one group activity and one group meeting presentation scheduled every week The students are assigned aerospace NDT literature review basic design projects related to aerospace NDT data acquisition and NDT
15. 4 QUARTER PROGRESS REPORT OF ICT R amp D FUNDED PROJECT Development of Flaw Diagnosis Dimensioning Prognostics Algorithms for the Improvement of In Country Aerospace Non Destructive Testing NDT Capabilities PI Dr Tariq Mairaj Rasool Khan Co PI Dr Faisal Amir Table of Contents TEAM VEO Tet NC orra r E A A E E E E E E 3 TALS Or WAS e E E E E E E 4 MATOS a i E E E AT E AN E E E A E E AAEE E 5 2 Recruitment of Workforce for Fourth Quarter eeseeeseeeseeesseessresssrresessressreseersrereseeseerseerses 5 2 1 Recruitment of Undergraduate Workf0rce cc eceecsccccecccceeeseeecececeeaaeeseeeeeeeeeeaeaeenees J 2 PD EO OT TO E E e A E E E 7 3 1 Development of MATLAB functions from ET algorithms for the GUL 7 3 2 Development of MATLAB functions from UT algorithms for the GUI 0 8 3 3 Development of GUI for flaw detection and profiling software eeeeeseeeeeeeeeeees 8 oa E E E E E EEE 12 341 Magnitude Dutor nN te ene ne nen er se nS er 13 Se MVS 0G athe aa aa dsc eects se cata E oosnanc 13 3 4 3 Adaptive Thresholding Button cecccccccccccccssseseeceeeceesaeeeeeeeceeeessaueeseeeeeeess 14 JAA ROP DG eCopt scene epee nscsaasesaaesodeneteaanenchiupennsteumsiedeesadmneteuaidecchetpenactenaneeades 15 IS RPO BO Paes ann ann nr eer en et er rene E O re rrr en 16 I TEUTONS 16 3 5 1 Amplitude Scan A SCaMN ccccccccccccsesssssseeccccceseeeessseeecccessuaeesseseeeeceessaeeesseeseeees 17 3
16. 5 2 B Scan Cross Sectional view Scan cccccccccsccccesccssccssccesccesecceeccessceusssessseeseenssees 17 J93 CSc Top VIN Deanne teem men tre E ee 18 3 5 4 FFT Fast Fourier Transform c cece ccccceecccsecceccenccsecceeucsesseesceuseseeseenseees 18 3 5 5 STFT Short Term Fourier Transform ccccceccesccceecceescessccesccessseesseesseees 19 3 6 Alpha Testing of GUI for flaw detection and profiling software eeeeeeeeeeeeeeeeees 20 3 7 Hilbert Huang Transform Based Flaw Profiling Algorithms using Ultrasonic Testing 20 3 8 Generation Of Historical Database iss ssicssecncdcncnsestevenancte ons enaauedersvencentendsevenchdveasaweewsveneves 21 4 Underoraduate Projecis OCS aa cates cierto cwecysiounaasaieesesen nioumatendedtnceqsieunaneneeteceewectasoaces 22 4 1 PC Based Eddy Current Testing System ceecccccccccccccesseeeeeeeceeeeeaeeeseeceeeeeeeaeaeenees 22 aA PE a PO EE E 22 a EA TEC o E E E E A EA E E E ETET 29 4 1 3 Eddy Current Probe Design amp Development nseesssoeenesssssssseerersssssssserrrsssssssees 26 4 1 4 Phase Shift Detection amp Demodulation cee ccccccccccceeeeeeeeeeesesesseeeeeeeeeeeeeees 26 4 1 5 Demodulation using XOR Logic Gate cccccccccccccceeeessseeccceeeeeaaeeeseeeceseeeeaeas 27 Alo SIM Cine POR Te CMI COS NSA ss castansccctte sc E A 28 4 1 7 Data Acquisition amp Signal Processing cccceeccsscccccecceeeeeseeecceeeeeseaeseeeeeeeeeeaaas 28 w EEPO MSE 115 Ole x cs a E E T EE E EE TE
17. EEE ZI Figure 29 utput ol RG Low Pass Fier eaencee ce ctrecet cy cdanteucueannaeenenicecteeaetcyeudauisrcusenauerentce eeectee 28 Picur 90 SOR ale FION IATE mee se sesevasecasemnatsostrosemorect noaorenteadewenadeaneroimeoeect wosroniendoracnaseostsoeeeoences 29 Fiore cE Data eo Sern on Lao VIEW seese E 29 Figure 32 Signal Processing using Filters on LabVIEW seeeeeesesssssssssssseeeeeresssssssssssssssseeeeereeeeees 30 Figure 33 Results of Filtering on LabVIEW cccccccccccccccccccccceeeeeeeeeeessseeeeeeeeceeeeeeeeeeeeeaaaaas 30 Figure 34 GUI figure for the ET position SeNSOP cece eeecccccccccccceeeeeeeeeesseeeeeeeeeeceeeceeeeeeeeenaaeas 31 Figure 35 Real time data acquisition displayed on command WIndOW ccccccceceeeeeeeeeeeeeees 32 Figure 36 Pointer Ballistics problem eessssseessssssssseseeeerreesesssssssssssseseeerererereessssssssssssseeeereeeeeeee 32 Figure 37 Primary ET Position sensor GUI features and improvements cccseeeeeeeeeeeees 33 Figure 38 Graph of position vs time by ET position sensor having some erroneous spikes 34 Fig re 39 M d lated Gaussian OUIS ss ccssctecsctencnencepunsoraiowssscasnnceecctereonceneosyiciiontsscaseneretereeiencseeet DD Figure 40 Generation of modulated Gaussian pulse Modulation approach cccseeeseeeeeees 35 Figure 41 Console from Eclipse IDE showing output of java program ccccceeesseeeeeeeeeees 37 Figure 42
18. Environment GUIDE tool of MATLAB software GUIDE allows developing the front panel or the User Interface UI interactively This UI is stored as a separate binary file called a figure in MATLAB with the extension fig It basically contains an arrangement of different objects such as buttons check boxes drop down lists text boxes display axes panel etc and their properties There may be many properties related to an object in MATLAB depending upon its type Some important groups of properties that were set for different objects are described below 1 Style Appearance properties which decide colors font sizes etc of the object 2 Base properties which contain the handle tag and other important parameters of the object 3 Control properties which define the callback function and enable disable status of the object 4 Position properties which define the size and relative position of the object 5 Data properties which define the properties pertaining to the data or text the object handles The UI is programmed by the help of call backs Callbacks are technically function pointers which implement the logic to handle a particular event Events are generated by user actions such as pressing a button or selecting a value out of the drop down menu etc Each object has its own unique handle or pointer by which it can be addressed The UI is linked with a corresponding m file by the help of handles and callbacks A tem
19. Figure 29 if ta Y 12 440m iry Wavg E ijji 11 2m V y J2 9 96U Frequency E E Figure 29 Output of RC Low Pass Filter The output waveform shown in blue color was observed at a time scale of 1s The two voltage levels indicate the voltages in air and near test specimen whereas the small spikes seen at the bottom indicate the presence of crack As clear from the above waveform that there was a lot of noise seen in the dc output which can give false alarm of a crack in from of voltage spikes Hence the students are working on the active filter approach in order to minimize the noise at output and to increase the voltage level of the signal 4 1 7 Data Acquisition amp Signal Processing Meanwhile the students have also started working on the software side of the project as well The modulated signal has to be interfaced to the PC using a Data Acquisition DAQ card which has also been procured The signal from the EC probe will be interfaced to the PC and plotted on software like LABVIEW which is a graphical programming language which will be used for real time data acquisition and display plus analysis Following flowchart shows the functions that are to be carried out on software as seen in Figure 30 DATA DATA SIGNAL Relcicii ic EXTRACTION PROCESSING Figure 30 Software Flowchart Programming was done on software in order to learn data logging techniques on LabVIEW software and
20. Square waveform reproduced in Matlab seeeeeesssssssssssssseseeerereresssssssssssssssseeeerrereeeee 37 Table of Tables Table 1 Three Cracks Diameter Values 2 0 0 0 ccccccsssssesseeseeeeeeeccecececeeeeeaaaaaaeasasseseeeeeeeeeeeeeeees 20 Table 2 Energy Distribution between 6 mm till 10 mm depth of Specimen eee 21 1 Introduction The ICT R amp D funded project Development of Flaw Diagnosis Dimensioning Prognostics Algorithms for the Improvement of In Country Aerospace Non Destructive Testing NDT Capabilities started on April 1 2013 In this regard an NDT Centre has been established at Pakistan Navy Engineering College National University of Sciences and Technology PNEC NUST This document describes the activities that have been performed at the NDT Centre during the fourth quarter of the project The activities for this quarter included re recruitment of undergraduate workforce Guided User Interface GUI development for flaw detection software incorporating both ET and UT testing methods alpha testing of the GUI and generation of historical database A website is also set up according to the directions of ICT R amp D The web site link is http ndt pnec nust edu pk index html The web site contains details of different project activities The details of project activities are as discussed in the subsequent sections 2 Recruitment of Workforce for Fourth Quarter Competitive and research oriented huma
21. ant peak value The few designs tried were reported in the 3rd quarter report The IC OPA564 that was ordered from abroad for the constant current source It was obtained in SMD form and hence practical testing could not be done immediately after the procurement Probe design and development was also carried out using the Analytical Approach that incorporated graphs and constants for the physical parameters of the copper wire used Three different probes were developed with different inductances and the one with 106uH was finalized It did not give accurate results due to the fact that it was hand wounded These can be seen below in Figure 19 Figure 19 Eddy Current Probes hand wounded The third most important hardware part of the project is the demodulation stage for demodulating the signal received from the eddy current probe For this purpose a Phase Locked Loop which is a phase sensitive detector was chosen and some work was done in order to use it to detect a phase change in the signal offered by the eddy current probe 4 1 1 1 ET Instrumentation Flowchart Figure 20 ET Instrumentation 4 1 2 Excitation The excitation part refers to the constant alternating current source A smooth sinusoidal waveform with current above 500mA is required for exciting the eddy current probe 4 1 2 1 OPA564 Based Howland Current Pump The high current operational amplifier IC OPA564 chosen for this
22. ated with the help of amplitude scans and plotted accordingly In C Scan view we have dimensions Length and Breadth of the actual piece on X axis and Y Axis and their thickness is along the Z axis With the help of C Scan we can estimate the sub surface issues which are not visible with bared eye Below mention is sample C Scan plot obtained using 25 location inspection results ww ul y daq x 57 5 iiec 12 2 RGE 0 315 1 0 666 Figure 14 C Scan 3 5 4 FFT Fast Fourier Transform Fourier transform is one of the basic techniques used for signal characterization in frequency domain In this method multiplication has performed with the signal under observation and sine and cosine Sampling frequency is selected based on Shannon Frequency Theorem as transducer used to carry out examination In this frequency is at X Axis logarithm Scale and Y Axis refers to amplitude Figure 15 was obtained from one of healthy location of test specimen Figure 15 FFT Spectrum Plot 3 5 5 STFT Short Term Fourier Transform Short Term Fourier Transform STFT shows three plots first one is STFT spectrum second is Time Frequency plot at particular location and third is A Scan refer to section 1 1 for better understanding of user STFT Spectrum is three axes plot with time information in on X Axis Y Axis represents frequency information and Z Axis shows the amplitude of the signal Figure 16 is the spectrum of h
23. cesses serial data in the following sequence Obtains the log file where data was previously logged Converts data in file from ASCII code to Hexadecimal form Extracts information bits from a series of packets Formats data bits into groups of four hexadecimal codes Converts the formatted data into decimal form for plotting in MATLAB Creates if required and logs data into a file ee a lt terminated gt WSNDataReader fava Application JSystem Library Java JavaVirtualMachines 1 6 0 jdk Conte nts Home bin java 18 Apr 2014 8 26 09 PM J 1 gt Hexadecimal representation of cutecom log 7E 45 00 FF FF 00 88 16 08 93 Bo OA E7 05 9B OA E7 05 A3 QA EB 05S SB OA EB 05 OB OA E3 05 OB 8D 11 7E 7E 45 00 FF FF 68 16 2A 93 20 B OB 1D 85 BS BB 1D 05 Bb B 23 05 Bi Data Size 185 2 gt Correct data format for plotting in matlab QAE OSOB QAE 05A3 QAER 0598 GAER 0598 QAEI 0598 OBID 0565 OR1D 05EG 0R23 0581 ARIF OSEE ABLE 0583 BAE 059R QAE Q59B QAE 0598 QAE 0598 BAL 059E 3 gt Data in decimal form required for plotting in matlab 2 044189453125 1 051025100625 2 044189453125 1 056484765625 2 047119140625 1 051025390625 2 047119140625 1 051025390625 2 041259765625 1 051025390625 2 083740234375 1 0700683593 Data extraction succesful Filing complete data in file DecimalValues txt Figure 41 Console from Eclipse IDE showing output of java program During final testing a square wave generate
24. could not be achieved even after exciting the probe with an efficient circuit such as the Howland current pump The probes were then designed by the students amp then machine wounded from the local market These can be seen in the Figure 26 below 4 1 4 Phase Shift Detection amp Demodulation With reference from the previous report the Phase Locked Loop was finalized for FM demodulation The students have already purchased the PLL IC CD4046B and are trying to use it as a demodulator Initially the working of the IC was successfully verified in its most simple design by checking the operation of the built in Voltage Controlled Oscillator VCO of the IC To start with a self generated FM signal was used to test the PLL as a demodulator The FM signal was designed on MATLAB and tested on hardware The result of which is shown in Figure 27 Later when actual results were obtained from the eddy current probe the signal was passed on to the PLL and it was working just fine Only problem was that the sensitivity of the PLL could not detect the feeble phase shift offered by the eddy current probe under use GY iSTEK we 8 8005 Trisd a Measure F c M m Dae BERRIES adadi j TEE T TU INNEN i a TEEN i COT ot te E 4 an a fui Lf i T E asin ERR ERER GEETE t eea EE IETEK h aA peat E aLa Eat tr tastes te cc te ERT aas EEN pie FE F ERTE i a i ki iai i Hi Hh TA ayt hgh i 25 rm Enara a Y utahet a iiir th i Pere be
25. d of Aerospace NDT through which the data has been acquired E Aerospace NDT GUI Wings Method Select B A B OS ae i E E 2sP1A KauonaliET Flaw Detection Software pony Sep D Fund x N lt a g 2014 NDT Center PNEC NUST 4 Clicking either one of the options leads to a unique GUI designed and coded for processing particular data Depending on what the user clicks the following windows will appear a Eddy Current E Aerospace NDT GUI Wings ET a Fae eT Aerospace NDT National ICT Flaw Detection Software R amp D Fund Magnitude Histogram Sy NUST Defining futures Adaptive Thresh 2014 NDT Center PNEC NUS As evident from the figure shown above the calibration file amp raw data directory need to be loaded in order to activate the Eddy Current GUI Clicking on the Select Calibration File button opens up a window which allows the user to select a dat file E Aerospace NDT GUI Wings ET l File to Open l j gt k ET Datafiles 100K R amp _ Ee oa PIA Great People to Fly Vystrr Organize v New folder S x Euit Name Date modified e EE Desktop Ldat l 3 25 2013 8 32AM DAT File i Downloads 2 dat 3 25 2013 8 32AM DAT File Dropbox _ 3 dat 3 25 2013 8 33AM DAT File E Recent
26. d using a function generator was fed into a WSN mote That mote was connected to a computer USB port and data was logged into a file Information bits were extracted from the logged file through the program mentioned earlier The obtained data bits were then used to plot a waveform in MATLAB as illustrated below in Figure 42 Figure 42 Square waveform reproduced in Matlab Appendix A Aerospace NDT GUI v1 1 User Manual 1 Run the code on MATLAB The Aerospace NDT GUI should appear on screen The first window that will appear is the welcome screen BE Aerospace NDT GUI Welca me Aerospace NDT National ICT Flaw Detection Software R amp D Fund Development of Flaw Diagnosis Dimensioning x Prognostics Algorithms for the Improvement of In Country Aerospace Non Destructive NDT Capabilities y START 2014 NDT Center PNEC NUST 2 Click start to proceed Clicking start leads to a window which allows the selection of a target area of the aeroframe namely the Fuselage Wings or Landing Gear BB Aerospace NDT GUI Targe Area Selection le r Aerospace NDT P IA National ICT Flaw Detection Software raii Po EAK Witt FUSELAGE LANDING GEARS i 2014 NDT Center PNEC NUST 3 Upon selection of the target area the following window pops up prompting the user to select between the metho
27. e visible changes in energy distribution at and near to cracked location In order to profile the crack based on HHT spectrum plot energy has been added to get the relation between flaw size and energy values Below mention is the table that shows the summation of the points selected around cracked dimensions which clearly shows that as the crack size increases more energy will be dissipated Table 2 Energy Distribution between 6 mm till 10 mm depth of Specimen Healthy con CS ca Content Location 4mm 4mm n leptin 3 8 Generation of Historical Database Through the generation of historical database the remaining useful life RUL of aircraft structure can be predicted This database would be used in damage progression crack growth studies for different structures parts of the aircraft The database would also show the degradation progression in different components specimens with respect to flight hours The knowledge of RUL would ensure aircraft safety as well as enable aircraft management agencies to plan repair replacement accordingly Thus development of historical database is a long and continuous process which remained in progress during the a quarter 4 Undergraduate Projects Progress Subsequent sections document the progress on different UG projects in the fourth quarter 4 1 PC Based Eddy Current Testing System 4 1 1 Previous Progress The undergrads started off with designing an alternating current source but with const
28. ealthy which is obtained using 6 point rectangular window rectangular window is most preferred for detection of discontinuity and abrupt changes Frequency Hz tne Figure 16 STFT Spectrum Plot Short Term Fourier Transform s second plot is the Time Frequency plot obtained at selected location to observe the behavior of time and frequency at particular distance User has been given access to select point which gives Time Frequency Plot similar to Figure 17 Time 6 3333e Dhsee 0 03 Dielance 0 O18 him O05 i AU eee eee ie I 3 amp nE aa a nee poten ones Ao a A aed er ok es E E j PE MET EN oe 1 i o_o i J J 6 3 Frequency Hi ay Figure 17 STFT Time Frequency Plot 3 6 Alpha Testing of GUI for flaw detection and profiling software Software Testing is a critical part of any software development Alpha Testing is an initial part of software testing which is conducted by the developers and programmers to verify whether the software under test 1s behaving as expected or not The developers and programmers write a User Manual which documents expected use and behaviour of the software Alpha testing ensures that the software functions according to the User Manual The GUI for flaw detection and profiling software has been tested by the development team and is working in accordance with the User Manual which is attached as Appendix A 3 7 Hilbert Huang Transform Based F
29. es could be appropriately addressed The main idea was to isolate ADC operations in motes from Wireless transmission of data from one mote to another Therefore we decided to communicate data from a single mote serially to a computer this allowed us to address issues with ADC sampling and the amendments done previously in our Tiny OS program At the time we succeeded in Increasing the sampling rate to 10 kHz Retrieving a square wave signal serially from a mote Extracting information bits from a Tiny OS data package through a java program Reproducing the square wave signal in MATLAB iS Currently we are working to further increase the sampling rate to 200 kHz 4 3 3 1 Java program for extracting information bits A WSN data package in Tiny OS contains the following bits 1 Header 2 Metadata 3 Data bits Information 4 Footer Except data bits all other bits were found to be superfluous for reproducing a signal from a zigbee mote on a base station these superfluous bits are however mandatory for data transmission and cannot be deleted from a package In order to obtain only the information bits a program was written in java By considering the fact that a total of 20 bits are transferred in each packed at a fixed offset from the current package s starting point an algorithm was devised and implemented in java The program was developed and tested in Eclipse IDE Figure 41 shows the program s output The program pro
30. esitop ANO _GUl 201403 10M NK UTWata_fites ee ee ee ee Oe ee ee 2014 NDI Center INLE SUS Figure 11 UT GUI Figure showing A Scans A brief overview of important buttons and their functionality for UT GUI follows 3 5 1 Amplitude Scan A Scan Amplitude Scan is the plot between time and amplitude where x axis is time axis and y axis is amplitude This is exactly the same plot which can be seen at the equipment screen at the time of inspection A Scan is the base for all other processing of ultrasonic signal Rough estimate can be deduced from this plot initial Puke Dead Zone Back Surface Reflection he peated Back Surface Reflection Figure 12 A Scan 3 5 2 B Scan Cross Sectional view Scan B Scan is cross sectional view of the test specimen displayed graphically B Scans also termed as brightness scan is obtained with the help for A Scans at predetermined intervals This is 2 D type of plot in which we have linear distance on which scans are obtained displayed at X Axis Y Axis shows the depth of the test material and color shows the intensity of the pulse at specific location WLU ui y dag g 05 1 14 2 25 35 4 a6 5 5 Linear Distance in Inches Figure 13 B Scan 3 5 3 C Scan Top View C Scan is top view of the test specimen and it is top view thickness mapping of the material which is obtained with the help of A Scans Thickness is calcul
31. how to interface it with the DAQ card see Figure 31 Figure 31 Data Logging on LabVIEW Similarly filtering was also done on software by introducing noise randomly in a given signal Its programming was also done and the results can be seen below in Figure 32 Waveform Graph 2 Waveform Graph low cutoff freq fl iE al Figure 32 Signal Processing using Filters on LabVIEW Waveform Graph 2 Beans m Waveform Graph Pito E n Waveform Graph 3 Piot 0 Amplitude Time Original Signal Self Induced Noise Filtered Signal Figure 33 Results of Filtering on LabVIEW The above procedure was only done for learning purposes Results are as seen above in Figure 33 The demodulated signal is still being worked upon for reduction of noise and amplification to get acceptable voltage level The students are currently working on the demodulation stage of the project and then will be moving on to the software side in the upcoming month 4 2 ET Position sensor Manual scanning methods give reading with respect to time Due to non uniform speed the accuracy decreases because in eddy current testing we want coordinates of the position moved by the probe versus eddy current signal instead of time Therefore ET Position Sensor project was initiated to easily determine the exact position of the crack flaw 4 2 1 Previous Work Approach PIC microcontroller was sought to be
32. ical operation has to be performed Morphological image processing pursues the goals of removing these imperfections by accounting for the form and structure of the image Potential ROW for Classification and Ril Detection Figure 9 Image with detected ROI s 3 4 5 Report Button Report button displays the final report which gives adequate detail about the effected regions Generated report saves as a text format and place in the current folder The first column represents the location of potential regions in terms of rows and columns The features such as maximum reactance maximum magnitude phase at 200 kHz and phase at 100 kHz are extracted from defined location The values of the extracted features are placed in third column Classification of the ROI is done using heuristically defined rule and result is shown in the last column 1 e either the detected ROI contains DEFECT or NO DEFECT Phe 100 58 ROI Locations gs O MeMa eao 3343 Phs 200 75 3498 Phs 100 43 o Figure 10 Generated Report 3 5 The UT GUI The UT GUI is developed for ultrasonic testing diagnostics part of the project Diagnosis results and their appearance are made user friendly different push buttons are made for different techniques to analyze ultrasonic result effectively as shown in Figure 11 Aerospace NDT Flaw Detection Software CoWsers SalariDesktop ANDT _GUI 20140310 MNK UT Data_files C WsersiSalarM
33. ions were developed in MATLAB software to realize the algorithms in the form of software ET_extract_data ET calibrate ET land mark elimination ET _Adaptive_Thresholding ET_morph_ops ET roi_ detection ET feature _ extraction SAHOO PWD FE 8 ET classification 9 ET_report_generation These functions and their outputs are described briefly in section 3 4 3 2 Development of MATLAB functions from UT algorithms for the GUI Following UT functions were developed in MATLAB software to realize the algorithms in the form of software 1 UT_initialize 2 UT_AScan 3 UT_BScan 4 UT _CScan 5 UT_spctstft 6 UT_emdn 7 UT_hlhut 8 UT_reportgen These functions and their outputs are described briefly in section 3 5 3 3 Development of GUI for flaw detection and profiling software A Graphical User Interface is necessary for any software to let the end users interact conveniently without memorizing specific commands and following strict flow requirements Thus a well designed GUI allows the software to assist the user in his her work without disturbing the user s focus with non application specific details In context of flaw detection and profiling software GUI should allow its user to identify faulty parts and quantize the flaw af present without having significant knowledge of the signal processing algorithms being used The GUI is developed using GUI Design
34. law Profiling Algorithms using Ultrasonic Testing Flaw profiling using ultrasonic testing needs analysis of signal in time frequency domain due to non stationary nature of the signal i e there is an effect of time on signal frequency Short term Fourier Transform STFT was used to analyze raw signal which was obtained from test piece During analysis with the help of STFT different size of window was used to get better profile of the crack It was also assumed that signal was linear for certain duration whereas original signal obtained from test piece was non linear and non stationary in nature In order to analyze the signal recent technique Hilbert Huang Transform has been used to get more accurate and precise information about crack Table 1 shows the crack diameters Table 1 Three Cracks Diameter Values Hilbert Spectrum Plots te st a Figure 18 a is of Healthy location b is of Cracked Location of 3 mm dia c is of Cracked Location of 4 mm dia and d is of Crack location of 5 mm dia Figure 18 plots are the Hilbert Spectrum obtained from the test data and by analyzing the energy distribution changes that occurs due to presence of crack Figure 18 shows time frequency and energy distribution of cracked and healthy location It can easily be observed that there is no energy between selected depth readings i e between 6 mm till 10 mm as there was no crack whereas in rest of the figures we have som
35. lect figure as text in Title bar National ICT R amp D Fu Fund Aerospace NDT GUI Wings bjethod Select SER Gr crest Perugeter bor Ply VVar Aerospace NDT Flaw Detection Software Figure 3 Text from previous figure as an example of inter figure communication Both ET and UT GUI need data files to operate on Therefore all other buttons are disabled until filenames or file paths for both calibration and data files are not selected Figure 4 shows such a scenario in ET GUI Ji Wings ET Aerospace NDT Flaw Detection Softwure Defining futures 2014 NDT Center PNLC NUST Figure 4 ET GUI Figure with buttons disabled until input files are selected When files are loaded Load button activates but all others are still disabled Pressing this button calls functions which are needed before any other operation is done i e it initializes the GUI and enables all other buttons This is true for both ET and UT GUI figures When any other button or command is passed the GUI calls necessary functions listed in sections 3 1 and 3 2 in predefined order Among other requisite parameters the GUI passes handles to display axis to these functions so that the functions can directly output results on the given axis Such GUI specific parameters are passed to the functions using variable argument inputs This allows debugging the functions when run stand alone Following sections brief the
36. les et calib _filepath Stores calibration filepath for ET c handles et raw_ filename Stores raw filename for ET handles et raw_filepath Stores raw filepath for ET handles et impedance Stores raw impedance values returned by ET extract _data when Load Button on the ET GUI is called It is used by different signal processing functions handles et impedance_mag Stores corresponding magnitudes for handles et impedance handles et Real_Component Stores corresponding real components for handles et impedance handles et Imaginary_Component Stores corresponding imaginary components for handles et impedance 3 Handles for inter callback communication in UT GUI oa oc SF handles ut calib filename Stores calibration filename for UT handles ut calib_ filepath Stores calibration filepath for UT handles ut raw_ filename Stores raw filename for UT handles ut raw_filepath Stores raw filepath for UT handles ut A Stores Amplitudes returned by UT_initialize function when Load button is pressed on UT GUI It is used by different signal processing functions in various call backs handles ut D Stores distances corresponding to amplitudes in handles ut A Using the igc structure the figures delete their parents and update their local variables with the user selections made in previous figures For instance Figure 3 shows the Target Area selected by user in the Target Area Select figure which is displayed in Method Se
37. mage contains the logos of PIA ICTR amp D PNEC and NUST within top and bottom strips The title of the software is also evident on the top strip Figure 2 shows this background image All other GUI objects including panels lie on front of this image except the strips in every figure Aerospace NDT Flaw Detection Software National ICT R amp D Fund TE y f N 2014 NDT Center PNEC NUST Figure 2 Background image incorporated in every figure of the ANDT FDS GUI Each function has its own namespace Therefore any variables created or updated within a call back function are local to it To communicate between call backs GUIDE creates and uses a handles structure which is passed as a default parameter to every callback function It primarily contains handles to all objects on the current GUI figure This structure is used for inter callback and inter GUI communication in ANDT FDS by introducing new fields into it Some important fields introduced are listed below 1 Handles for inter GUI communication a handles igc prev_fig_h stores handle of previous figure it is used to delete previous figure when new figure is invoked b handles igc ta_sel communicates selection of target area to following figures c handles igc m_sel communicates selection of NDT method to following figures 2 Handles for inter callback communication in ET GUI a handles et calib filename Stores calibration filename for ET b hand
38. n resource is highly desirable for performing rapid development activities In this regard Under Graduate UG Post Graduate PG Research Assistant RA and other support staff has been recruited The UG students and staff have been re recruited for this quarter 2 1 Recruitment of Undergraduate Workforce Undergraduate recruitment for 06 positions was carried out instead of two positions as approved in budget A change of request form was raised giving justification of the change The change has been approved According to the new plan 06 positions are filled on quarterly basis Short listing and selection of UG students depended upon their GPA technical knowledge attitude motivation commitment for summers and final year project The selected UG students have been divided into two groups as follows For Fee Waiver 1 Salar Bin Javaid 2 Taha Saeed Khan For Stipend 1 Talha Wagar 2 Summaya Abbas 3 Muhammad Mansoor 4 Sulaiman Rais All the students listed above give 10 hrs week to the project Students are categorized into different group projects based on the various aerospace NDT techniques The RA acts as the principal supervisor and coordinator for these projects The UG students availing tuition waiver are acting as the group leaders The UG group leaders are responsible for the tasks assigned to the group by the PI Co PI and RA as well as other support tasks assigned from time to time Therefore their committed time
39. plate containing call back functions is automatically generated by GUIDE which can be populated for specific needs The GUI was named Aerospace NDT Flaw Detection Software ANDT FDS and is composed of five different figures The ANDT FDS was developed as a set of figures instead of a single figure to follow a modular approach this allows re usability and easy prototyping Moreover a wizard like approach is adopted which unburdens the user from doing routine settings and problems caused by forgetting to set important ones Furthermore each figure is stand alone as well i e it can also run directly However the first figure is a bit redundant as it is only a welcome screen that may be omitted in latter versions Each figure calls another figure until the user reaches the ET GUI or the UT GUI Figure 1 depicts the flow the user can adopt between figures Welcome Screen Press Start NDT Method Selection Screen Target Area Selection Screen NDT Method Target Area ET UT 1 Wings 2 Fuselage 3 Landing Gears 5 Figure 1 Typical flow through figures for the ANDT FDS GUI Because of the modular approach we can for instance design a specific GUI for ET of Landing Gears if future requirements compel us to do so Each figure contains a background axis on which a common background image is displayed This background i
40. rT H A pias M 0 h rin L i 0 10 20 30 40 50 0 10 20 30 40 50 Depth in mm Depth in mm 2014 NDT Center PNEC NUSSI C Scan button The C Scan button gives the top view of the test specimen and it is top view thickness mapping of the material which is obtained with the help of A Scans With the help of C Scan the user can estimate the sub surface issues which are not easily visible or M a n _ DEN HH r Aerospace NDT Flaw Detection Software National ICT C Users SalariDesktop ANDT_GUI 20140310 MNK UT Data_files C Users SalanDesktop ANDT_GUI 20140310 MNK UT Data_files C Scan Plot Distance Location 1 15 2 25 3 3 5 4 45 Distance 2014 NDT Center PNEC NUS
41. s Normal pointer velocity in s Mouse Velocity in s Figure 36 Pointer Ballistics problem 3 To delimit the position sensor from pointer s screen limitation java awt robot function was used to make pointer come back to origin of screen as it approached the end of the screen retaining its reading In this way it continues the reading as it can be moved multiple time across the screen taking readings so that there is no effect on the movement of physical mouse structure placed on the plate 4 Screen size was set to full screen for easy calibration and avoiding to get out of the specified path Figure 37 further illustrates various features of ET position sensor GUI y loc 1 7181 x loc 2 3501 AXES SHOWS DISTANCE V5 TIME PLOT OF THE PROBE MOVEMENT GOTO POSITION 4 7 0 0 Figure 37 Primary ET Position sensor GUI features and improvements 4 2 2 2 Future tasks Though ET position sensor is operating successfully some minor issues related to the working of the mouse near the screen limit exists If the mouse is moved very fast then it sometimes gets out of the screen limit and java robot function can t detect if it has moved out of the limit When this happens the pointer gets struck on the extreme edge of the screen and can t move in the direction of motion yet if moved in other direction it gets detected and comes back to origin Figure 38
42. shows the graph plotted for distance covered by mouse against time which has some spikes due to the issue discussed above This problem is being resolved y loc 25 145 x loc 42 1647 Edi Tert Edit Tari Figure 38 Graph of position vs time by ET position sensor having some erroneous spikes 4 3 GWUT over WSNs 4 3 1 Envelope detector circuit Up till third phase we were working with only 300 kHz PZTs In fourth phase we imported some new PZTs which are larger thicker and more robust with lower resonant frequency 1 e 200 kHz First we confirmed the resonant frequency by exciting the PZT in series with a resistor and noting the voltages across it A dip in voltage near 200 kHz indicated series resonance within PZT as expected in Radial mode We continued our work with those new low cost PZTs and found some good results Due to change in frequency now working at lower frequencies we faced problems with envelope detector that was designed for 300 kHz So we first redesign it mathematically for variable frequencies and then check it practically We also derived a mathematical equation for its RC based filter for Gaussian signal 4 3 2 Exciter circuit After redesigning of envelope detector we moved towards the designing of the exciter circuit The exciter circuit has to replace the function generator being used to excite the PZTs A modulated Gaussian pulse is used to excite the PZT at its resonant frequency see Figure 39
43. signal interpretation 3 Principal Project Progress Following were the technical milestones achieved in the preceding quarter 1 Development of flaw detection software a Report generation module 2 Flaw Profiling algorithm development a Development of calibration curves b Development of Method based on neural networks c Development of method based on Bayesian technique known as SMC sequential Monte Carlo 3 Generation of historical database The technical milestones set for the reporting quarter are as follows GUI development for flaw detection and profiling software Alpha testing of flaw detection and profiling software User manual for flaw detection and profiling software and its GUI oe Generation of historical database All of the milestones set for the fourth quarter are achieved except the incorporation of SMC algorithm and some other methods in the GUI such as the one based on Hilbert Huang Transform HHT which is developed for UT The methods such as HHT are not originally present in the project milestones but are a productive addition All methods will be incorporated in the next release version of GUI The development of stand alone MATLAB functions programs from the flaw detection and profiling algorithms for the GUI the GUI itself its alpha testing results and HHT based method for UT are presented in the following sections 3 1 Development of MATLAB functions from ET algorithms for the GUI Following ET funct
44. tainer and displays The height of each rectangle indicates the number of elements in the bin For finding the region of interest it s essential to have an idea of the different data present ee i ee amp 2sPIA Aerospace NDT National ICT Flaw Detection Software peas dns wrap foes R m amp D Fund OOOO anena O Histogram of Calibrated Magnitude gt 2 5 1500 a w m 1000 500 0 1 0 1 2 3 4 5 Voltage 2014 NDT Center PNEC NUS I iii Adaptive Thresholding button The adaptive thresholding button displays the processed image of particular area in an aircraft part Adaptive thresholding is used to remove the 1ll influence which typically takes a grayscale or color image as input and in the simplest implementation outputs a binary image representing the segmentation The area in red is the possible effected Aerospace NDT GUI Wings ET D a se e ET a _ m P Se a m e Te _ Aerospace NDT PILA National ICT Flaw Detection Software Deas E R m i ay amp D Fund C Users Salar Desktop ANDT_GUI 20140310 ET Data_files 100K C Users Salar Desktop ANDT_GUI 20140310 ET Data_files 200k Imagesc plot of Magnitude Rows 0 0 500 1000 1500 2000 2500 3000 3500 4000 oltage indices 2014 NDT Center PNEC NUS iv ROI Detection button The ROI detection button shows
45. tainers and returns the number of elements in each container and displays Height of each rectangle indicates the number of elements in the bin It s necessary to have an idea about how much different amount of data present in the image before adaptive thresholding The elimination percentage of an image can be decided by visualizing the histogram of that image Histogram of Calibetared Magnitude ui Cc ak oa T le LL J 4 Voltage Figure 7 Histogram of Image 3 4 3 Adaptive Thresholding Button Adaptive Thresholding button displays the processed image of particular area in an aircraft part as shown in Figure 8 Adaptive thresholding is used to remove this ill influence which typically takes a grayscale or color image as input and in the simplest implementation outputs a binary image representing the segmentation The areas in red are the possible effected regions in an aircraft Imagesc plot of Magnitude ee 1000 41500 2000 2500 3000 3500 Voltage Indices Figure 8 Image after Adaptive Thresholding Algorithm 3 4 4 ROI Detection Button The ROI detection button shows the potential interested regions in the image as shown in Figure 9 The image formed after applying adaptive thresholding scheme which is in binary format Binary images may contain numerous imperfections In particular the binary regions produced by thresholding are distorted by noise and texture To find potential region of interest a morpholog
46. ures E Videos i Homegroup a i aili eet t Folder Data_files Ce aia Defining futures Click Select Folder After the file and the folder have been selected the user can click the Load button to load the selected data and enable the other buttons An axes is displayed by default The buttons and there functions are as stated A Scan The Amplitude Scan button gives the plot between time and amplitude This is exactly the same plot which can be seen at the equipment screen at the time of inspection A Scan is the basis for all other processing of ultrasonic signals DANDY CULT i O a ih E r Aerospace NDT National ICT Flaw Detection Software o DE oH C Users Salar Desktop ANDT_GUI 20140310 MNK UT Data_files C Users Salar Desktop ANDT_GUI 20140310 MNK UT Data_files Amplitude Scan N S Oo N S So ak n ok n ao EE ee eee ee eee rr ee ie C1 0 ee ee eee eee eee LELLE on So oS Se See Ra et ee Fee 100 ceeseoctessessoaeh ae Amplitude Amplitude Ae tae i ee ee PRIR EA ERA L Re 0 ai i 0 La i 0 10 20 30 40 50 0 10 20 30 40 50 Depth in mm Depth in mm 200 pv 200 p Amplitude Scan Amplitude Scan AE AOR N er ee o E EE E TEE E 7 Ses P EEN EA TE Son ONN e AN AE hs P A EAU Amplitude Amplitude 50 SE TA PA TN 50 A e a A T G E
47. used having serial interface with PC But it was a mechanical platform a ball mouse recording the increment in the mouse wheel for position sensing as the ball moved x and y wheels of the internal circuitry It posed following problems Complex external interfacing and data acquisition at a very fast rate was very difficult Moreover its accuracy could be disturbed by mechanical factors such as ball slip or backlash 4 2 2 Final Approach for ET Position Sensor Software based approach was adopted This involves capturing the position increment sent by mouse to the operating system for cursor movement MATLAB based GUI was implemented using GUIDE tool In this approach Mouse position changes are taken as probe displacements where probe will be attached to the mouse assembly The GUI s axis that acts as a Cartesian plane is shown in Figure 34 y loc 1 0589 x loc 7 302 Figure 34 GUI figure for the ET position sensor 4 2 2 1 Features implemented and further improvements 1 Real time acquisition of data and display on command window was implemented which lists X y axis position and time instantaneously Figure 35 shows real time data acquired from mouse t i Ax New to MATLAB Watch this Video see Demos or read Getting Started x Mouse Button Elapsed time Mouse Button Elapsed time Mouse Button Elapsed time Mouse Button Elapsed time Mouse Button Elapsed time Mouse Button Elapsed time
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