# US 10,481,116 B2 · High resolution inspection device for casting defects using IR imaging

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- Number: US 10,481,116 B2
- Document ID: US10481116B2
- Status: Granted
- Kind: B2
- Application number: 15/522,823
- Filed: 2015-08-07
- Published: 2017-11-16
- Granted: 2019-11-19
- Earliest claimed: 2014-10-30
- Assignees: BAE Systems Information and Electronic Systems Integratlon Inc.; Mark B. Lyles
- Applicants: BAE Systems Information and Electronic Systems Integration Inc.
- Inventors: John R. Franzini; Mark B. Lyles; Robert H. Murphy
- Web page: https://patentgrep.com/patent/US10481116B2

## CPC

- G01N 25/72: Investigating presence of flaws
- H04N 21/42204: {User interfaces specially adapted for controlling a client device through a remote control device; Remote control devices therefor (constructive details of casings for the remote control device H01H9/0235; user interfaces for controlling a tuning device of a television receiver through a remote control H03J9/00; remote control of peripheral devices connected to a television receiver through the remote control device of the television receiver H04B1/205)}
- G01J 2005/0077: {Imaging}
- H04N 21/42221: {Transmission circuitry, e.g. infrared [IR] or radio frequency [RF]}
- G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q)
- H04N: PICTORIAL COMMUNICATION, e.g. TELEVISION
- G01J: MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY (light sources F21, H01J, H01K, H05B; investigating properties of materials by optical means G01N)

## Abstract

A nondestructive system and method for high resolution thermal imaging in metal casting applications is provided to detect defects and starts with the article under test being subjected to a thermal gradient, followed by infrared images taken thereof. The creation of the thermal gradient results in any defects reacting differently to the thermal gradient application to accentuate the defect in the infrared image. The apparatus for conducting the tests in one embodiment includes a single channel sensor, remote cable, and a laptop controller with real time image processing software. This hardware provides high resolution, real-time viewable infrared (IR) images with a variable focus distance adjustable from six inches to infinity. The apparatus enables crisp, clear imagery of various metal casting defects.

## Claims

### Claim 1

A system for high definition thermal imaging for industrial inspection applications, said system comprising:
a single channel, uncooled thermal sensor in a camera, wherein the sensor has low noise characteristics;
a cable connected to the camera, wherein the cable provides power to the camera and image data from the camera;
a controller with enhanced real time image processing software connected to the camera through the cable for processing the image data from the camera;
wherein the enhanced real time image processing software includes a plurality of preset filters that are user selectable;
wherein the preset filters include a spatial band-pass filter and a scene based noise suppression system for removing low frequency spatial noise and high frequency spatial noise; and
a unit under test that is subjected to a thermal gradient, wherein the camera produces at least one thermal gradient image of a subsurface of the unit under test, wherein the thermal gradient represents temperatures at least one of above or below ambient and the image is used to inspect the unit under test, and wherein the system operates at a working distance of less than about two feet.

### Claim 2 (depends on 1)

The system of claim 1, wherein the enhanced real time image processing software provides near real time image processing and an imperceptible amount of delay in the displayed image, wherein the imperceptible amount of delay is less than 0.1 seconds.

### Claim 3 (depends on 1)

The system of claim 1 wherein the sensor is a 12 micron uncooled thermal sensor.

### Claim 4 (depends on 1)

The system of claim 1, wherein the sensor has less than 17 micron pixel spacing.

### Claim 5 (depends on 1)

The system of claim 1, wherein the camera has an objective lens and employs a manual focus adjustment for the objective lens.

### Claim 6 (depends on 1)

The system of claim 1, wherein the camera is devoid of autofocus components.

### Claim 7 (depends on 1)

The system of claim 1, wherein the image processing identifies subsurface defects in the unit under test.

### Claim 8 (depends on 7)

The system of claim 7, wherein the subsurface defects are displayed on a display screen.

### Claim 9 (depends on 1)

The system of claim 1, further comprising a graphical user interface of the controller for image contrast enhancement.

### Claim 10 (depends on 1)

The system of claim 1, wherein the cable is an HDMI cable.

### Claim 11 (depends on 1)

The system of claim 1, wherein the system has an increased depth of field of greater than six inches.