3D Ultrasonic Inspection for Stick Weld Detection
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Solution Overview
Problem
Conventional three-dimensional ultrasonic inspection apparatuses face challenges in accurately determining the state of joined areas, particularly in stick weld states, where the joined area is tightly joined without melting, leading to reduced inspection accuracy and difficulty in distinguishing between acceptable and non-acceptable quality.
Innovation Solution
The apparatus employs a matrix sensor ultrasonic transducer with a signal processing unit that generates three-dimensional ultrasonic images, using attenuation correction and inverse correction processing to enhance image clarity and accuracy, and a determination unit that performs primary and secondary weld state determinations to assess the quality of the joined area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ultrasonic inspection methods are used to inspect welded areas, then the inspection can be performed non-destructively, but the inspection accuracy is reduced in stick weld states where the joined area is tightly joined without melting
Solution Approach 1:
The patent transitions from conventional two-dimensional ultrasonic inspection to three-dimensional ultrasonic inspection by introducing a third dimension (depth) to the inspection process. This dimensional enhancement allows the system to distinguish stick weld states by analyzing ultrasonic wave propagation characteristics in three-dimensional space, thereby improving inspection accuracy for tightly joined areas without melting.
Solution Approach 2:
The patent changes the inspection parameters by using three-dimensional ultrasonic wave propagation analysis instead of conventional two-dimensional methods. This parameter change enables the detection of subtle differences in ultrasonic wave characteristics that indicate stick weld states, improving the ability to distinguish between different weld qualities and states.
2Measurement precision
If the inspection accuracy is increased to accurately determine the state of welded areas, then the apparatus can correctly determine positional relationships in three dimensions, but the complexity of the device increases
Solution Approach 1:
The patent segments the three-dimensional inspection space into multiple two-dimensional cross-sectional planes. By dividing the complex three-dimensional inspection task into multiple simpler two-dimensional analyses, the system achieves high measurement precision while managing device complexity through modular processing of ultrasonic data from different spatial planes.
Solution Approach 2:
The patent introduces a third dimension to conventional ultrasonic inspection, transforming two-dimensional inspection into three-dimensional inspection. This dimensional enhancement enables accurate determination of welded area states and positional relationships by analyzing ultrasonic wave propagation in three-dimensional space, achieving high measurement precision through added spatial information.
3Reliability
If conventional two-dimensional ultrasonic imaging is used, then the device complexity is lower, but the ability to determine the soundness of joined areas and detect weld defects is reduced
Solution Approach 1:
The patent enhances conventional two-dimensional ultrasonic imaging by introducing a third dimension, enabling three-dimensional visualization of welded areas. This dimensional enhancement improves the ability to determine soundness of joined areas and detect weld defects by providing comprehensive spatial information about ultrasonic wave propagation and reflection patterns.
Solution Approach 2:
The patent changes the imaging parameters from two-dimensional to three-dimensional by analyzing ultrasonic wave propagation characteristics in three-dimensional space. This parameter change improves detection reliability for weld defects and joined area soundness by utilizing additional spatial dimensions for more comprehensive analysis of ultrasonic echo patterns.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves the visibility and accuracy of determining the soundness of joined areas, enabling precise inspection results and automatic detection of stick weld states, thereby enhancing the overall inspection process.
Implementation Method 1
the ultrasonic waves are irradiated to the welded area of the object to be inspected, and then are reflected from the welded area of the object to be inspected as echoes of the ultrasonic wave
Data Source
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AI summary
A three-dimensional ultrasonic inspection apparatus 10 can make increased inspection accuracy in comparison to the conventional apparatus and includes: an ultrasonic transducer 1 disposed m × n piezoelectric vibrators in a matrix; a signal processing unit 17 to receive, detect an echo, and generate a three-dimensional image data by processing an electric signal of the echo detected; a peak detecting element 51, 52 to detect a first peak and a second peak of an intensity distribution of the three-dimensional image data in a depth (z) direction; a joint portion image creation unit 36 to create a three-dimensional image of the joined area 15 by mapping z direction distance of the first peak and the second peak to x-y plane; a determination unit 37 to determine whether the joined area 15 is sound by two-step determination; and a display unit 38 to display the three-dimensional image and the determination result, of the joined area 15.