15 th Asia Pacific Conference for Non-Destructive Testing (APCNDT2017), Singapore.

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1 Time of flight computation with sub-sample accuracy using digital signal processing techniques in Ultrasound NDT Nimmy Mathew, Byju Chambalon and Subodh Prasanna Sudhakaran More info about this article: Centre for Development of Advanced Computing, Thiruvananthapuram, India. Abstract Highly precise and accurate estimation of distance to target using ultrasound requires precise estimation of Time of Flight. Conventional methods of threshold based Time of flight estimation provides a best case accuracy of +/- 1 sampling period which is not enough for highly accurate and precise estimation of distance. A novel method has been devised for estimating the Time of flight with sub-sample precision and improved accuracy making use of digital signal processing methods. This major improvement is achieved by augmenting the estimate of TOF from the threshold method with a sub-sample estimation of the phase difference. This method has been successfully implemented in a high precision measurement system capable of measuring target distances with an accuracy of 5 micrometers in water. The method employed can be put to use in a wide range of high precision distance measurement systems using non contact ultrasound and can replace highly costly high precision distance measurement systems currently in use. Keywords: Ultrasonic Testing (UT), ultrasound, NDT, TOF 1 Introduction Time of Flight (TOF) in a measurement system refers to the time taken for a wave front to travel from one location to another. In measurement systems utilising TOF method, an actively excited transducer or exciter generates a wave front which is picked up at a later time and the time elapsed is used as the measurement. The availability of highly accurate clocks has made this method the backbone of many precision measurement systems. This paper outlines a research carried out in sub-sample accuracy TOF computation and its application in ultrasound based distance measurement. Distance measurement is an important industrial control parameter and a majority of these applications require non contactt measurements. The non contact measurement requirements span a wide area, ranging from measurement over appreciably large distances to precisee measurements as in metrological applications. This spectrum is being serviced by various technologies such as radio frequency, ultrasonic signals, infra-red and laser. Among them, ultrasound based technology is simpler and cheaper and also has fairly good accuracy. This method is based on the principle of echo location which has been perfected by nature. The high accuracy of ultrasonic based range measurement is mainly due to the low velocity of propagation of ultrasonic waves in the medium allowing estimating precise distance based on time of flight (TOF) measurement [1]. We have investigated a pulse echo based method using single ultrasonic transducer for non contact high 1

2 precision distance measurement. The precise TOF and the real time estimate of sound velocity in the medium are used to compute the distance precisely. Many methods for TOF measurement are available today. Some of the popular methods include threshold based detection, cross correlation and Fourier domain phase based methods [1] [2] [3]. However they have various limitations which make them inadequate for precision measurements. To obtain precise distance measurement, we need precise TOF and accurate estimate of velocity of the medium. Direct measurement of time of flight in a sampled system limits the precision in TOF measurement to one sample period. For micro-meter precision, we require either an acquisition system having high sampling frequency or a low sampling frequency system with a method for achieving sub-sample accuracy in TOF measurement. In this work, an innovative signal processing technique is developed to obtain sub-sample accuracy in TOF measurement and details are discussed in the following sections. Based on the feasibility study of high precision TOF measurement, a new system has been realised and used for measuring distance with an accuracy of 5 µm. This method is employed in developing the ultrasonic diameter measuring system which has successfully demonstrated the precision in field trials. One of the applications of the system is to measure precisely the internal diameter of the composite alloy pipes used in nuclear power plants. Repeated high resolution and accurate measurements are essential to track the dimensional variations of these pipes which in turn determine the maintenance schedule of the reactor. 2 Theory A variety of methods are available for estimating TOF and may be classified as time domain methods and frequency domain methods [2]. We intend to build up on the existing time domain methods and they are briefly explained here. 2.1 Threshold based detection Low cost implementation for TOF measurement generally use threshold based detection. Several cycles of a single tone signal are transmitted and an isochronous receiver identifies TOF based on received signal amplitude exceeding a predefined threshold. However, the problems due to low sampling frequency, poor signal to noise ratio and inherent bias inherent in this method affect the precision performance and hencee cannot be suitable for precise distance measurement systems [2]. The amplitude variation of signal due to medium attenuation can also lead to error in estimating TOF. This is more prevalent in systems with large measurement range. This may be partly overcome by increasing the power level in the transmitter. The method may be augmented with dynamic 2

3 thresholding to reduce time skew due to signal amplitude change. However there is also a chance of increased false triggers and missing of triggers. 2.2 Cross-correlation Threshold based sampling uses a few sample points with signal amplitude around threshold point to determine the TOF. Poor SNR can lead to more errors in such scenario. In order to improve upon this condition, the estimate has to be based on more number of sampling points and hence correlation of the received echo is employed. Correlation as a mathematical operation is a measure of the likeness between two signals. As the transmitted and received signals are expected to be highly similar (but shifted in time and added with noise) correlating the received signal with the time shifted samples of the transmitted signal gives the best estimate of the TOF. This method is computationally intensive and requires wider bandwidth transceivers and also more complex hardware. Both methods described have a precision in the TOF measurement which is limited by the sampling rate. In order to enhance the precision performance of the system better than one sampling period, an innovative signal processing technique is used and is discussed in the following section. 3 Method of TOF measurement with sub-sample accuracy Conventional methods for signal extraction use thresholding, which is simple and works well for non- high precision measurements [2] [3] [4]. In this work, echo is first located using a dynamic threshold based echo detection technique as shown in Figure 1. The dynamic threshold is calculated using the noise levels during silence zones in the acquired signal itself. The threshold based trigger identifies that there is a valid echo with a coarse estimate of TOF. Figure 1: Threshold detection. 3

4 In order to improve upon this estimate, the next occurrence of a zero cross is identified as shown in Figure 2. Figure 2: Identification of zero cross point. The zero cross of the echo obtained using the above method always contains an error corresponding to a maximum of one sample which has to be corrected to improve the accuracy. A phase lag computation methodology has been developed to estimate this error. In order to find how much the identified zero cross point deviates from the actual zero point, a reference signal with zero phase is generated and then cross correlated with the received signal for one cycle. The correlation will give the phase difference between the identified zero cross point of the received signal and the actual zero cross point. This phase difference is converted to equivalent time as the transmission frequency is known apriori. This is used to improve the already available zero cross point. Thus the zero cross time is estimated with the subsample accuracy. The actual zero cross point identified after cross correlation is shown in Figure 3. Figure 3: Identification of actual zero cross point 4

5 Finally, the actual signal start is found by shifting the time window by a factor N which is the resultant of correlation of reference signal with the received signal, see Figure 4. Figure 4: Identification of actual signal start In addition to these corrections, in a real world scenario, there will be unknown time delays for starting the transmission which is contributed by hardware. This is factored into our measurement algorithm by applying the same procedure for transmitted signal also. 4 Validations The validation set-up for TOF measurement is as shown in Figure 5. The transducer is focused on to a reflecting surface which is kept at a known distance. The reflected echo is captured by the transducer and using the calibrated velocity and known distance the TOF is computed using the equation TOF = Distance/ Velocity. Sensor Reflector Hardware Controller PC Figure 5: Validation Set up 5 Results and Analysis 5

6 The TOF measurement method has been simulated and verified using matlab and extensively validated using the experimental setup shown in Figure 5. In the first set of simulations (in an ideal condition with zero noise), the accuracy of our method (method 1) with normal zero cross detection (method 2) is compared depending on various sampling rates. The zero cross point of a wave with 5ms time period is found out using the two methods. Actual zero cross should occur at 2.5 ms. The method 2 has a fixed uncertainty depending on the sampling rate which may be reduced by ncreasing the sampling rate. The column 2 & 4 in the Table 1 shows the zero cross point and the errorr estimated by method 1. It is obvious that irrespective of the sampling rate, method 1 is able to achieve zero cross measurement with zero errorr in ideal conditions at low sampling rates itself. Sampling Rate 10 times 20 times 50 times 100 times Zero Cross Point in ms Error in ms Method 1 Method 2 Method 1 Method Table 1: Zero cross point at different sampling rates. To study the effect of noise on the method, the simulation model was augmented to add random noise on received signal at an SNR greater than 30 db. The reading was taken for 1000 values and histogram plot is as shown in the Figure 6. 6

7 Figure 6: Error in TOF measurements at 30dB noise level. From the Figure 6 it is evident that the method can be used to make accurate TOF measurement when the system SNR is better than 30dB. The method is validated using the experimental set up as mentioned in section 4..The fixed distance is kept as 85 mm.the reading was taken at different intervals of time and the data was analysed for precision in TOF. Measurement Time (Hrs) TOF measurement in µs Deviation in µs Table 2: Zero cross point at different sampling rates. From Table 2, it is clear that maximum deviation in TOF is less than 3 ns whichh is very less than the actual sampling period of 50 ns. 6 Application The above method is used in a diameter measurement system wherein four opposing transducers measure the orthogonal internal diameters of pipe. The hardware consists of transducers (orthogonally arranged) focused on to the internal diameter of the pipe, Transmitter section, Receiver section, Digitizer section and System controller sections. The transmitter with the help of Direct Digital Synthesizer (DDS) generates ultrasound of required frequency and amplitude. Receiver section amplifies and conditions the weak noisy signal received from the transducer to a level which can be digitized by the ADC. This data is then transmitted to PC where all the analysis is done and results are displayed. Using this system, the measurements have been taken with pipes of different diameters and the errors are plotted. From figure 7 it is evident that measurement error is less than +/- 5µm. 7

8 0.01 Error in Measurement in mm mm diameter 85 mm diameter 95 mm diameter 110 mm diameter Figure 7: Error Analysis 7 Conclusions Precision of TOF measurement is a critical parameter in many NDT applications. Conventional methods have limited precision on account of finite sampling period. A novel method has been developed using Digital Signal Processing methods to overcome the limitations imposed by sampling rate. This translates to simpler hardware and lower cost. The method was simulated using a model developed in Matlab and experimentally validated using a test setup. Based on this simulation and experimental results, we have used the method in a high precision measuring system with a specification of less than 5 µm in water. This precise TOF measurement method is used to realise a diameter measurement system for reactor pipes in nuclear power plant. References [1] M. Parilla, J. J. Anaya, and C. Fritsch, Digital signal processing techniques for high accuracy ultrasonic range measurements, IEEE Trans. Instrum., vol. 40, no. 4, pp , Aug,1991. [2] Joseph C. Jackson, Rahul Summan, Gordon I. Dobie, Simon M. Whiteley S. Gareth Pierce and Gordon Hayward, Time-of-flight Measurement techniques for airborne ultrasonic ranging, IEEE Trans. Ultrasonics, Ferroelectrics, and Frequency control, vol. 60, no. 2, pp , Feb,2013. [3] M. M. Saad, Chris J. Bleakley and Simon Dobson, Robust high-accuracy ultrasonic range measurementsystem, IEEE Trans. Instrum., vol. 60, no. 10, pp , Oct,2011. [4] Shinnosuke Hirata, Minoru Kuribayashi Kurosawa, and Takashi Katagiri, Accuracy and resolution of ultrasonic distance measurement with high-time-resolution cross-correlation function obtained by single-bit signal processing, Acoust. Sci. & Tech., vol. 30, no. 6(2009), pp , Jun, [5] M. Ramankutty, D. Kumar kokkoden, S. Prasanna sudhakaran, B. Chambalon, N. Mathew, Non Contact High Precision Distance Measurement Using Single Probe Ultrasonic Transducer, 19 th WCNDT, Munich, Jun,2016 8

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