Claims:1. A method comprising:
transmitting an acoustic wave through a radiator tube, wherein the radiator tube comprises a cross-sectional geometry that varies along a length of the radiator tube;
receiving a reflected wave corresponding to the acoustic wave;
filtering the reflected wave based on the cross-sectional geometry of the radiator tube;
identifying a defect in the radiator tube based on the filtered reflected wave;
determining a serviceability of the radiator tube based on the defect; and
providing a notification that comprises at least one of a type of the defect and the serviceability of the radiator tube.

2. The method of claim 1, wherein the radiator tube comprises a first tapering portion, a second tapering portion, and a straight portion disposed between the first and the second tapering portions.

3. The method of claim 1, wherein identifying the defect in the radiator tube further comprises determining at least one of the type of the defect, a location of the defect and an amount of the defect.

4. The method of claim 3, wherein the type of defect comprises at least one of a discontinuity, an erosion, and a constriction.

5. The method of claim 3, further comprising determining the serviceability of the radiator tube based on at least one of the type of the defect, the location of the defect, and the amount of the defect.

6. The method of claim 3, further comprising determining a repair action based on at least one of the type of the defect, the location of the defect and the amount of the defect.

7. The method of claim 1, further comprising identifying the defect based on at least one of a rise time, a fall time, an amplitude, and a phase of the filtered reflected wave.

8. A system comprising:
at least one processor;
a communication unit configured to transmit an acoustic wave through a radiator tube and receive a reflected wave corresponding to the acoustic wave, wherein the radiator tube comprises a cross-sectional geometry that varies along a length of the radiator tube;
a filtering unit communicatively coupled to the communication unit and configured to filter the reflected wave based on the cross-sectional geometry of the radiator tube;
an analysis unit coupled to the filtering unit and configured to identify a defect in the radiator tube based on the filtered reflected wave; and
a determination unit coupled to the analysis unit and configured to determine a serviceability of the radiator tube based on the defect and provide a notification that comprises at least one of a type of the defect and the serviceability of the radiator tube.

9. The system of claim 8, wherein the radiator tube comprises a first tapering portion, a second tapering portion, and a straight portion disposed between the first and the second tapering portions.

10. The system of claim 8, wherein the analysis unit is further configured to identify at least one of the type of the defect, a location of the defect and an amount of the defect.
, Description:[0001] The technology disclosed herein generally relates to inspection systems. More specifically, the subject matter relates to systems and methods for inspection of a radiator.
[0002] A radiator is a heat exchanger that transfers thermal energy from one medium to another for the purpose of cooling and/or heating. Often, radiators are used in, for example, locomotives, automobiles, motorcycles, power generation plants for cooling an internal combustion engine. Typically, a coolant passes through an engine block to absorb the heat from the internal combustion engine. The hot coolant then passes through one or more radiator tubes of the radiator. As the hot coolant passes through the one or more radiator tubes, the hot coolant gets cooled since it transfers the heat to the one or more radiator tubes. In turn, the one or more radiator tubes transfer the heat to the ambient air. However, the radiator may sometimes fail to function properly due to defects in the one or more radiator tubes. The defects include, for example, a hole, a block, and the like, which disrupt the flow of the coolant through the one or more radiator tubes. Since the proper functioning of the radiator is critical to the efficiency of the internal combustion engine, the radiator needs to be inspected for these defects and serviced.
[0003] Currently, radiators are inspected using, for example, leak test methods, where a test fluid is passed through the radiator tubes to identify defects. However, such leak test methods have numerous problems. For example, the leak test methods may detect defects such as a hole, however, the leak test methods may fail to detect defects such as a block and an erosion that may be on the verge of causing a radiator tube to fail. Such failures in detecting defects increase the maintenance costs due to frequent unscheduled visits to the inspection site. Further, operating the radiators employing the radiator tubes that have one or more defects may decrease the life of the radiators.
BRIEF DESCRIPTION
[0004] In accordance with one aspect of the present technique, a method includes transmitting an acoustic wave through a radiator tube, wherein the radiator tube comprises a cross-sectional geometry that varies along a length of the radiator tube. The method further includes receiving a reflected wave corresponding to the acoustic wave and filtering the reflected wave based on the cross-sectional geometry of the radiator tube. The method also includes identifying a defect in the radiator tube based on the filtered reflected wave and determining a serviceability of the radiator tube based on the defect. The method further includes sending a notification to a user, wherein the notification comprises at least one of a type of the defect and the serviceability of the radiator tube.
[0005] In accordance with another aspect of the present technique, a system includes a communication unit configured to transmit an acoustic wave through a radiator tube and receive a reflected wave corresponding to the acoustic wave, wherein the radiator tube comprises a cross-sectional geometry that varies along a length of the radiator tube. The system further includes a filtering unit configured to filter the reflected wave based on the cross-sectional geometry of the radiator tube. The system also includes an analysis unit configured to identify a defect in the radiator tube based on the filtered reflected wave. The system further includes a determination unit configured to determine a serviceability of the radiator tube based on the defect and send a notification to a user, wherein the notification comprises at least one of a type of the defect and the serviceability of the radiator tube.
DRAWINGS
[0006] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0007] FIG. 1 is a block diagram illustrating an exemplary system for inspection of a radiator, according to one embodiment of the present technique;
[0008] FIG. 2 is a block diagram illustrating an exemplary inspection controller, according to one embodiment of the present technique;
[0009] FIG. 3 is a pictorial representation of an exemplary radiator tube including a defect, according to one embodiment of the present technique;
[0010] FIG. 4 is a pictorial representation of a reflection graph representing a reflected wave, according to one embodiment of the present technique;
[0011] FIG 5 is a pictorial representation of a filter graph representing a filtered reflected wave, according to one embodiment of the present technique;
[0012] FIG. 6 is a pictorial representation of an exemplary radiator tube including two defects, according to one embodiment of the present technique;
[0013] FIG. 7 is a pictorial representation of a filter graph representing a filtered reflected wave, according to one embodiment of the present technique;
[0014] FIG. 8 is a graphical representation of a correlation between an amplitude of a peak with an amount of a defect present in a radiator tube, according to one embodiment of the present technique;
[0015] FIG. 9 is a graphical representation of a correlation between an amplitude of a peak with an amount of the defect, according to another embodiment of the present technique; and
[0016] FIG. 10 is a flow diagram illustrating an exemplary method for inspection of a radiator, according to one embodiment of the present technique.
DETAILED DESCRIPTION
[0017] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.
[0018] The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0019] As used herein, the term “non-transitory computer-readable media” is intended to be representative of any tangible computer-based device implemented in any method or technology for short-term and/or long-term storage of information, such as, computer-readable instructions, data structures, program modules and sub-modules, or other data in any device. Therefore, methods described herein may be encoded as executable instructions embodied in a tangible, non-transitory, computer readable medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. Moreover, as used herein, the term “non-transitory computer-readable media” includes all tangible, computer-readable media, including, without limitation, non-transitory computer storage devices, including, without limitation, volatile and non-volatile media, and removable and non-removable media such as a firmware, physical and virtual storage, a compact disc read only memory, a digital versatile disc, and any other digital source such as a network or the Internet, as well as yet to be developed digital means, with the sole exception being a transitory, propagating signal.
[0020] As used herein, the terms “software” and “firmware” are interchangeable, and include any computer program stored in memory for execution by devices that include, without limitation, mobile devices, clusters, personal computers, workstations, clients, and servers.
[0021] As used herein, the term “computer” and related terms, e.g., “computing device”, are not limited to integrated circuits referred to in the art as a computer, but broadly refers to at least one microcontroller, microcomputer, programmable logic controller (PLC), application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein throughout the specification.
[0022] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
[0023] Systems and methods for inspection of a radiator is described herein. The radiator is a heat exchanger that transfers thermal energy from one medium to another. Typically, the radiator is used in, for example, locomotives, automobiles, motorcycles, power generation plants for cooling an internal combustion engine. FIG. 1 illustrates a block diagram of a system 100 configured to inspect a radiator 105 according to one embodiment. The system 100 includes the radiator 105 and an inspection device 170. In the illustrated embodiment, the radiator 105 may be configured to transfer heat energy from a locomotive engine. The radiator 105 includes one or more radiator tubes, represented generally by reference numerals 110a, 110b, and 110n, where n is any integer depending on the number of radiator tubes desirable in the radiator 105. In FIG. 1 and the remaining figures, a letter after a reference number, such as “110a,” is a reference to the element having that particular reference number. A reference number in the text without a following letter, such as “110,” is a general reference to any or all instances of the element bearing that reference number.
[0024] The one or more radiator tubes 110 include a cross-sectional geometry that varies along a length of the radiator tubes 110. In the illustrated embodiment, each radiator tube 110 includes a first tapering portion 120, a second tapering portion 130, and a straight portion 125 disposed (e.g., welded, glued, and the like) between the first tapering portion 120 and the second tapering portion 130. The first and the second tapering portions 120 and 130 are conically shaped with circular cross-sections of varying diameters. The tapering configurations of the first and the second tapering portions 120 and 130 may be similar or dissimilar. In one example, the first and the second tapering portions 120 and 130 may be shaped as a right circular cone. In another example, the first tapering portion 120 may be shaped as a right circular cone and the second tapering portion 130 may be shaped as an oblique circular cone. In one example, the largest diameter of the first and the second tapering portions 120 and 130 is lesser than 12.5 millimeters. The straight portion 125 is a hyper rectangle with a rectangular cross-section. In one example, the height and the width of the straight portion 125 are lesser than 2.8 millimeters and 16.5 millimeters respectively. Although in the illustrated embodiment, the radiator tube 110 includes two tapering portions 120 and 130, in alternative embodiments the radiator tube 110 may include one or more tapering portions. In one example, the radiator tube may include a straight portion welded with a tapering portion.
[0025] The inspection device 170 may be configured to inspect the one or more radiator tubes 110 of the radiator 105. The inspection device 170 includes a transceiver 175 and an inspection controller 180. The transceiver 175 is configured to generate and transmit one or more acoustic waves through the one or more radiator tubes 110. An acoustic wave is a type of a longitudinal wave that propagates based on adiabatic compression and decompression. A longitudinal wave is a wave that has the same direction of vibration as the direction of propagation. In one embodiment, the transceiver 175 is configured to generate and transmit a bulk acoustic wave. A bulk acoustic wave is a type of an acoustic wave that propagates in a hypothetical medium which has no boundaries. The transceiver 175 is further configured to receive a reflected wave corresponding to the acoustic wave, from the radiator tube 110. The transceiver 175 is also configured to transmit the reflected wave to the inspection controller 180. Non limiting examples of a transceiver 175 include a piezoelectric device, a capacitive micromachined ultrasonic transducer, a speaker coupled with an acoustic receiver, such as a microphone, etc. For the purpose of clarity and convenience, the acoustic wave and the reflected wave are represented in FIG. 1 by signal lines 160 and 165 respectively. Although, the acoustic wave 160 and the reflected wave 165 are illustrated as being transmitted and received through the same end of the radiator tube 110b according to one embodiment, in alternative embodiments, the acoustic wave 160 may be transmitted and received through different ends of a radiator tube. For example, the acoustic wave 160 may be transmitted through a first end 112 of the radiator tube 110b and the reflected wave may be received from a second end 114 of the radiator tube 110b. In such an embodiment, instead of the transceiver 175, the inspection device 170 includes a transmitter (not shown) configured to generate and transmit the acoustic wave and a receiver configured to receive the reflected wave.
[0026] The inspection controller 180 may be a computing device configured to control the operation of the transceiver 175, identify one or more defects in the one or more radiator tubes 110, and determine a serviceability of the one or more radiator tubes 110. FIG. 2 illustrates a block diagram of inspection controller 180 according to the embodiment of FIG. 1. The inspection controller 180 includes a communication unit 202, a filtering unit 204, an analysis unit 206, a determination unit 208, a processor 235, and a memory 237 which are communicatively coupled with each other via a bus 220.
[0027] The processor 235 may include at least one arithmetic logic unit, microprocessor, general purpose controller or other processor arrays to perform computations, and/or retrieve data stored in the memory 237. In one embodiment, the processor 235 may be a multiple core processor. The processor 235 processes data signals and may include various computing architectures including a complex instruction set computer (CISC) architecture, a reduced instruction set computer (RISC) architecture, or an architecture implementing a combination of instruction sets. In one embodiment, the processing capability of the processor 235 may support retrieval of data and/or transmission of data. In another embodiment, the processing capability of the processor 235 may also perform relatively complex tasks, including various types of feature extraction, modulating, encoding, multiplexing, and the like. It may be noted that other type of processors, operating systems, and physical configurations are also envisioned.
[0028] The memory 237 may be a non-transitory storage medium. For example, the memory 237 may be a dynamic random access memory (DRAM) device, a static random access memory (SRAM) device, flash memory, or other non-transitory storage mediums. The memory 237 may also include a non-volatile memory or similar permanent storage device, and media such as a hard drive, a floppy drive, a compact disc read only memory (CD-ROM) device, a digital versatile disc read only memory (DVD-ROM) device, a digital versatile disc random access memory (DVD-RAM) device, a digital versatile disc rewritable (DVD-RW) device, a flash memory device, or other non-volatile storage devices.
[0029] The memory 237 may include data that may be required by the inspection controller 180 to perform associated functions. In one embodiment, the memory 237 includes the units of the inspection controller 180. For example, the memory 237 includes the communication unit 202, the determination unit 208, and the like. In another embodiment, the memory 237 includes a prototype wave, a-priori data, an amount threshold, a location threshold, and the like. The prototype wave, the a-priori data, the amount threshold, and the location threshold are described below in further detail with reference to the filtering unit 204, analysis unit, 206, and the determination unit 208.
[0030] The communication unit 202 includes codes and routines configured to facilitate communications between the transceiver 175 and one or more units of the inspection controller 180. In one embodiment, the communication unit 202 includes a set of instructions executable by the processor 235 to provide the functionality for facilitating communication between the transceiver 175 and one or more units of the inspection controller 180. In another embodiment, the communication unit 202 is a part of the memory 237. For example, the communication unit 202 may be stored in the memory 237 and is accessible and executable by the processor 235. In either embodiment, the communication unit 202 may be configured to communicate with the processor 235 and other units of the inspection controller 180 via the bus 220.
[0031] In one embodiment, the communication unit 202 is configured to send an instruction to the transceiver 175 for generating and subsequently transmitting an acoustic wave through a radiator tube 110. In one example, the communication unit 202 receives an input from a user of the inspection device 170 for inspecting the one or more radiator tubes 110. In such an example, the communication unit 202 sends the instruction to the transceiver 175 in response to the received input. The communication unit 202 is further configured to receive a reflected wave corresponding to the acoustic wave, from the transceiver 175. The communication unit 202 then sends the reflected wave to the filtering unit 204. In one example, the communication unit 202 converts the reflected wave from an analog form to a digital form prior to sending the reflected wave to the filtering unit 204. Although the communication unit 202 is described above as sending an instruction to the transceiver 175 for transmitting the acoustic wave according to one embodiment, in other embodiments, the communication unit 202 may transmit the acoustic wave through a radiator tube and receive the corresponding reflected wave. In such an embodiment, the transceiver 175 may be a part of the communication unit 202. In another embodiment, the communication unit 202 receives a notification from the determination unit 208. In such an embodiment, the communication unit 202 sends the notification to, for example, a display device (not shown), a user of the inspection device 170, and the like. The notification is described below in further detail with reference to the determination unit 208.
[0032] The filtering unit 204 includes codes and routines configured to filter the reflected wave. In one embodiment, the filtering unit 204 includes a set of instructions executable by the processor 235 to provide the functionality for filtering the reflected wave. In another embodiment, the filtering unit 204 is a part of the memory 237. For example, the filtering unit 204 may be stored in the memory 237 and is accessible and executable by the processor 235. In either embodiment, the filtering unit 204 may be configured to communicate with the processor 235 and other units of the inspection controller 180 via the bus 220.
[0033] The filtering unit 204 receives the reflected wave from the communication unit 202. The reflected wave corresponds to the acoustic wave transmitted through a radiator tube 110. The filtering unit 204 filters the reflected wave based on the cross-sectional geometry of the radiator tube 110. The filtering unit 204 filters one or more components in the reflected wave that are present due to the varying cross-sectional geometry of the radiator tube. In one embodiment, the filtering unit 204 filters the reflected wave by subtracting the reflected wave with the prototype wave. As used herein, the term “prototype wave” refers to a wave that represents acoustic wave reflections due to the varying cross-sectional geometry of a prototype radiator tube that is devoid of any detectable defects. The filtering unit 204 is further configured to send the filtered reflected wave to the analysis unit 206.
[0034] The filtering unit 204 may receive the prototype wave from the memory 237. In one embodiment, a user of the inspection device 170 generates the prototype wave based on a prototype radiator tube that is devoid of any detectable defects. In such an embodiment, the communication unit 202, upon receiving a user input, instructs the transceiver 175 to transmit a test acoustic wave through the prototype radiator tube. The filtering unit 204 then receives a test reflected wave that corresponds to the test acoustic wave from the prototype radiator tube. The filtering unit 204 may store the test reflected wave in the memory 237 as the prototype wave. In another embodiment, the user of the inspection device 170 generates the prototype wave based on a plurality of radiator tubes 110a, 110b, 110n in the radiator 105. In such an embodiment, the communication unit 202 in response to receiving a user input, transmits a plurality of test acoustic waves through a plurality of radiator tubes 110a, 110b, 110n, in the radiator 105. The plurality of radiator tubes 110a, 110b, 110n may be randomly selected by the user. The filtering unit 204 then receives a plurality of test reflected waves corresponding to the plurality of test acoustic waves from the plurality of radiator tubes 110a, 110b, 110n. The filtering unit 204 then generates a prototype wave based on the plurality of test reflected waves and stores the prototype wave in the memory 237. In one example, the filtering unit 204 generates the prototype waves by calculating the average of the plurality of the test reflected waves. In yet another embodiment, the filtering unit 204 generates the prototype wave based on a numerical simulation using a model of the prototype radiator tube.
[0035] The analysis unit 206 includes codes and routines configured to identify one or more defects in the radiator tube 110. The one or more defects in the radiator tube include a discontinuity, a constriction, an erosion, and the like. Non-limiting examples of a discontinuity include a hole, a crack, an opening in the joints between any two portions 120, 125, 130 of the radiator tube, etc. Non-limiting examples of a constriction include a blockage due to residual coolant, a dent due to external forces on the radiator tube, etc. A non-limiting example of erosion includes erosion of the internal surface of the radiator tube caused by the coolant. In one embodiment, the analysis unit 206 includes a set of instructions executable by the processor 235 to provide the functionality for identifying one or more defects in the radiator tube 110. In another embodiment, the analysis unit 206 is a part of the memory 237. For example, the analysis unit 206 may be stored in the memory 237 and is accessible and executable by the processor 235. In either embodiment, the analysis unit 206 may be configured to communicate with the processor 235 and other units of the inspection controller 180 via the bus 220.
[0036] The analysis unit 206 receives the filtered reflected wave from the filtering unit 204. The analysis unit 206 is configured to identify one or more defects in the radiator tube by identifying one or more corresponding peaks in the filtered reflected wave. Once the analysis unit 206 identifies a peak, the analysis unit 206 is further configured to determine one or more characteristics of the peak. The one or more characteristics of the peak include, a location of the peak, an amplitude of the peak, a rise time of the peak, a fall time of the peak, a phase of the peak, and the like.
[0037] In one embodiment, the analysis unit 206 analyzes the one or more characteristics of the peak to determine a type (e.g., a discontinuity, an erosion, and a constriction) of the defect, a location of the defect, and an amount (e.g., the size or dimensions) of the defect. For example, the analysis unit 206 determines that the phase of the peak is positive. In such an example, the analysis unit 206 infers that the type of the defect is a constriction. In a further example, the analysis unit 206 may further determine the sub-type of the constriction (e.g., a blockage, a dent, and the like) based on the one or more characteristics of the peak. In another example, the analysis unit 206 determines that the phase of the peak is negative. In such an example, the analysis unit 206 determines that the defect is an erosion or a discontinuity. The analysis unit 206 may further classify the defect as either an erosion or a discontinuity based on the rise time and fall time of the peak. In the above example, if the analysis unit 206 classifies the defect as a discontinuity, the analysis unit 206 may further determine the sub-type of the discontinuity (e.g., a hole, a crack, an opening between joints, and the like). Further, the analysis unit 206 may determine the location of the defect in the radiator tube based on the location of the peak in the filtered reflected wave. For example the analysis unit 206 determines the location of the peak in the filtered reflected wave as the location of the defect in the radiator tube 110. Furthermore, the analysis unit 206 may determine an amount of the defect based on the amplitude of the peak in the filtered reflected wave.
[0038] In another embodiment, the analysis unit 206 determines the type of the defect, the location of the defect, and the size of the defect by comparing the peak with a-priori data. The analysis unit 206 may receive the a-priori data from the memory 237. The a-priori data may be generated by, for example, a user of the inspection device 170 based on data collected in previously performed radiator inspections or previously performed simulation experiments of different types of defects using a radiator model. The a-priori data includes a plurality of prior peaks. As used herein, the term “prior peak” refers to a peak in a filtered reflected wave corresponding to a defect in the a-priori data. The a-priori data may further include one or more characteristics of each of the plurality of prior peaks. In one example, subsequent to the comparison, if a peak in a filtered reflected wave matches with a prior peak representing a discontinuity, the analysis unit 206 infers that the type of the defect in the radiator tube 110 is a discontinuity. In a further example, the analysis unit 206 determines the size of the discontinuity (i.e., the amount of defect) in the radiator tube 110 by comparing the amplitude of the peak in the filtered reflected wave with the amplitude of the prior peak. The analysis unit 206 may be further configured to send information representative the type, the location, and the amount of the one or more defects in the radiator tube 110 to the determination module 208.
[0039] The determination unit 208 includes codes and routines configured to determine a serviceability of the radiator tube 110. In one embodiment, the determination unit 208 includes a set of instructions executable by the processor 235 to provide the functionality for determining a serviceability of the radiator tube 110. In another embodiment, the determination unit 208 is a part of the memory 237. For example, the determination unit 208 may be stored in the memory 237 and is accessible and executable by the processor 235. In either embodiment, the determination unit 208 may be configured to communicate with the processor 235 and other units of the inspection controller 180 via the bus 220.
[0040] In one embodiment, the determination unit 208 determines the serviceability of the radiator tube 110 based on the type of the one or more defects in the radiator tube 110. In one example, the analysis unit 206 determines that the type of the defect is a blockage (i.e., a constriction) due to frozen residual coolant. In such an example, the determination unit 208 determines that the radiator tube 110 is serviceable since the blockage may be removed by, for example, passing a solvent through the radiator tube. In another example, the analysis unit 206 determines that the type of the defect is a mechanical dent (i.e., a constriction) due to an external force applied on the radiator tube 110. In such an example, the determination unit 208 determines that the radiator tube 110 is not serviceable as the mechanical dent may not be undone. In yet another example, the analysis unit 206 determines that the type of the defect is a hole (i.e., a discontinuity). In such an example, the determination unit 208 determines that the radiator tube 110 is not serviceable since the hole may not be sealed.
[0041] In another embodiment, the determination unit 208 determines the serviceability of the radiator tube 110 based on the amount of the one or more defects in the radiator tube 110. In such an embodiment, the determination unit 208 determines the serviceability by comparing the amount of the defect with a corresponding amount threshold (e.g., a blockage threshold, an erosion threshold). The amount threshold may be set by, for example, a user of the inspection device 170, based on previously generated data. In one example, the analysis unit 206 determines that the radiator tube 110 is constricted by 15% due to a blockage. In such an example, the determination unit 208 determines that the radiator tube 110 is serviceable since the amount of blockage is lesser than a blockage threshold of 40%. In another example, the analysis unit determines that the radiator tube 110 is eroded by 60%. In such an example, the determination unit 208 determines that the radiator tube 110 is not serviceable since the amount of erosion exceeds the erosion threshold of 30%.
[0042] In yet another embodiment, the determination unit 208 determines the serviceability of the radiator tube based on the location of the defect. In such an embodiment, the determination unit 208 determines the serviceability by comparing the location of the defect with a location threshold. The location threshold may be defined by, for example, a user of the inspection device 170 based on previously generated data. In one example, the analysis unit 206 determines that a crack is located at 0.02 meters from the opening of the radiator tube 110. In such an example, since the location of the defect is within the location threshold of 0.1 meters, the determination unit 208 determines that the radiator tube may be serviced by dispensing a sealant over the crack.
[0043] In one embodiment, the determination unit 208 is further configured to generate graphical data for providing a notification to, for example, a user of the inspection device 170. The notification includes, for example, a type of each of the one or more defects, a location of each of the one or more defects, an amount of each of the one or more defects, the serviceability of the radiator tube 110, and the like. In a further embodiment, the notification includes a repair action for the radiator tube 110. In such an embodiment, the determination unit 208 is configured to determine a repair action based on the defect and/or the serviceability of the radiator tube 110. The repair action includes, for example, shutting the radiator tube 110 from being used, passing a solvent through the radiator tube to dissolve a blockage, using a sealant to seal a crack or an erosion, and the like. For example, if the determination unit 208 determines that the radiator tube 110 is not serviceable, the determination unit 208 generates a notification including an action type that states “Shut the radiator tube 110 as it is not serviceable.” In another example, the determination unit 208 determines that the radiator tube 110 is serviceable as the blockage is less than the blockage threshold. In such an example, the determination unit 208 generates a notification including an action type that states “Radiator tube maybe serviced by passing solvent X.” In one embodiment, where the radiator tube 110 is devoid of any defect, the determination unit 208 generates a notification that states, for example, “The radiator tube is good.” In such an embodiment, the analysis unit 206 determines that the filtered reflected wave does not indicate any defect.
[0044] In one embodiment, the determination unit 208 sends the graphical data to a display device (not shown) that is operatively coupled to the inspection device 170. In such an embodiment, the display device renders the graphical data and displays the notification. In another embodiment, the determination unit 208 sends the notification to a user via, for example, an e-mail, a short messaging service, a voice message, and the like. In either embodiment, the user may use the notification to take an action on the radiator tube 110a and move on to inspecting the next radiator tube 110b of the radiator 105.
[0045] Referring now to FIGS. 3, 4, and 5 an exemplary radiator tube 300, a reflection graph 350, and a filter graph 370 are illustrated according to one embodiment. For the purpose of clarity and convenience, FIG. 3 illustrates a tapering portion 312 and a straight portion 314 of the radiator tube 300. The length of the illustrated radiator tube 300 is 0.35 meters. The width 316 of the straight portion 314 is 0.015 meters. In the illustrated embodiment, the tapering portion 312 of the radiator tube 300 includes a defect, generally represented by reference numeral 310. The reflection graph 350 represents a reflected wave 360 received by the inspection device in response to an acoustic wave transmitted through the radiator tube 300. The y-axis of the reflection graph 350 represents the amplitude of the reflected wave 360. The x-axis of the reflection graph 350 represents the length of the radiator tube 300 in meters. The filter graph 370 represents a filtered reflected wave 380. The y-axis of the filter graph 370 represents the amplitude of the filtered reflected wave 380. The x-axis of the filter graph 370 represents the length of the radiator tube 300 in meters. The filtering unit of the inspection device generates the filtered reflected wave 380 by filtering the reflected wave 360 based on the cross-sectional geometry of the radiator tube 300. In the illustrated embodiment, a peak 390 in the filtered reflected wave 380 may be identified by the analysis unit. The presence of the peak 390 is indicative of the defect 310 present in the radiator tube 300. The analysis unit further analyzes one or more characteristics of the peak 390. The analysis unit determines that the type of the defect 310 is a constriction, the size of the defect 310 is 8 millimeters, and the location of the defect 310 is at 0.05 meters of the radiator tube 300, based on the one or more characteristics.
[0046] FIGS. 6 and 7 illustrate an exemplary radiator tube 400 and a filter graph 450 according to one embodiment. For the purpose of clarity and convenience, FIG. 4 illustrates a straight portion 412 of the radiator tube 400. The length of the illustrated radiator tube 400 is 0.3 meters. The width of the radiator tube is 0.015 meters. In the illustrated embodiment, the radiator tube 370 includes two defects, generally represented by reference numerals 410 and 420. The filter graph 450 represents a filtered reflected wave 460 received by the analysis unit in response to an acoustic wave transmitted through the radiator tube 400. The y-axis of the filter graph 450 represents the amplitude of the filtered reflected wave 460. The x-axis of the filter graph 450 represents the length of the radiator tube 400 in meters. In the illustrated embodiment, two peaks 470 and 480 in the filtered reflected wave 460 are identified by the analysis unit. The presence of the two peaks 470 and 480 are indicative of the defects 410 and 420 respectively, present in the radiator tube 400. The analysis unit further analyzes one or more characteristics of the peaks 470 and 480. The analysis unit determines that the type of the defect 410 is a discontinuity, the size of the defect 410 is 3 millimeters, and the location of the defect 410 is 0.09 meters, based on the one or more characteristics of the peak 470. Similarly, the analysis unit determines that the type of the defect 420 is a discontinuity, the size of the defect 420 is 4.5 millimeters, and the location of the defect 420 is 0.18 meters, based on the one or more characteristics of the peak 480.
[0047] FIG. 8 illustrates an exemplary graph 500 indicating a correlation between an amplitude of a peak and an amount of the defect, according to one embodiment. The y-axis of the graph 500 represents the amplitude of a peak in a filtered reflected wave. The x-axis of the graph 500 represents the size of the discontinuity (e.g., a diameter of a hole along the longitudinal axis of the radiator tube, a length of a crack, and the like) in millimeters. The curve 550 represents the variation of the size of the discontinuity in a radiator tube with reference to the amplitude of the peak in the filtered reflected wave. In one embodiment, the analysis unit may determine the size of a discontinuity in a radiator tube based on the curve 550.
[0048] FIG. 9 illustrates an exemplary graph 600 indicating a correlation between an amplitude of a peak with an amount of the defect according to one embodiment. The y-axis of the graph 600 represents the amplitude of a peak in a filtered reflected wave. The x-axis of the graph 600 represents the percentage of a constriction (e.g., the amount constriction caused due to a block) in the radiator tube. The curve 650 represents the variation of the size of the constriction with reference to the amplitude of the peak in the filtered reflected wave. In one embodiment, the analysis unit may determine the amount of a constriction in a radiator tube based on the curve 650.
[0049] FIG. 10 is a flow diagram illustrating an exemplary method 700 for inspecting one or more radiator tubes in a radiator according to one embodiment. At step 702, the communication unit transmits an acoustic wave (e.g., an acoustic bulk wave) through a radiator tube. The radiator tube includes a cross-sectional geometry that varies along a length of the radiator tube. At step 704, the communication unit receives a reflected wave corresponding to the acoustic wave from the radiator tube. At step 706, the filtering unit filters the reflected wave based on the cross-sectional geometry of the radiator tube. For example, the filtering unit filters one or more components present in the reflected wave due to the varying cross-sectional geometry of the radiator tube. . At step 708, the analysis unit identifies a defect based on the filtered reflected wave. For example, the analysis unit identifies a peak in the filtered reflected wave. The analysis unit then identifies that the radiator tube includes an erosion (i.e., a defect) based on one or more characteristics of the peak. At step 710, the determination unit determines a serviceability of the radiator tube based on at least one of a type, an amount, and the location of the defect. In the above example, the determination unit determines that the radiator tube is serviceable since the type of the defect is an erosion and the amount of erosion is lesser than the erosion threshold. At step 712, the determination unit sends a notification to a user of the inspection device. The notification includes at least one of the type of the defect and the serviceability of the radiator tube. In the above example, the notification includes a message stating that the type of the defect is an erosion, the location of the erosion and the amount of the erosion. Although the method illustrated in FIG. 7 is described above as identifying a single defect in the radiator tube, in another embodiment, the method may identify a plurality of defects in the radiator tube. In such an embodiment, the method determines the serviceability of the radiator tube based on at least one of the type, the location, and the amount of the plurality of defects.
[0050] The inspection device described above is advantageous as it determines defects in radiator tubes that include a varying cross-sectional geometry. The inspection device is further advantageous as it identifies all types of defects such as an erosion, a mechanical defect, and the like, that may not be identified by prior leak test methods. Furthermore, the inspection device determines a serviceability of the radiator tubes and suggests a repair action based on the identified defect. Although the inspection device is described hereinabove as inspecting a radiator tube, in some embodiments the inspection device may be configured to inspect any tube with a varying cross-sectional geometry.
[0051] It is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular implementation. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
[0052] While the technology has been described in detail in connection with only a limited number of implementations, it should be readily understood that the present technique is not limited to such disclosed implementations. Rather, the technology can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the disclosure. Additionally, while various implementations of the technology have been described, it is to be understood that aspects of the technology may include only some of the described implementations. Accordingly, the systems and methods of the present technique are not to be seen as limited by the foregoing description, but are only limited by the scope of the appended claims.