Systems, devices, and methods for maintaining acoustic coupling of sensors to nonferrous materials

Abstract

Methods, systems, and apparatus for testing or inspecting bodies such as composite cylinders. A system may include one or more sensors. The one or more sensors may be configured for testing or inspecting one or more composite cylinders. The one or more sensors may each include a suction cup. The suction cup may have an internal volume. The suction cup may be configured to acoustically couple a respective sensor of the one or more sensors to an outer surface of a respective composite cylinder of the one or more composite cylinders when a vacuum is pulled within the internal volume.

Description

SYSTEMS, DEVICES, AND METHODS FOR MAINTAINING ACOUSTIC COUPLING OF SENSORS TO NONFERROUS MATERIALSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 669, 146, filed July 9, 2024, the entire contents of which is incorporated herein by reference.BACKGROUND

[0002] 1. Field

[0003] This specification relates to systems, devices, and / or methods for maintaining acoustic coupling of sensors to nonferrous materials.

[0004] 2. Description of the Related Art

[0005] Various pressure cylinders (e.g., filled with a fluid such as air, hydrogen, and / or other types of gases and / or fuels) may require periodic inspection and / or requalification for safety or regulatory reasons. Certain cylinders, such as cylinders made of nonferrous materials (e.g., composites, aluminum, titanium, etc.), may be especially difficult and costly to inspect. It may, for example, be difficult to maintain a proper acoustic coupling with such forms of cylinders.SUMMARY

[0006] Aspects disclosed herein may be directed to testing or inspecting of nonferrous materials. Such materials may comprise cylinders and may comprise nonferrous pressure cylinders. Systems, apparatuses, and methods for proper coupling to nonferrous materials are disclosed herein.

[0007] In general, one aspect of the subject matter described in this disclosure comprises a system for testing or inspecting one or more objects made of non-ferrous materials. The one or more objects may comprise composite cylinders in examples. The system may comprise one or more sensors configured for testing or inspecting the one or more objects. The one ormore sensors may each include a suction cup having an internal volume and configured to acoustically couple a respective sensor of the one or more sensors to an outer surface of at least one of the one or more objects when a vacuum is pulled within the internal volume.

[0008] In one aspect, a device is disclosed for coupling to surfaces of nonferrous materials.The device comprises a sensor configured for testing or inspecting a body made of a nonferrous material, the sensor including a suction cup having an internal volume, the suction cup being configured to acoustically couple the sensor to a surface of the body when a vacuum is pulled within the internal volume.

[0009] In one aspect, a method is disclosed for testing or inspecting composite cylinders. The method may comprise placing one or more suction cups on an outer surface of a composite cylinder, the one or more suction cups being coupled to one or more ultrasonic sensors and each having an internal volume. The method may comprise pulling a vacuum within the internal volume of each of the one or more suction cups to acoustically couple the one or more ultrasonic sensors to the outer surface of the composite cylinder. The method may comprise receiving, from the one or more ultrasonic sensors, deformation data associated with the composite cylinder.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Other systems, methods, features, and advantages of the present invention will be apparent to one skilled in the art upon examination of the following figures and detailed description. Component parts shown in the drawings are not necessarily to scale, and may be exaggerated to better illustrate the important features of the present invention. In the drawings, like reference numerals designate like parts throughout the different views.

[0011] FIG. 1A illustrates a side view of a cylinder, according to aspects of the present disclosure.

[0012] FIG. IB illustrates a close up cross sectional view of the portion of the cylinder indicated as “FIG. IB” in FIG. 1A, according to aspects of the present disclosure.

[0013] FIG. 2A illustrates a perspective view of an example sensor for testing or inspecting nonferrous materials, according to aspects of the present disclosure.

[0014] FIG. 2B illustrates a cross sectional view of the example sensor of FIG. 2A, according to aspects of the present disclosure.

[0015] FIG. 3 illustrates a bottom perspective view of an example sensor for testing or inspecting nonferrous materials, according to aspects of the present disclosure.

[0016] FIG. 4 illustrates a cross sectional view of an example sensor for testing or inspecting nonferrous materials, according to aspects of the present disclosure.

[0017] FIG. 5 illustrates a perspective view of an example sensor attached to a test surface, according to aspects of the present disclosure.

[0018] FIG. 6 illustrates a cross sectional perspective view of an example sensor for testing or inspecting nonferrous materials, according to aspects of the present disclosure.

[0019] FIG. 7 illustrates a perspective view of an example sensor attached to a test surface and having a foam layer, according to aspects of the present disclosure.

[0020] FIG. 8 illustrates a plan view of an example foam layer for a sensor, according to aspects of the present disclosure.

[0021] FIG. 9 illustrates a schematic view of an example sensor rail, according to aspects of the present disclosure.

[0022] FIGS. 10 and 11 illustrate side views of portions of the example sensor rail of FIG.9, according to aspects of the present disclosure.

[0023] FIG. 12 illustrates a perspective schematic view of a plurality of sensor rails attached to a plurality of cylinders, according to aspects of the present disclosure.

[0024] FIG. 13 illustrates a perspective view of an arrangement of a plurality of cylinders within a container, according to aspects of the present disclosure.

[0025] FIG. 14 illustrates a top view of a portion of the arrangement of the plurality of cylinders of FIG. 13, according to aspects of the present disclosure.

[0026] FIG. 15 illustrates a block diagram of components for testing, inspecting, and / or requalifying a cylinder, according to aspects of the present disclosure.

[0027] FIG. 16 illustrates a perspective view of a sensor for testing or inspecting nonferrous materials, according to aspects of the present disclosure.

[0028] FIG. 17 illustrates a bottom perspective view of the sensor of FIG. 16.

[0029] FIGS. 18 and 19 illustrate cross sectional views of the sensor of FIG. 16.

[0030] FIG. 20 illustrates a cross sectional view of a foam layer assembly.

[0031] FIG. 21 illustrates a perspective view of the foam layer assembly of FIG. 20 separate from a sensor.

[0032] FIG. 22 illustrates a perspective view of an arrangement of a plurality of cylinders within a container and a plurality of sensors on a cylinder, according to aspects of the present disclosure.

[0033] FIGS. 23 and 24 illustrate enlarged views of portions of the plurality of sensors on the plurality of cylinders of FIG. 22, according to aspects of the present disclosure.DETAILED DESCRIPTION

[0034] Disclosed herein are systems, devices, and methods for maintaining acoustic coupling of sensors to nonferrous materials. The sensors may comprise ultrasonic sensors in examples. The systems, devices, and methods disclosed herein may enable testing, inspecting, or requalifying of nonferrous materials having curved, rough, uneven, and / or porous outer surfaces, such as composite pressure cylinders (e.g., that are configured to be filled with a fluid such as air, hydrogen, and / or other types of gases and / or fuels). Moreover, the systems,devices, and methods described herein may improve the ease and reduce the expense of testing, inspecting, or requalifying composite pressure cylinders by enabling the testing, inspecting, or requalifying to be done in the field and not requiring the removal of the composite pressure cylinders from the field to a laboratory setting.

[0035] While objects such as nonferrous and / or composite pressure cylinders are discussed herein, the systems, devices, and / or methods may be adapted to a variety of contexts or objects, such as wind turbines, a fuselage, a leading edge of a wing, or any composite structure where impact damage, cyclic fatigue, and / or static fatigue is deleterious.

[0036] Field failures of composite pressure cylinders may be derived from various events, such as thermal exposure events, impact damage, or cumulative damage (e.g., from cyclic fatigue and / or static fatigue) that is deleterious to a composite pressure cylinder (e.g., a composite laminate of a composite pressure cylinder). For example, when a composite pressure cylinder has experienced impact damage of a sufficiently significant level or accumulated latent damage due to improper environmental conditions (e.g., a bolt caught between the cylinder and the enclosure), catastrophic failure of the cylinder may occur on subsequent filling cycle(s) when the stress state within the composite pressure cylinder exceeds a critical level. Moreover, cyclic fatigue or static fatigue, among other factors, may further increase the stress state within the composite pressure cylinder. Thus, it may be desirable to continually or periodically test, inspect, or requalify composite pressure cylinders to determine the stress state (or damage) within the composite pressure cylinders (or composite laminates of the composite pressure cylinders).

[0037] Conventional sensors may have difficulty acoustically coupling to or reliably maintaining acoustic coupling with objects such as composite pressure cylinders because composite pressure cylinders are generally nonferrous. For example, conventional sensors often rely on magnets to acoustically couple to pressure cylinders and thus are inadequate foracoustic coupling with nonferrous pressure cylinders. Moreover, composite and / or nonferrous pressure cylinders generally have rough, uneven, and / or porous outer surfaces such that conventional sensors are not able to acoustically couple to the composite and / or nonferrous pressure cylinders. In addition, some conventional sensors may require being permanently coupled to nonferrous and / or composite pressure cylinders to be acoustically coupled to the nonferrous and / or composite pressure cylinders.

[0038] Systems, devices, and methods disclosed herein may include sensors configured to acoustically couple to and reliably maintain acoustic coupling with nonferrous and / or composite pressure cylinders or other objects. The sensors, in examples, may be configured to be selectively and easily attached and detached from the nonferrous and / or composite pressure cylinders or other objects.

[0039] FIG. 1A illustrates an object in the form of a cylinder (or pressure vessel) 100 configured to store a fluid, such as compressed natural gas or hydrogen (in examples, the cylinder 100 may store other fluids). The cylinder 100 may be formed of one or more nonferrous materials such as stainless steel, aluminum, titanium, glass fiber, carbon fiber, polymer, carbon fiber reinforced polymer, and / or other composite materials (in examples, the cylinder 100 may include one or more ferrous materials in addition to or as an alternative to the one or more nonferrous materials). In examples, the cylinder 100 may be a Type II, Type III, Type IV, or Type V composite cylinder.

[0040] FIG. IB illustrates a side cross-sectional view of a wall 108 of the cylinder 100. In examples, the cylinder 100 may have a plurality of layers forming the wall 108 of the cylinder 100. For example, the cylinder 100 may have an inner layer (or liner) 102 and an outer layer 104. The inner layer 102 may be made of a metal or a plastic or any other rigid material (or nonferrous rigid material). The outer layer 104 may be made of a fiber (e.g., carbon fiber, glass fiber) combined with a resin that is disposed on top of the inner layer 102during the manufacturing process of the cylinder 100. For example, the cylinder 100 may include an inner layer 102 made of a gas-tight, polyethylene plastic and an outer layer 104 made of a high-pressure carbon fiber reinforced plastic located over the inner layer 102. In another example, the cylinder 100 may include a nonferrous metal inner layer 102 that is wrapped by a composite (e.g., fiber reinforced resin) outer layer 104. In examples, the outer layer 104 and / or inner layer 102 may comprise a nonferrous material. In examples, the outer layer 104 and / or inner layer 102 may comprise a composite material. Combinations of materials may be utilized for different layers, or the same material may be utilized for different layers. A single layer having the same material may be utilized in examples.

[0041] The outside of the outer layer 104 may define an outer surface 106 of the cylinder 100 that spans the body of the cylinder 100. The wall 108 of the cylinder 100 may define an interior cavity (or an internal volume) 110 for storage of fluid. While two layers (e.g., the inner layer 102 and the outer layer 104) are shown in FIG. IB, any number of layers may be used to form the wall 108 of the cylinder 100. In examples, a greater number of layers (e.g., three or more) may be utilized. In examples, a single layer may be utilized. Various combinations may be utilized as desired.

[0042] Referring back to FIG. 1A, the cylinder 100 includes a central portion 112 and two end portions 114, 116. The two end portions 114, 116 may include a first end portion 114 and a second end portion 116 opposite the first end portion 114 defining a length of the cylinder 100. The central portion 112 may be a cylindrical tubular shape or any other shape. Thus, the cylinder 100 may have a curved outer surface 106. In examples, each of the two end portions 114, 116 includes a dome structure, as shown in FIG. 1A. The dome structure may be generally hemispherical at least at the end portions thereof. In examples, the two end portions 114, 116 are symmetrical to each other. In examples, the two end portions 114, 116 have different shapes such that the cylinder 100 has an asymmetrical shape.

[0043] In examples, the cylinder 100 includes at least one neck 118, 120 (e.g., a longitudinal projection of a boss) that provides an inlet and / or an outlet of the interior cavity 110 of the cylinder 100. The necks 118, 120 may be formed at both of the end portions 114, 116, for example. In examples, a neck may be formed only at one of the end portions 114, 116. The neck 118, 120 may be part of a metallic structure, sometimes referred to as a boss, that is formed through a first end portion of an internal pressure enclosure, which is sometimes referred to as an inner liner assembly (e.g., the inner layer 102) or simply a liner of the cylinder 100. The neck 118, 120 may be made of any number of materials, such as metal. In examples, the neck 118, 120 may be formed using one or more materials not used for the internal pressure enclosure of the cylinder 100. In examples, the neck 118, 120 may be made of the same material as the internal pressure enclosure of the cylinder 100. The outer surface 106 may include the neck 118, 120. In examples, the outer surface 106 does not include the neck 118, 120.

[0044] As described herein, damage may be experienced by the cylinder 100. For example, the damage may be a result of a collision between the cylinder 100 and an object, such as, for example, a rock, a vehicle, or another cylinder. As another example, the damage may be a result of an object, such as a bolt, being trapped between the cylinder 100 and a housing of the cylinder 100 and damaging the cylinder 100 when the cylinder 100 expands based on pressure or temperature changes. In addition, the damage may be a result of cyclic fatigue (e.g., from filling and emptying of the cylinder 100) and / or static fatigue. In some situations, the damage may be visible (e.g., a visible dent, fraying, etc.) but in many other situations, the damage may not be visible. This damage that is invisible or not easily visible to a human eye may be as damaging to the cylinder 100 as visible damage. The systems, devices, and methods described herein may be used to test objects such as cylinders (e.g., the cylinder 100) by detecting and / or measuring visible damage and / or damage that is invisible ornot easily visible to the human eye. Other forms of tests or inspection of cylinders may be utilized in examples herein.

[0045] For example, to test, inspect, and / or requalify the cylinder 100, a plurality of sensors 122 may be removably attached to the outer surface 106 of the cylinder 100 at various sensor locations 124. The plurality of sensors 122 may be for detecting and / or measuring damage (or a magnitude of damage) to the cylinder 100 and / or to determine the structural integrity of the cylinder 100, and / or to otherwise test or inspect the cylinder 100. In examples, the plurality of sensors 122 may be configured to detect an impact (or past impact) to the cylinder 100. The plurality of sensors 122 may detect (or generate) deformation data which may be utilized to determine the structural integrity of the cylinder 100 and / or whether the cylinder 100 is damaged (e.g., fiber fracture, matrix cracking, interfacial delamination, etc.). As used herein, “deformation data” may be used to refer to the deformation of the cylinder 100. In this regard, “disturbance data,” “impact data,” or “cylinder integrity data,” among others, may be used interchangeably with “deformation data.”

[0046] The plurality of sensors 122 may be located at sensor locations 124 that are known, and data detected and / or generated by the sensors, along with the sensor locations 124 on the cylinder 100, may be used to determine the location and / or the magnitude of any detected damage.

[0047] The plurality of sensors 122 may be and / or include piezoelectric transducers, piezoelectric sensors, and / or ultrasonic sensors. In examples, the plurality of sensors 122 may be broadband piezoelectric sensors which are sensitive to an out-of-plane displacement component of a laminate of a composite pressure cylinder (e.g., cylinder 100). In examples, the plurality of sensors 122 may be utilized to detect and establish an energy level of an impact event. The plurality of sensors 122 may utilize a piezoelectric material in communication with the wall 108 of the cylinder 100 (e.g., a composite laminate) to measure stress wavescaused by impact or progressive damage accumulation within the wall 108 of the cylinder 100. In examples, the broadband piezoelectric sensors used herein do not necessarily rely on measurement of a shift in resonant or anti-resonant frequency caused by a change in stress state in the piezoelectric material to detect damage in a composite laminate. In examples, the broadband piezoelectric sensors used herein intentionally do not use measurement of a shift in resonant or anti-resonant frequency caused by a change in stress state in the piezoelectric material to detect damage in a composite laminate.

[0048] The plurality of sensors 122 may be active sensors. In examples, one or more of the plurality of sensors 122 may be considered passive sensors in that the one or more of the plurality of sensors 122 may not actively emit a wave to be detected by one or more other sensors. Instead, the plurality of sensors 122 may be used to determine when, where on the cylinder 100, and to what severity an impact event occurred, and / or for passively monitoring the wall 108 (or composite laminate) as the wall 108 is stressed from an external source. One or more of the sensors 122 may be configured to perform a non-destructive test or inspection of one or more of the objects or cylinders. For example, the plurality of sensors 122 may be used to perform an ultrasound test or inspection. The plurality of sensors 122 may be used to perform a Modal Acoustic Emission (MAE) test or inspection and / or a Phased Array Modal Acoustic Emission (PA-MAE) inspection to detect a loss of cylinder integrity during refilling of the cylinder 100. In examples, in the event that an impacted cylinder with compromised strength were to be refilled, the same plurality of sensors 122 used to detect the impact may also be used to perform an MAE inspection to detect a loss of cylinder integrity during refilling.

[0049] In examples, the plurality of sensors 122 may be used to gather information on the cylinder’s 100 physical characteristics to determine or estimate a stress state (or damage) within the wall 108 (or composite laminate) and / or the remaining useful life of the cylinder100. Ultrasonic wave propagation can be evaluated in the wall 108 to assess the structural integrity of the cylinder 100 and may provide information regarding fiber fracture, matrix cracking, and / or interfacial delamination, for example. Other forms of testing or inspection may be utilized in examples. In examples, the sensors 122 may be configured for testing or inspecting a body made of a nonferrous material or another form of material as desired. The body may comprise a cylinder as disclosed herein or another form of body.

[0050] While four sensors 122 are shown in FIG. 1A, any number of sensors may be used. The use of more sensors may result in more accurate determinations of the location and / or magnitude of the damage (e.g., more than four). In examples, a fewer number of sensors may be utilized (e.g., less than four).

[0051] FIG. 2A illustrates an example sensor 200 of the plurality of sensors 122 fortesting the cylinder 100 (or other bodies or pressure vessels). The sensor 200 may include a sensor housing 202, a mounting assembly 204, and / or a suction cup 206. As described herein, the sensor 200 may be an active and / or passive sensor and may be and / or include a piezoelectric transducer, a piezoelectric sensor, and / or an ultrasonic sensor. Other forms of sensors may be utilized in examples.

[0052] FIG. 2B illustrates a cross-sectional view of the sensor 200 of FIG. 2A. Referring to FIG. 2B with continuing reference to FIGS. 1A and 2A, the sensor housing 202 may include a removable lid 213. The sensor housing 202 may house and / or secure one or more sensor elements 214, one or more interface portions 216, a circuit board 218, and / or one or more data connectors 210. The one or more sensor elements 214 may be a single sensor element in examples. In examples, the one or more sensor elements 214 may be an array of sensor elements such that the sensor 200 includes two, three, or more sensor elements. The one or more sensor elements 214 may comprise transducer elements including a piezoelectric crystal.The one or more interface portions 216 may be positioned between the one or more sensor elements 214 and atest surface, such as the outer surface 106 of the cylinder 100.

[0053] The circuit board 218 may include one or more electronic components to facilitate the emission and / or detection of ultrasonic (or sonar) waves and / or to process received data (or signals). In examples, the circuit board 218 may include a microcontroller, amplification circuitry, driver circuitry, and / or receiver circuitry. The circuit board 218 may be configured to receive data (e.g., deformation data) from the one or more sensor elements 214 and may process and / or transmit (e.g., via the one or more data connectors 210) the received data to a controller (e.g., a controller 318 (not yet shown, marked in FIG. 9)) for viewing and / or further processing. The one or more data connectors 210 may be configured to receive and / or connect to one or more other data connectors and / or data cables (e.g., data cables 314 or 320 (not yet shown, marked in FIG. 9)) for relaying data to and / or from the sensor 200.

[0054] FIG. 3 illustrates a bottom perspective view of the sensor 200. Referring to FIGS. 2B and 3 with continuing reference to FIGS. 1A and 2A, the mounting assembly 204 may include a top (or first) flange 220 and a bottom (or second) flange 222. The top flange 220 may be coupled to the bottom flange 222 via one or more fasteners 228 (marked in FIG. 3). The bottom flange 222 may be coupled to the sensor housing 202 via one or more additional fasteners 226. The mounting assembly 204 may couple the sensor housing 202 to the suction cup 206 by clamping a flange 224 (marked in FIG. 2B) of the suction cup 206 between the top flange 220 and the bottom flange 222 via the one or more fasteners 228. The clamping of the flange 224 of the suction cup 206 may form an airtight seal between the sensor housing 202 and the suction cup 206.

[0055] The suction cup 206 may be coupled to the sensor housing 202 via the mounting assembly 204.

[0056] The suction cup 206 may be configured to removably attach and / or acoustically couple the sensor 200 to a surface, such as the outer surface 106 of the cylinder 100. The sensor 200 may be acoustically coupled in a configuration in which fidelity of measured waveforms (or deformation data) are acceptably preserved. The suction cup 206 may facilitate testing or inspection of nonferrous materials by providing and maintaining strong adhesion to a surface of the nonferrous materials (e.g., the outer surface 106 of the cylinder 100).

[0057] The suction cup 206 may have an internal volume 230 (marked in FIG. 3). When the suction cup 206 is attached to the outer surface 106, the internal volume 230 may be defined by the outer surface 106, the suction cup 206, the bottom flange 222, and / or the sensor housing 202. Other configurations of internal volumes or suction cups may be utilized in examples. The suction cup 206 may be made of a compliant material, such as a rubber and / or a silicone. Other materials may be utilized in examples.

[0058] In examples, the sensor 200 may be removably attached and acoustically coupled to the outer surface 106 of the cylinder 100 by pressing or placing the sensor 200 on or adjacent to the outer surface 106 and then pulling a vacuum within the internal volume 230 of the suction cup 206. A suction force secures and holds the sensor 200 against the outer surface 106. In examples, the outer surface 106 of the cylinder 100 may be wetted to facilitate attaching the sensor 200 to the outer surface 106 (e.g., by improving a seal between the suction cup 206 and the outer surface 106).

[0059] In examples, the suction cup 206 may include one or more bellows 232. The one or more bellows 232 may be for acoustically coupling the respective sensor 200 to curved and / or uneven surfaces. For example, the one or more bellows 232 may increase the compliance of the suction cup 206 and may facilitate the suction cup 206 conforming to curved and / oruneven surfaces (e.g., concave, convex, slanted, curved, etc.). The one or more bellows232 may facilitate attaching the sensor 200 to the outer surface 106 of the cylinder 100 by aiding the suction cup 206 in conforming to the curvature of the outer surface 106.

[0060] FIG. 4 illustrates a cross-sectional front view of the sensor 200. The sensor 200 may further include a port 212. The port 212 may be in fluid communication with the internal volume 230 of the suction cup 206. The port 212 may be a channel and / or an air passageway positioned (or integrated) within (or through) the mounting assembly 204, the sensor housing 202, and / or the one or more fasteners 228. Other positions may be utilized in examples. The port 212 may be configured for pulling a vacuum within the internal volume 230 of the suction cup 206 to attach and acoustically couple the sensor 200 to the outer surface 106. For example, the port 212 may be in fluid communication with a vacuum source such as a vacuum pump 238 (not yet shown, marked in FIG. 5) such that the vacuum pump 238 may pull a vacuum (or a partial vacuum) within the internal volume 230 of the suction cup 206 thereby attaching (or securing) the sensor 200 to the outer surface 106 and acoustically coupling the sensor 200 to the outer surface 106. In examples, other forms of vacuum sources may be utilized (e.g., a venturi valve, or other form of vacuum source as desired).

[0061] FIG. 5 illustrates the sensor 200 attached to a test surface 234 (e.g., the outer surface 106 of the cylinder 100). Referring to FIG. 5 with continuing reference to FIG. 4, the sensor 200 may further include an airline (or hose) connector 208 that is in fluid communication with the port 212 and the internal volume 230 of the suction cup 206. The airline connector 208 may be configured to fluidly couple (or removably attach) to one or more airlines (or hoses or vacuum lines) 240. The one or more airlines 240 may fluidly couple the internal volume 230 of the suction cup 206 to the vacuum pump 238 such that the vacuum pump 238 may pull a vacuum (or partial vacuum) within the internal volume 230 of the suction cup 206 thereby attaching (or securing) the sensor 200 to the test surface 234 and acoustically coupling the sensor 200 to the test surface 234.

[0062] A vacuum may be pulled within the internal volume 230 of the suction cup 206 for a whole duration (e.g., less than one hour, between one and three hours, or more than three hours) of a test or an inspection (e.g., an MAE inspection) of the cylinder 100. The vacuum pump 238 may maintain a vacuum within the internal volume 230 of the suction cup 206 such that the sensor 200 remains acoustically coupled to the cylinder 100 for the whole duration of the test or the inspection of the cylinder 100. This may ensure that the sensor 200 remains attached and acoustically coupled to the test surface 234 for the whole duration of the test or the inspection. For example, the sensor 200 may remain attached and acoustically coupled to the test surface 234 regardless of whether air leaks past a seal 242 formed between the test surface 234 and the suction cup 206 by having the vacuum pump 238 evacuate air that leaked into the internal volume 230 of the suction cup 206. Thus, maintaining vacuum or continuously pulling a vacuum may enable the sensor 200 to be attached and acoustically coupled to rough, uneven, and / or porous surfaces. For example, the sensor 200 may be attached and acoustically coupled to the rough, uneven, and / or porous surfaces of composite cylinders. In examples, the vacuum pump 238 may not continuously pull a vacuum within the internal volume 230 of the suction cup 206 for the whole duration of the test or the inspection of the cylinder 100.

[0063] For example, the sensor 200 may be fluidly coupled to an isolation valve 236. The isolation valve 236 may have a closed position (i.e., fluid is prevented from flowing through the isolation valve 236) and an open position (i.e., fluid may flow through the isolation valve 236). The sensor 200 may include the isolation valve 236 or may be separate from the isolation valve 236. The isolation valve 236 may be in fluid communication with and located fluidly between the internal volume 230 of the suction cup 206 and the vacuum pump 238. For example, the isolation valve 236 may be fluidly coupled to the vacuum pump 238, the port 212 (marked in FIG. 4), and / orthe airline connector 208 directly orviathe one ormore airlines240 or vacuum lines. After the vacuum pump 238 has pulled a vacuum within the internal volume 230 of the suction cup 206, the isolation valve 236 may be manually actuated (e.g., by a user) from the open position to the closed position. In the closed position, the isolation valve 236 may seal or isolate the internal volume 230 of the suction cup 206 from the vacuum pump 238. The internal volume 230 of the suction cup 206 may be sealed or isolated such that the vacuum within the internal volume 230 is maintained even though the vacuum pump 238 is not continuously pulling a vacuum within the internal volume 230. In examples, the isolation valve 236 may include an electric or pneumatic actuator that is configured to automatically open or close the isolation valve 236 (e.g., by being controlled by the controller 318 (marked in FIG. 9)).

[0064] In examples, the sensor 200 may further include a vacuum sensor (or vacuum transmitter) 256 for determining whether the sensor 200 is acoustically coupled to the test surface 234. The vacuum sensor 256 may be a pressure sensor and / or a transducer. The vacuum sensor 256 may be coupled to the mounting assembly 204 and / or the sensor housing 202. Other positions may be utilized in examples. In examples, the vacuum sensor 256 may be contained within the sensor housing 202 and / or coupled to the circuit board 218 (marked in FIG. 2B). The vacuum sensor 256 may be in fluid communication with the internal volume 230 of the suction cup 206. The vacuum sensor 256 may be configured to detect vacuum data indicating a state of vacuum coupling between the sensor 200 and the outer surface 106 of the cylinder 100. For example, the vacuum sensor 256 may determine, detect, and / or measure a pressure within the internal volume 230 of the suction cup 206. Vacuum data may be produced corresponding to such a pressure. In examples, the vacuum sensor 256 may transmit the determined, detected, and / or measured pressure (or vacuum data) to a controller (e.g., the circuit board 218 and / or the controller 318 (marked in FIG. 9)) . The controller (or the vacuum sensor 256) may determine whether the sensor 200 is acoustically coupled (or decoupled) tothe test surface 234 based on the determined, detected, and / or measured pressure (or vacuum data) of the internal volume 230.

[0065] For example, the controller may determine that the sensor 200 is acoustically coupled to the test surface 234 when the determined, detected, and / or measured pressure of the internal volume 230 is below atmospheric pressure and / or a threshold pressure. In examples, the controller may control the vacuum pump 238 to deactivate the vacuum pump 238 when the determined, detected, and / or measured pressure of the internal volume 230 is below atmospheric pressure and / or the threshold pressure. In examples, the controller may generate an alert and / or control the vacuum pump 238 to activate the vacuum pump 238 to pull a vacuum within the internal volume 230 when the determined, detected, and / or measured pressure of the internal volume 230 is equal to or above atmospheric pressure and / or another threshold pressure. For example, the controller may indicate that the internal volume 230 is equal to or above atmospheric pressure and / or the another threshold pressure by, for example, generating an audio or visual alert (e.g., via speakers 504 (marked in FIG. 15) or lights connected to the controller 318) and / or displaying a message (e.g., via a display 502 (marked in FIG. 15) connected to the controller 318) indicating that the internal volume 230 is equal to or above atmospheric pressure and / or the another threshold pressure.

[0066] The vacuum sensor 256 may enable a user to monitor the acoustic coupling of the sensor 200. This may be especially useful in some measurement and / or testing scenarios (e.g., MAE inspection) where multiple sensors are used and / or where multiple cylinders are being tested simultaneously. Moreover, the vacuum sensor 256 may enable a user to verify that the sensor 200 is acoustically coupled to the test surface 234 in situations where the sensor 200 is difficult to visually inspect. In addition, the vacuum sensor 256 may enable the controller to activate and deactivate the vacuum pump 238 as needed to maintain the acoustic coupling of the sensor 200.

[0067] When the sensor 200 is placed adjacent to and / or on the test surface 234 and a vacuum (or partial vacuum) is pulled within the internal volume 230 of the suction cup 206, the sensor 200 may be pulled perpendicular to the test surface 234 due to the direction and nature of the applied force. This improves the acoustic coupling of the sensor 200 to the test surface 234 and the reliability of the acoustic coupling. As discussed herein, the sensor 200 may be acoustically coupled to the test surface 234 in a configuration in which fidelity of measured waveforms (or deformation data) are acceptably preserved. For example, the sensor 200 may be acoustically coupled to the test surface 234 when a vacuum (or partial vacuum) is pulled within the internal volume 230 such that the one or more sensor elements 214 (marked in FIG. 2B) and / or the one or more interface portions 216 (marked in FIG. 2B) come into direct contact with the test surface 234. However, in examples, the one or more sensor elements 214 and / or the one or more interface portions 216 may not be in direct contact with the test surface 234 when the sensor 200 is acoustically coupled to the test surface 234.

[0068] For example, the sensor 200 may further include a barrier 244 positioned between the test surface 234 and the one or more sensor elements 214 and / or the one or more interface portions 216, as shown in FIG. 6. In examples, the barrier 244 may be made of a compliant material and / or a water tight material (e.g., a rubber and / or a silicone). The barrier 244 may be coupled to the sensor housing 202. For example, a portion 246 of the barrier 244 may be clamped between the sensor housing 202 (or the top flange 220) and the bottom flange 222 of the mounting assembly 204 thereby forming an internal volume 252 of the barrier 244. The internal volume 252 of the barrier 244 may be filled with a liquid (e.g., water or another form of liquid) via one or more fill ports (or passageways) 250 thereby forming a compliant fluid filled bladder 254 (shown more clearly in FIG. 3). The one or more fill ports 250 may be positioned within the sensor housing 202 and / or the mounting assembly 204, or anotherposition for fluid communication with the internal volume 252 of the barrier 244. The one or more fill ports 250 may be sealed with one or more sealing fasteners 248.

[0069] In some measurement and / or testing scenarios, (e.g., when needing to acoustically couple the sensor 200 to a rough, uneven, and / or irregular surface, and / or when automating placement of the sensor 200) it may not be possible to acoustically couple the sensor 200 to the test surface 234 when the sensor 200 has a stiff interface portion 216 between the test surface 234 and the one or more sensor elements 214; in these scenarios, the compliant fluid filled bladder 254 (formed by filling the internal volume 252 of the barrier 244 with liquid) enables acoustically coupling the sensor 200 to the test surface 234. The compliant fluid filled bladder 254 may conform to a rough, uneven, and / or irregular test surface 234 and acoustically couple the one or more sensor elements 214 to the test surface 234 such that the fidelity of measured waveforms (or deformation data) may be acceptably preserved. The acoustic coupling is facilitated by the compliant fluid filled bladder 254.

[0070] FIG. 7 illustrates the sensor 200 attached to the test surface 234 and FIG. 8 illustrates a top view of a foam layer 258. Referring to FIGS. 7 and 8 with continuing reference to FIG. 6, to further ensure the maintenance of acoustic coupling to rough, uneven, and / or irregular surfaces, the sensor 200 may further include the foam layer 258. The foam layer 258 may be coupled to an edge 264 of the suction cup 206 (e.g., an outer edge of the suction cup 206). The foam layer 258 may be positioned between the test surface 234 and the suction cup 206 when the sensor 200 is attached to the test surface 234. The foam layer 258 may have an annular shape such that the foam layer 258 has an outer edge 260 and an inner edge 262, as shown in FIG. 8. The annular shape of the foam layer 258 may allow the one or more sensor elements 214, the one or more interface portions 216, and / or the compliant fluid fdled bladder 254 to make direct contact with the test surface 234. The foam layer 258 may be made of a closed cell foam (e.g., neoprene, polyethylene foam, etc.). The acoustic couplingis facilitated by the foam layer 258. The foam layer 258 may increase vacuum levels within the internal volume 230 (marked in FIG. 4) for certain surfaces (e.g., the test surface 234) that have rough, uneven, and / or irregular surfaces, such as the surfaces of certain cylinders, by conforming to the rough, uneven, and / or irregular surfaces. In examples, the foam layer 258 and / or the test surface 234 may be wetted (e.g., sprayed with water) before and / or while the sensor 200 is attached to the test surface 234 to further increase vacuum levels within the internal volume 230 and / or to maintain acoustic coupling of the sensor 200 to the test surface 234.

[0071] FIG. 9 illustrates a sensor rail (or mounting structure) 300 for housing and / or spacing the plurality of sensors 122. Referring to FIG. 9 with continuing reference to FIG. 1A, as described herein, to test and / or monitor the cylinder 100, the plurality of sensors 122 may be removably attached to the outer surface 106 of the cylinder 100 at known sensor locations 124. The plurality of sensors 122 may be used and / or placed independently on the cylinder 100 and / or may be placed using the sensor rail 300 to achieve a desired or required sensor installation layout. The sensor rail 300 may be configured for grasping by a user (e.g., the sensor rail 300 may be an elongate pole) such that the user may manipulate the sensor rail 300 to place the plurality of sensors 122 on the cylinder 100.

[0072] The sensor rail 300 may space and position one or more of the plurality of sensors 122 such that the one or more of the plurality of sensors 122 are axially aligned when attached to the cylinder 100. In examples, the sensor rail 300 may be configured to axially align at least two sensors of the plurality of sensors 122. The sensor rail 300 may facilitate placing the plurality of sensors 122 at the known sensor locations 124 because the one or more of the plurality of sensors 122 are axially aligned and have fixed positions relative to one another on the sensor rail 300. The sensor rail 300 may include one or more sensor assemblies (or boxes) 302, a connector assembly (or box) 304, and / or one or more tube (or conduit) portions 306.

[0073] Each of the one or more sensor assemblies 302 may include at least one sensor of the plurality of sensors 122. While two sensors are shown in FIG. 9, any number of sensors may be included in the sensor rail 300. The one or more sensor assemblies 302 may hold, house, and / or protect the plurality of sensors 122 in a housing 322 (shown more clearly in FIG. 10). In examples, the one or more sensor assemblies 302 may each hold, house, and / or protect an isolation valve (e.g., an isolation valve 236 as marked in FIG. 5) in the housing 322. The one or more sensor assemblies 302 may further include a lid 312. The lid 312 may enclose the one or more sensor assemblies 302 and may enable access to the sensor and / or the isolation valve within a respective sensor assembly of the one or more sensor assemblies 302.

[0074] Referring to FIG. 11, the connector assembly 304 may include one or more airline connectors 308 and / or one or more data connectors 310 within a housing 324. The one or more airline connectors 308 may be in fluid communication with the vacuum pump 238 via the one or more airlines 240 or vacuum lines. The one or more airline connectors 308 may include a valve to isolate the sensor rail 300 from the vacuum pump 238 such that the plurality of sensors 122 included in the sensor rail 300 may maintain a vacuum (and thus stay attached and / or acoustically coupled to the cylinder 100) without the vacuum pump 238 continuously pulling a vacuum within the internal volumes of each of the plurality of sensors 122.

[0075] The one or more data connectors 310 may be configured to connect with one or more data cables 320 to connect the plurality of sensors 122 to the controller 318 (in examples, one or more digitizers 404 (marked in FIG. 12) may be connected between the plurality of sensors 122 and the controller 318). In examples, the one or more data cables 320 may also supply power to the plurality of sensors 122. As described herein, the plurality of sensors 122 may each transmit (e.g., via the circuit board 218 (marked in FIG. 2B)) deformation data (or signals) to the controller 318 for processing, further processing, storing on a memory, and / or viewing (e.g., by being displayed on the display 502 (marked in FIG. 15)). Moreover, theplurality of sensors 122 may each transmit (e.g., via the vacuum sensor 256) a determined, detected, and / or measured pressure within a respective internal volume 230 (marked in FIG. 4) of each of the plurality of sensors 122 to the controller 318 such that the controller 318 may determine whether each of the plurality of sensors 122 are acoustically coupled to the cylinder 100 based on the received determined, detected, and / or measured pressures. In examples, when the controller 318 determines that a respective sensor of the plurality of sensors 122 is acoustically coupled to the cylinder 100, the controller 318 may control the isolation valve 236 of the respective sensor to close the isolation valve 236 such that the internal volume 230 of the respective sensor is sealed off or isolated. In examples, the controller 318 may control the vacuum pump 238 to activate or deactivate the vacuum pump 238 based on the controller 318 determining that a respective sensor of the plurality of sensors 122 is not acoustically coupled to the cylinder 100 or is acoustically coupled to the cylinder 100, as described herein.

[0076] The controller 318 may be and / or include a computer processor, a microprocessor, a control unit, and / or any device configured to execute instructions stored in non-transitory memory. The controller 318 may be located in a housing that is physically coupled to the sensor rail 300 and / or the cylinder 100 (e.g., located directly on the cylinder 100, on a housing of the cylinder 100, or on a device coupled to the cylinder 100) or separate from the sensor rail 300 and the cylinder 100. The controller 318 may be communicatively coupled to the plurality of sensors 122 via the one or more data cables 320 and / or in a wireless manner, using respective transceivers (e.g., a transceiver for each sensor and a transceiver for the controller 318).

[0077] In examples, the controller 318 may utilize MAE analysis algorithms with digitally captured waveforms (e.g., the deformation data). The MAE analysis algorithms of the digitally captured waveforms may be focused on at least one of: the detection and quantification of fiber tow fracture above a specified threshold, the measurement of instabilitywithin a local volume of material above a specified threshold, damage mechanisms being accumulated in a localized volume of material above a specified threshold, and / or the detection of a fretting emission above a specified threshold for a given cylinder laminate. Other analyses may be provided in examples.

[0078] When combinations of the above are used together for detection of a compromised cylinder during filling, the factors may be weighted based on various characteristics of the cylinder 100, including the dimensions and construction thereof. For example, a combination of fretting emission and localized growth may be used to determine whether a particular cylinder is compromised during filling, the fretting emission being weighted more heavily than the localized growth.

[0079] The one or more tube portions 306 may extend between the one or more sensor assemblies 302 and the connector assembly 304. The one or more tube portions 306 may couple together each of the one or more sensor assemblies 302 and / or the connector assembly 304. The one or more tube portions 306 may house and protect portions of the one or more airlines 240 or vacuum lines connecting each of the plurality of sensors 122 included in the sensor rail 300 to the one or more airline connectors 308. The plurality of sensors 122 included in the sensor rail 300 may be fluidly coupled to the same portions of the one or more airlines 240 or vacuum lines such that the portions form a single continuous airline within the sensor rail 300 (as shown by FIGS. 9 and 10). In examples, the plurality of sensors 122 included in the sensor rail 300 may be fluidly coupled to separate portions of the one or more airlines 240 or vacuum lines such that the portions form a separate continuous airline for each sensor within the sensor rail 300.

[0080] The one or more tube portions 306 may further house and protect one or more data cables 314 connecting each of the plurality of sensors 122 included in the sensor rail 300 to the one or more data connectors 310. Each of the plurality of sensors 122 included in thesensor rail 300 may be connected to a respective connector of the one or more data connectors 310 via a separate data cable 314 (as shown by FIGS. 9 and 10). In examples, the one or more data connectors 310 may be a single data connector configured to receive the one or more data cables 314 from the plurality of sensors 122. In examples, the one or more tube portions 306 may insulate the one or more data cables 314 to improve signal integrity. The one or more tube portions 306 may prevent the one or more data cables 314 and the portions of the one or more airlines 240 or vacuum lines from snagging on extraneous hardware.

[0081] The one or more tube portions 306 may define a distance “X” between the connector assembly 304 and a first sensor assembly of the one or more sensor assemblies 302 and / or a distance “Y” between the first sensor assembly and a second sensor assembly of the one or more sensor assemblies 302. That is, the sensor rail 300 may have a certain distance X and / or a certain distance Y based on a length of the one or more tube portions 306. For example, the distance X and / or the distance Y may be altered as desired for testing various types and / or sizes of cylinders.

[0082] FIG. 12 illustrates a plurality of sensor rails 402 attached to a plurality of cylinders 400 for the testing, inspecting, and / or requalification of the plurality of cylinders 400. The plurality of sensor rails 402 may include two or more variations of a sensor rail. For example, the plurality of sensor rails 402 may include a short (or first) variation 401 and a long (or second) variation 403 of the sensor rail 300. The short variation 401 may be configured such that the distance X (marked in FIG. 9) of the short variation 401 is shorter than the distance X of the long variation 403. The distance Y (marked in FIG. 9) of the short variation 401 may be the same as the distance Y of the long variation 403. Each of the plurality of cylinders 400 may be the same as or substantially similar to the cylinder 100 (marked in FIG. 1A). That is, the plurality of cylinders 400 may be and / or include duplicates of the cylinder 100.

[0083] The plurality of sensors 122 included within the plurality of sensor rails 402 may be connected to one or more digitizers 404 via the one or more data cables 320. In examples, the plurality of sensor rails 402 may be wirelessly connected to the one or more digitizers 404 via respective transceivers of the one or more digitizers 404 and the plurality of sensor rails 402. The one or more digitizers 404 may convert (e.g., from analog data to digital data) the deformation data (or signals) received from the plurality of sensors 122. The one or more digitizers 404 may be connected to the controller 318 via the one or more data cables 320 or may be wirelessly connected to the controller 318 via respective transceivers of the one or more digitizers 404 and the controller 318. The one or more digitizers 404 may transmit the converted deformation data to the controller 318 for processing, further processing, saving on a memory, and / or viewing by a user. In examples, the plurality of sensors 122 included within the plurality of sensor rails 402 may be directly connected to the controller 318 via the one or more data cables 320.

[0084] The plurality of sensors 122 included within the plurality of sensor rails 402 may be in fluid communication with the vacuum pump 238 via the one or more airlines 240 or vacuum lines. In examples, the one or more airlines 240 or vacuum lines coming from each of the plurality of sensor rails 402 may be fluidly coupled to one or more pneumatic manifolds 406 to reduce a number of airlines or vacuum lines running to the vacuum pump 238.

[0085] The plurality of cylinders 400 may be stored or otherwise held vertically as shown, for example, in FIG. 12. In examples, the plurality of cylinders 400 may be stored or otherwise held horizontally as shown, for example, in FIG. 22. In other examples, the plurality of cylinders 400 may be stored or otherwise held at various angles. In examples, the plurality of cylinders may be stored or otherwise held in multiple orientations. For example, a part of the plurality of cylinders 400 may be stored horizontally, and a part of the plurality of cylinders400 may be stored vertically. The attachment of the plurality of sensors 122 as shown in FIG.12 may be adapted for various numbers of cylinders 400 in various orientations.

[0086] As shown in FIG. 12, each of the plurality of cylinders 400 may have rows of the plurality of sensors 122 (mounted on the plurality of sensor rails 402) with a radial spacing of about 90 degrees around each of the plurality of cylinders 400. In examples, the number of rows of sensors and / or the spacing between the rows of sensors may be based on cylinder diameter, material attenuation behavior, testing or inspection method, and / or other factors. For example, the rows of sensors may be spaced with a radial spacing of about 180 degrees for use with PA-MAE sensors.

[0087] The plurality of sensors 122 may be used for testing, inspecting, and / or requalification of cylinders in the field where the cylinders are used, such as in an arrangement 412 of the plurality of cylinders 400 contained within a container 405, as shown in FIG. 13. The container 405 may be coupled to a trailer 408 that is configured to couple to and be pulled by a vehicle, such as a semi-trailer truck. In examples, the container 405 may be separate from the trailer 408 and may be loaded and / or transported by other vehicles, such as boats or trains. For example, the container 405 may be a typical intermodal shipping container, such as one suitable for use with semi-trailer trucks, trains, cargo ships, and barges. In FIG. 13, a roof of the container 405 has been removed to allow access to a top portion of the arrangement 412 of the plurality of cylinders 400. The container 405 may have a rectangular shape as shown in FIG. 13. In examples, the container 405 may have a square shape.

[0088] As shown in FIG. 13, the arrangement 412 of the plurality of cylinders 400 may include forty five (45) cylinders within the container 405. In examples, the arrangement 412 of the plurality of cylinders 400 may include more or fewer cylinders based on cylinder diameter and / or dimensions of the container 405, for example. The arrangement 412 of the plurality of cylinders 400 may position the plurality of cylinders 400 such that an axis 409 ofeach of the plurality of cylinders 400 is parallel to side walls 410 of the container 405. In examples, an arrangement of the plurality of cylinders 400 may position the plurality of cylinders 400 such that the axis 409 of each of the plurality of cylinders 400 is perpendicular to the side walls 410 of the container 405.

[0089] FIG. 14 illustrates a top view of a portion of the container 405 and the arrangement 412 of the plurality of cylinders 400. The container 405 may include a plurality of crossmembers 414 spanning across the side walls 410 of the container 405 at the top of the container 405. The plurality of crossmembers 414 may locate and / or secure the plurality of cylinders 400 by, for example, holding and / or securing the neck 118 of each of the plurality of cylinders 400.

[0090] As described herein, the plurality of sensor rails 402 may be attached to the plurality of cylinders 400 for testing, inspecting, and / or requalification of the plurality of cylinders 400 and each of the plurality of cylinders 400 may have rows of sensors of the plurality of sensors 122 (mounted on the plurality of sensor rails 402) with a radial spacing of about 90 or more degrees around each of the plurality of cylinders 400. The plurality of sensor rails 402 may allow fortesting, inspecting, and / or requalification of the plurality of cylinders 400 out in the field by allowing the plurality of sensors 122 to be manipulated in narrow and remote spaces 416 around the plurality of cylinders 400 as they are arranged in an actual use, such as in the container 405, for example. That is, the plurality of sensor rails 402 may be configured to have slim elongate profiles such that a user may grasp and manipulate the plurality of sensor rails 402 to place the plurality of sensors 122 in the narrow and remote spaces 416 around and between the plurality of cylinders 400. Thus, the plurality of sensor rails 402 may enable the plurality of sensors 122 to be placed more easily than conventional sensors and may achieve greater acoustic coupling than conventional sensors. The sensor rails402 may enable the plurality of sensors 122 to be placed on the cylinders within a composite cylinder container 405.

[0091] In examples, at least one digitizer of the one or more digitizers 404 may be coupled to each of the plurality of crossmembers 414 (e.g., via one or more brackets 411 that may be retrofitted to the container 405). In examples, the one or more digitizers 404 may be coupled to one crossmember of the plurality of crossmembers 414 and / or may be coupled to another location on the container 405 or the plurality of cylinders 400. The one or more data cables 320 connecting the plurality of sensor rails 402 to the one or more digitizers 404 and / or the controller 318 (marked in FIG. 9) may be positioned along each of the plurality of crossmembers 414, as shown in FIG. 14. The controller 318 may be positioned within the container 405 or outside of the container 405.

[0092] The vacuum pump 238 (marked in FIG. 9) may be positioned within the container 405 or outside of the container 405. The one or more airlines 240 or vacuum lines fluidly coupling the plurality of sensor rails 402 to the vacuum pump 238 may be positioned along each of the plurality of crossmembers 414, as shown in FIG. 14.

[0093] FIG. 15 illustrates a block diagram of a system 500 for testing, inspecting, or requalifying the cylinder 100. The system 500 may also be for testing, inspecting, or requalifying the plurality of cylinders 400. The system 500 may include the cylinder 100 (or the plurality of cylinders 400), the plurality of sensors 122, the vacuum pump 238, and / or the controller 318, as described herein.

[0094] The controller 318 may be communicatively coupled to a valve 506 that controls a flow of fluid during refilling of the cylinder 100. The controller 318 may also be communicatively coupled to the display 502 and / or a speaker 504. The controller 318 may be configured to render a graphical user interface that is displayed by the display 502. The graphical user interface may include notifications of whether the cylinder 100 should beinspected prior to filling, and the display 502 may display these notifications. The controller 318 may also be configured to provide a notification of whether the cylinder 100 should be inspected prior to filling using the speaker 504. The speaker 504 may emit a noise, alarm, spoken words (e.g., “Inspect the cylinder prior to filling”), or any other indication.

[0095] Testing, inspecting, or requalifying the object or cylinder 100 may include placing the suction cup 206 (marked in FIG. 2A) of each of the plurality of sensors 122 on the outer surface 106 (marked in FIG. 1A) of the cylinder 100. One or more suction cups 206 may be placed on an outer surface 106 of a cylinder 100, the one or more suction cups 206 may be coupled to the sensors 122 (e.g., ultrasonic sensors) and each having an internal volume 230. In examples, the sensor rail 300 (marked in FIG. 9) or the plurality of sensors rails 402 (marked in FIGS. 12 and 14) may be manipulated (e.g., by a user) to place the suction cup 206 of each of the plurality of sensors 122 on the outer surface 106 of the cylinder 100.

[0096] When the suction cup 206 of each of the plurality of sensors 122 are on or adjacent to the outer surface 106 of the cylinder 100, the controller 318 (or a user) may activate the vacuum pump 238 to pull a vacuum within the internal volume 230 (marked in FIG. 4) of the suction cup 206 of each of the plurality of sensors 122 to acoustically couple the plurality of sensors 122 to the outer surface 106 of the cylinder 100. In examples, the controller 318 may control the vacuum pump 238 to pull the vacuum within the internal volume 230 of the suction cup 206 of each of the plurality of sensors 122 for a whole duration of a test, inspection, or requalification of the cylinder 100.

[0097] When the plurality of sensors 122 are acoustically coupled to the outer surface 106 of the cylinder 100, the controller 318 (or a user) may control the valve 506 to open the valve 506 to start filling the cylinder 100 with fluid. As the cylinder 100 is being filled with fluid, the plurality of sensors 122 may detect deformation data associated with the cylinder 100 and provide the detected deformation data to the controller 318.

[0098] In addition, the system 500 may monitor the acoustic coupling of the plurality of sensors 122 to the outer surface 106 of the cylinder 100 during the duration of the test, inspection, or requalification of the cylinder 100. The system may monitor, via the vacuum sensors 256 in fluid communication with the internal volume 230 of each of suction cups 206, the acoustic coupling of the sensors 122 to the outer surface of the cylinder 100. For example, the controller 318 may determine whether the plurality of sensors 122 are acoustically coupled to the cylinder 100 based on the determined, detected, and / or measured pressure of the internal volume 230 of each of the plurality of sensors 122 received from the vacuum sensor 256 (marked in FIG. 5), as described herein.

[0099] The controller 318 may receive the detected deformation data associated with the cylinder 100 from the sensors 122. The controller 318 may detect or determine damage to the cylinder 100 (e.g., caused by the cylinder 100 being filled) and when the detected or determined damage exceeds a threshold, the controller 318 may automatically close the valve 506 to prevent further filling of the cylinder 100. The testing may occur for other forms of objects. The objects may include non-ferrous materials in examples.

[0100] Other configurations may be utilized in examples. Features as disclosed in regard to FIGS. 1-15 may be utilized solely or in combination with any other example herein.

[0101] FIG. 16 illustrates an alternate example sensor 600 for testing the cylinder 100 and / or cylinder 400 (or other bodies or pressure vessels). The sensor 600 may be utilized in substitution or in combination with any other form of sensor (e.g., sensor 122, sensor 200) disclosed herein. Features as disclosed herein regarding sensors (e.g., sensor 122, sensor 200) may be utilized with the sensor 600 unless stated otherwise. The sensor 600 may be utilized with any form of system disclosed herein and may be mounted to one or more sensor rails or any other device as disclosed herein. The sensor 600 may comprise a sensor design that may be used in place of or alongside the sensor(s) 200 in the plurality of sensors 122.

[0102] In examples, the sensor 600 may be an active and / or passive sensor and may be and / or include a piezoelectric transducer, a piezoelectric sensor, and / or an ultrasonic sensor.Other forms of sensors may be utilized in examples.

[0103] The sensor 600 may include a sensor housing 602, a mounting assembly 604, and / or a suction cup 606. In examples, the sensor housing 602 and the mounting assembly 604 together may be a singular component.

[0104] The sensor housing 602 may be configured to retain one or more sensor elements 614 (marked in FIG. 18) for the sensor. The sensor housing 602 may be configured to retain one or more electrical components and / or vacuum components for the sensor in examples. In examples, one or more fasteners 599 may connect a lid 605 to the sensor housing 602. The lid 605 may be removable. In other examples, the lid 605 may snap on, screw on, or otherwise removably attach to the sensor housing 602. The sensor housing 602 may provide a same or similar function as the sensor housing 202 of the sensor 200, and features as described regarding the sensor housing 202 may apply to the sensor housing 602 unless stated otherwise.

[0105] The mounting assembly 604 may provide a same or similar function as the mounting assembly 204 of sensor 200, and features as described regarding the mounting assembly 204 may apply to the mounting assembly 604 unless stated otherwise. The mounting assembly 604 may be integral with the remainder of the sensor housing 602 in examples.

[0106] Referring to FIG. 18, the mounting assembly 604 may include a receiving portion 603 configured to receive the suction cup 606. The receiving portion 603 may comprise a cavity or a recess of the mounting assembly 604. The cavity or recess may receive a portion of the suction cup 606 (e.g., an upper or proximal portion 635 of the suction cup 606) to stabilize the suction cup 606 with respect to the sensor housing 602. The receiving portion 603 may have an annular shape, or may have another shape as desired. An upper or proximal end of the receiving portion 603 may comprise a lower or distal surface 638 of the sensorhousing 602 that may face towards the object being tested or inspected. The lower or distal surface 638 of the sensor housing 602 may form an upper bound of the receiving portion 603. One or more side walls 621 having one or more side surfaces 637 may surround and bound the sides of the receiving portion 603. Other configurations may be utilized in examples.

[0107] The suction cup 606 may provide a same or similar function as the suction cup 206, and features as described regarding the suction cup 206 may apply to the suction cup 606 unless stated otherwise. The suction cup 606 may be made of a compliant material, such as a rubber and / or a silicone. Other materials may be utilized in examples. The suction cup 606 may have an internal volume 612 (marked in FIG. 18). The suction cup 606 may be configured to acoustically couple the sensor 600 to an outer surface of the object to be tested or inspected when a vacuum is pulled within the internal volume 612.

[0108] The suction cup 606 may have one or more bellows 632. The bellow 632 may function the same as or similar to the bellow 232 of suction cup 206, and features as described regarding the bellow 232 may apply to the bellow 632 unless stated otherwise.

[0109] As seen in FIG. 18, the suction cup 606 may include an enforcement layer 625. The enforcement layer 625 may comprise a material that is stiffer than the material of the suction cup 606. For example, the enforcement layer 625 may consist of aluminum or one or more other metals. In examples, the enforcement layer 625 may comprise a hardened plastic. The enforcement layer 625 may have an annular or ring shape, or may have another shape in examples. The enforcement layer 625 may be surrounded on or more sides by the compliant material of the suction cup 606. The enforcement layer 625 may be embedded within the material of the suction cup 606 in examples. The enforcement layer 625 may be configured to provide strength and / or rigidity to the suction cup 606.

[0110] In examples, an upper or proximal portion 635 of the suction cup 606 may be configured to be positioned within the receiving portion 603 of the mounting assembly 604.The upper or proximal portion 635, for example, may comprise a protruding portion of the suction cup 606 configured to enter into the receiving portion 603. The protruding portion may protrude in an upper or proximal direction, and may protrude relative to a radially outward extending flange portion 623 of the suction cup 606 configured to seat beneath the one or more side walls 621 of the mounting assembly 604.[oni] In examples, the enforcement layer 625 is positioned within the upper or proximal portion 635 of the suction cup 606 and thus may be positioned within the receiving portion 603 of the mounting assembly 604. The enforcement layer 625 may stabilize the upper or proximal portion 635 within the receiving portion 603.

[0112] Referring to FIG. 17, the sensor 600 may include one or more fasteners 628. The fasteners 628 may be configured to couple the suction cup 606 to the mounting assembly 604 and / or the sensor housing 602 of the sensor 600. In examples, the fasteners 628 may extend in the upper or proximal direction through the suction cup 606 (e.g., through the upper or proximal portion 635 of the suction cup 606) and may engage with the sensor housing 602 (e.g., through a lower or distal surface 638 of the sensor housing 602 as represented in FIG. 19).

[0113] A lower or distal surface 617 of the upper or proximal portion 635 of the suction cup 606 may also include various surface features 615, such as shown in FIG. 17. The surface features 615 may comprise spaced protrusions in examples, protruding in a distal or lower direction. In examples, the sensor 600 may not include these surface features 615. Other configurations may be utilized in examples.

[0114] Referring to FIG. 18, in examples, the sensor 600 may include a foam layer 658.The foam layer 658 may assist with coupling the sensor 600 to curved, rough, uneven, and / or irregular surfaces. The foam layer 658 may be the same as or similar to the foam layer 258 of sensor 200, and features as described regarding the foam layer 258 may apply to the foamlayer 658 unless stated otherwise. The foam layer 658, for example, may be coupled to the suction cup 606 and configured to facilitate the acoustic coupling of the sensor 600 to the outer surface of the object for being tested or inspected.

[0115] The foam layer 658 may be configured to be positioned between a test surface, such as test surface 234, and the suction cup 606 when the sensor 600 is attached to a test surface. The foam layer 658 may have an annular shape. The annular shape of the foam layer 658 may allow one or more features of the sensor 600 to make contact with the test surface when the suction cup 606 is compressed and the bellows 632 of the suction cup 606 bend. The foam layer 658 may be made of a closed cell foam layer (e.g., neoprene, polyethylene foam, etc.) in examples. The acoustic coupling may be facilitated by the foam layer 658. The foam layer 658 may increase vacuum levels within an internal volume of the sensor 600, especially when the sensor 600 is placed on rough, uneven, or irregular surfaces, such as the surfaces of certain cylinders, by conforming to the rough, uneven, and / or irregular surfaces. In examples, the foam layer 658 and or atest surface may be wetted (e.g., sprayed with water) before and / or while the sensor 600 is attached to the test surface to further increase vacuum levels within the internal volume and / or to maintain acoustic coupling of the sensor 600 to the test surface.

[0116] In examples, a coupler 607 may be utilized to couple the foam layer 658 to the suction cup 606. The coupler 607 and foam layer 658 may comprise a foam layer assembly 619 (marked in FIGS. 20 and 21) in examples.

[0117] The coupler 607 may comprise a removable coupler that may attach the foam layer 658 to the suction cup 606 and allow the foam layer 658 to be removed from the suction cup 606 in examples. The foam layer 658, as such, may detachably couple with the suction cup 606. The coupler 607 may detachably couple the suction cup 606 with the foam layer 658.

[0118] The coupler 607 may have a variety of forms in examples. In examples, the coupler607 may comprise a ring that may be utilized to detachably couple the foam layer 658 to the suction cup 606. A cross sectional view of the ring is illustrated in FIG. 20. The ring may surround the outer circumference of the foam layer 658 in examples. The ring may include an annular channel 627 that may receive the outer circumference of the foam layer 658. The ring may include an upper lip portion 631 configured to extend over a side of the suction cup 606 to engage with the suction cup 606. The ring may include a lower lip portion 633 that may be positioned beneath the foam layer 658, to hold the foam layer 658 to the suction cup 606. Other configurations may be utilized in examples.

[0119] In examples, the coupler 607 may have one or more cutouts 601 for added flexibility. The cutouts 601 may be positioned on the upper lip portion 631 in examples. The cutouts 601 may allow for increased ease of removal or attachment of the coupler 607 to the suction cup 606 in examples. In other examples, the coupler 607 may not have cutouts.

[0120] The foam layer 658 may be coupled to an edge of the suction cup 606. The foam layer may be held in place via the coupler 607. The upper lip portion 631 may be placed over the suction cup 606 of the sensor 600. The upper lip portion 631 may cover at least a portion of the suction cup 606.

[0121] The coupler 607 may be clipped on to or otherwise attached to the suction cup 606 via a snug fit. The coupler 607 may be a rigid or semi-rigid metal or plastic. In examples, the coupler 607 may be 3D printed. In examples, the coupler 607 may be molded. In some examples, the coupler 607 may be made from a malleable or flexible material.

[0122] As seen in FIG. 18, the foam layer 658 may be clamped into place via the coupler607. The coupler 607 may be configured to wrap around an outer edge of the foam layer 658 and a lower edge of the suction cup 606, clamping them together, as shown in FIG. 18. The coupler 607 may be snapped on, slipped on, or clipped over the foam layer 658 and suctioncup 606 to hold the foam layer 658 in place, and the coupler 607 may be snapped, slipped, or clipped off of the suction cup 606 to remove the foam layer 658.

[0123] Beneficially, the foam layer 658 may be easily replaceable, as the coupler 607 may be easily removed and / or applied to the suction cup 606, and the foam layer 658 may be swapped out for a new foam layer if the foam layer has worn down over time. Improved ease of removal and replacement of the foam layer 658 may be provided. FIG. 21, for example, illustrates the coupler 607 and the foam layer 658 having been removed from the suction cup 606. A new foam layer assembly 619 may be applied to the suction cup 606 as desired. The use of the coupler 607 may aid in the durability and ease of maintenance of the sensor 600.

[0124] Other forms of couplers may be utilized in examples as desired.

[0125] Referring to FIG. 18, the sensor 600 may further include one or more sensor elements 614. The sensor elements 614 may function the same as or similar to the sensor elements 214 of the sensor 200, and features as described regarding the sensor elements 214 may apply to the sensor elements 614 unless stated otherwise.

[0126] The one or more sensor elements 614 may be a single sensor element in examples. The one or more sensor elements 614 may be an array of sensor elements such that the sensor 600 includes two, three, or more sensor elements. The one or more sensor elements 614 may comprise transducer elements including a piezoelectric crystal. Other forms of sensor elements 614 may be utilized as desired.

[0127] FIG. 17 illustrates a bottom perspective view of the sensor 600. Sensor 600 may include a compliant, fluid filled bladder 654. In examples, the bladder 654 may function the same as or similar to the bladder 254 of sensor 200, and features as described regarding the bladder 254 may apply to the bladder 654 unless stated otherwise.

[0128] The bladder 654 may be smaller than bladder 254. The bladder 654 may have a lesser diameter than the bladder 254. For example, the diameter of the bladder 654 may beabout half of the diameter of the bladder 254 as desired, or may have other dimensions as desired. In other examples, the bladder 654 may be various sizes and shapes, including being larger than bladder 254. An internal volume of the bladder 654 may be filled with a liquid (e.g., glycol, ultrasound gel, water, acoustically advantageous fluid, or another form of liquid). The liquid may be placed in the bladder 654 before the bladder 654 is attached to the sensor 600. In examples, the bladder 654 may be filled with liquid via one or more sealable fill ports, such as a fill port 250 of sensor 200. The bladder 654 may include a bladder cap 655 in examples. The bladder cap 655 may be configured to attach to an interior portion of the mounting assembly 604 and / or the sensor housing 602.

[0129] As seen in FIG. 18, for example, the bladder 654 may attach to the mounting assembly 604 and / or the sensor housing 602 via threads 657 on the bladder cap 655 that interface with threads 659 on the mounting assembly 604 and / or the sensor housing 602. The cap 655 accordingly may comprise a threaded cap for coupling the bladder 654 to the sensor 600. The threads 659 may be positioned on a protruding body that protrudes from the lower or distal surface 638. In other examples, the bladder 654 may attach to the mounting assembly 604 and / or the sensor housing 602 by clipping on, through a press fit, through a latching mechanism, or through other forms of attachment. The sensor element 614 may contact the fluid of the fluid filled bladder 654. When a vacuum is pulled through the sensor 600 and the suction cup 606 compresses, the bladder 654 may make contact with the surface of the item being tested by the sensor 600. The fluid within the bladder 654 may aid in the one or more sensor elements 614 being able to sense the item being tested by the sensor 600.

[0130] The sensor 600 may further include a data connector 610 that may be configured to receive and / or connect to one or more other data connectors and / or data cables (e.g., data cables 314 or 320) for relaying data to and / or from the sensor 600. The data connector 610may provide a same or similar function as the data connector 210, and features as described regarding the data connector 210 may apply to the data connector 610 unless stated otherwise.

[0131] Referring to FIG. 18, the data connector 610 may connect to a circuit board 618. The circuit board 618 may provide a same or similar function as the circuit board 218, and features as described regarding the circuit board 218 may apply to the circuit board 618 unless stated otherwise. The circuit board 618 may be configured to interface with the data connector 610. The circuit board 618 may include one or more electronic components to facilitate the emission and / or detection of ultrasonic (or sonar) waves and / or to process received data (or signals). In examples, the circuit board 618 may include a microcontroller, amplification circuitry, driver circuitry, and / or receiver circuitry.

[0132] The circuit board 618 may be configured to receive data (e.g., deformation data) from the one or more sensor elements 614 and may process and / or transmit (e.g., via one or more data connectors 610) the received data to a controller (e.g., the controller 318) for viewing and / or further processing.

[0133] The sensor 600 may further include an airline (or hose) connector 608. The airline connector 608 may provide a same or similar function as the airline connector 208 and features as described regarding the airline connector 208 may apply to the airline connector 608 unless stated otherwise.

[0134] FIG. 19 illustrates the sensor 600 at a cross-section through the one or more airline connectors 608. As seen in FIG. 19, the sensor 600 may include a channel 609 that extends through the sensor 600. The channel 609 may further connect to one or more vents 629. The one or more vents 629 may run through the one or more fasteners 628. The sensor 600 may additionally include one or more plugs 611 or ports 613 within the one or more airline connectors 608. The ports 613 may be configured to allow air to pass through the airline connector 608. The plugs 611 may be configured to stop the flow of out of the airlineconnector 608. Accordingly, two or more sensors 600 may be able to be connected (via a hose or other tubing) through their airline connectors 608. A plug 611 within an airline connector 608 may be configured to seal the airline connector 608, stopping the flow of air. This sensor 600 with a sealed airline connector 608 may then form one end of a chain of linked sensors 600. Another sensor 600 may have multiple ports 613, configured to allow for flow of air therethrough. While linked through their connected airlines, the vacuum pulled through one or more of the linked sensors 600 may be shared throughout the linked sensors 600, as the channel 609 through the sensors 600, continuing through the airline connectors 608 and into the volumes of the suction cups 606 through the vents 629, may all be fluidly connected. FIG. 19 illustrates a combination of a plug 611 and a port 613, although intermediate sensors connected with tubing may include two ports 613 to allow for air flow therethrough. One or more airlines 240 or vacuum lines may couple directly to the ports 613 and may extend directly between the ports 613 in examples.

[0135] In examples, the airline (or hose) connectors 608 may protrude horizontally from the respective sensor housing 602. Such a configuration may allow for horizonal or in-line connection of the connectors 608 between adjacent sensors 600. In examples, additional fittings such as T or Y connectors as represented in FIG. 10, for example, may be excluded from use. In examples, such forms of connectors may additionally be utilized. Any features of the sensor 600 may be utilized with any other form of sensor (e.g., sensor 122, 200) disclosed herein.

[0136] The sensor 600 may utilized as one of the plurality of sensors 122 as disclosed herein and configurations as disclosed regarding the plurality of sensors 122 may be utilized with the sensor 600. The plurality of sensors 122 may be used to test a plurality of cylinders 400. FIG. 22 illustrates the plurality of sensors 122 being used to inspect a plurality of cylinders 400 when the cylinders 400 are stored in a horizontal arrangement 450 in a container405 on a trailer 408. Sensor rails 460 including one or more airlines or vacuum lines may extend directly between adjacent sensors 122 (e.g., longitudinally spaced sensors 122) and may connect the sensors 122. The one or more airlines or vacuum lines may couple directly to the ports 613 and may extend directly between the ports 613 in a configuration as represented in FIG. 22. Sensor rails 460 may include the features of the sensor rails 300, 402 unless stated otherwise.

[0137] As illustrated in FIG. 22, a system of cables 452 may be configured to rig the plurality of sensors 122 in such a way as to facilitate the mounting of the plurality of sensors 122 on the cylinders 400 while the cylinders 400 are in the arrangement 450. The cables 452 may be made from steel, cord, or other similarly strong materials. The cables 452 may be connected to the container 405 at cable mounting points 454. The cables 452 may extend longitudinally throughout the container 405, such as shown in FIG. 22. One or more sensor rails 460 may also extend longitudinally throughout the container 405. The one or more sensor rails 460 may be configured to operate in a similar manner as the sensor rails 300, 402 disclosed herein. The sensor rails 460 may extend horizontally, however, within the container 405. Scaffolding 462 may exist along the walls of the container 405. The scaffolding 462 may provide attachment points for the sensor rigging, including locations for the cable mounting points 454. The plurality of sensors 122 may contact the cylinders 400 via their suction cups. The plurality of sensors 122 may be connected by the sensor rails 460 that run between each sensor in the plurality of sensors 122. The sensor rails 460 may be connected to the cables 452 via clips 458. The clips 458 may be strung on the cables 452 in between the sensors in the plurality of sensors 122. In other examples, the clips 458 may be removably connected to the cables 452. The clips 458 may also comprise an attachment portion that removably clips the clips 458 to the sensor rails 460. In other examples, the clips 458 may surround an entire diameter of the sensor rails 460. In other examples, the clips 458 maycomprise one or more prongs or teeth that surround a portion of the diameter of the rails 460. In examples, the clips 458 may be hooks. As illustrated in FIG. 22, multiple cylinders 400 may be included in the arrangement 450. Each cylinder 400 may have a dedicated plurality of sensors 122 and the accompanying cables 452, rails 460, and clips 458 to place the plurality of sensors 122 on the cylinders 400.

[0138] FIG. 23 illustrates a close-up view of one end of the plurality of cylinders 400 in arrangement 450 within the container 405, as shown in FIG. 22. FIG. 24 illustrates a closeup view of the plurality of sensors 122 placed on a surface of a cylinder 400. A configuration as represented in FIGS. 22-24 may be utilized with any form of sensor disclosed herein (e.g., sensors 200 as desired). A horizontal or vertical configuration as disclosed herein may be utilized with any implementation of sensor disclosed herein.

[0139] Other configurations may be utilized in examples. Features as disclosed in regard to FIGS. 16-24 may be utilized solely or in combination with any other example herein.

[0140] In examples, features of the methods may be modified, excluded, or substituted as desired. The methods may include variations of the methods disclosed herein.

[0141] Exemplary embodiments of the methods / systems have been disclosed in an illustrative style. Accordingly, the terminology employed throughout should be read in a nonlimiting manner. Although minor modifications to the teachings herein will occur to those well versed in the art, it shall be understood that what is intended to be circumscribed within the scope of the patent warranted hereon are all such embodiments that reasonably fall within the scope of the advancement to the art hereby contributed, and that that scope shall not be restricted, except in light of the appended claims and their equivalents. Each and every feature described herein, and each and every combination of two or more of such features, is included within the scope of the present invention provided that the features included in such a combination are not mutually inconsistent.

Claims

CLAIMSWhat is claimed is:

1. A system for testing or inspecting one or more objects made of non-ferrous materials, comprising: one or more sensors configured for testing or inspecting the one or more objects, the one or more sensors each including: a suction cup having an internal volume and configured to acoustically couple a respective sensor of the one or more sensors to an outer surface of at least one of the one or more objects when a vacuum is pulled within the internal volume.

2. The system of claim 1, wherein the suction cup includes one or more bellows for acoustically coupling the respective sensor to curved and / or uneven surfaces.

3. The system of claim 1 or claim 2, wherein the one or more sensors each further include a vacuum sensor configured to detect vacuum data indicating a state of vacuum coupling between the respective sensor and the outer surface of the at least one object.

4. The system of any of claims 1-3, further comprising: a vacuum source in fluid communication with the internal volume of the suction cup of each of the one or more sensors, the vacuum source being configured to maintain vacuum within the internal volume such that the one or more sensors remain acoustically coupled to the at least one object for a whole duration of a test or an inspection of the at least one object.

5. The system of any of claims 1-4, wherein the one or more sensors are configured to perform a non-destructive test or inspection of the one or more objects.

6. The system of any of claims 1-5, further comprising: a vacuum source in fluid communication with the internal volume of the suction cup of each of the one or more sensors, the vacuum source being configured to pull the vacuum within the internal volume to acoustically couple the respective sensor to the outer surface of the at least one object; and one or more valves located fluidly between the vacuum source and the internal volume of the suction cup of each of the one or more sensors, the one or more valves each being configured to seal or isolate the internal volume of the suction cup of each of the one or more sensors from the vacuum source.

7. The system of any of claims 1-6, wherein the one or more sensors each further include at least one of: a closed cell foam layer coupled to the suction cup and configured to facilitate the acoustic coupling of the one or more sensors to the outer surface of the at least one object; or a compliant fluid filled bladder configured to facilitate the acoustic coupling of the one or more sensors to the outer surface of the at least one object.

8. The system of claim 7, wherein the one or more sensors include the closed cell foam layer, and the system further comprises a coupler configured to detachably couple the suction cup with the closed cell foam layer.

9. The system of claim 8, wherein the coupler includes a ring.

10. The system of any of claims 7-9, wherein the one or more sensors include the compliant fluid fdled bladder, and the system further comprises a threaded cap for coupling the compliant fluid filled bladder to the sensor.

11. The system of any of claims 1-10, further comprising: one or more sensor rails each configured to: axially align two or more of the sensors; and house one or more vacuum lines fluidly coupled to each of the two or more sensors.

12. The system of claim 11, wherein the one or more sensor rails are each further configured to enable placement of the two or more sensors on the one or more objects within a container.

13. The system of claim 12, wherein the one or more sensor rails are configured to extend horizontally within the container.

14. A device for coupling to surfaces of nonferrous materials, comprising: a sensor configured for testing or inspecting a body made of a nonferrous material, the sensor including a suction cup having an internal volume, the suction cup being configured to acoustically couple the sensor to a surface of the body when a vacuum is pulled within the internal volume.

15. The device of claim 14, wherein the device is configured for requalification or inspection of nonferrous composite cylinders.

16. The device of claim 14 or claim 15, wherein the suction cup includes one or more bellows for acoustically coupling the sensor to curved and / or uneven surfaces.

17. The device of any of claims 14-16, further comprising: a vacuum sensor configured to detect vacuum data indicating a state of vacuum coupling between the sensor and the surface of the body.

18. The device of any of claims 14-17, wherein the sensor is a first sensor, and the suction cup is a first suction cup, and the internal volume is a first internal volume, and the device further comprises: a second sensor configured for testing or inspecting the body, the second sensor including a second suction cup having a second internal volume, the second suction cup being configured to acoustically couple the second sensor to the surface of the body when a vacuum is pulled within the second internal volume; and a sensor rail configured to: axially align the first sensor and the second sensor, house one or more vacuum lines fluidly coupled to the first internal volume and the second internal volume, and enable placement of the first sensor and the second sensor on the surface of the body within a cylinder container; and wherein the surface of the body is a surface of a cylinder.

19. The device of any of claims 14-18, further comprising:a valve in fluid communication with the internal volume of the suction cup and configured to seal or isolate the internal volume from a vacuum source.

20. The device of any of claims 14-19, further comprising at least one of: a closed cell foam layer coupled to the suction cup and configured to facilitate acoustically coupling the sensor to the surface of the body; or a compliant fluid filled bladder configured to facilitate acoustically coupling the sensor to the surface of the body.

21. The device of claim 20, wherein the sensor includes the closed cell foam layer, and the device further comprises a coupler configured to detachably couple the suction cup with the closed cell foam layer.

22. The device of claim 21, wherein the coupler includes a ring.

23. The device of any of claims 20-22, wherein the sensor includes the compliant fluid filled bladder, and the device further comprises a threaded cap for coupling the compliant fluid filled bladder to the sensor.

24. A method for testing or inspecting composite cylinders, the method comprising: placing one or more suction cups on an outer surface of a composite cylinder, the one or more suction cups being coupled to one or more ultrasonic sensors and each having an internal volume;pulling a vacuum within the internal volume of each of the one or more suction cups to acoustically couple the one or more ultrasonic sensors to the outer surface of the composite cylinder; and receiving, from the one or more ultrasonic sensors, deformation data associated with the composite cylinder.

25. The method of claim 24, wherein two or more of the ultrasonic sensors are coupled to one or more sensor rails that axially align the two or more ultrasonic sensors upon the outer surface of the composite cylinder.

26. The method of claim 24 or claim 25, further comprising: monitoring, via one or more vacuum sensors in fluid communication with the internal volume of each of the one or more suction cups, the acoustic coupling of the one or more ultrasonic sensors to the outer surface of the composite cylinder.

27. The method of any of claims 24-26, wherein: the internal volume of each of the one or more suction cups is in fluid communication with a vacuum source; and pulling the vacuum within the internal volume of each of the one or more suction cups includes controlling the vacuum source to pull the vacuum within the internal volume of each of the one or more suction cups.

28. The method of any of claims 24-27, wherein a coupler detachably couples at least one of the one or more suction cups with a closed cell foam layer, the closed cell foam layer facilitating acoustically coupling the ultrasonic sensor that is coupled to the suction cup to the outer surface of the composite cylinder.

29. The method of claim 28, wherein the coupler includes a ring.

30. The method of any of claims 24-29, wherein a threaded cap couples a compliant fluid fdled bladder to at least one of the one or more ultrasonic sensors, the compliant fluid fdled bladder facilitating acoustically coupling the ultrasonic sensor to the outer surface of the composite cylinder.

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