Acoustic Emission Sensor for Press Panel Defect Detection
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Solution Overview
Problem
Current non-destructive inspection methods for detecting defects in press panels, such as macroscopic, ultrasonic wave, radiation, and acoustic inspections, face limitations including reliance on skilled inspectors, radiation exposure risks, and accuracy issues due to background noise in acoustic inspections.
Innovation Solution
An apparatus and method utilizing an acoustic emission sensor unit to detect elastic wave signals during press work, with a period measurer and defect existence determination unit to assess signal parameters like pulse number, energy, and average frequency, determining defect presence based on reference values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If acoustic emission sensors are used to detect elastic wave signals during press work, then defect detection capability is improved, but background noise affects measurement precision
Solution Approach 1:
The patent extracts and measures specific parameters (period, pulse number, energy, average frequency) from the elastic wave signals to isolate defect-related information from background noise. By focusing on these extracted parameters rather than raw signals, the system achieves accurate defect detection despite noisy environmental conditions.
Solution Approach 2:
The patent transforms the raw elastic wave signals into specific measurable parameters (period, pulse number, energy, average frequency) and establishes reference value ranges for these parameters. This parameter transformation allows the system to distinguish defect signals from background noise by comparing measured parameter values against predetermined reference ranges.
2Measurement precision
If radiation inspection is used to detect internal defects, then defect detection capability is improved, but radiation exposure risk increases
Solution Approach 1:
The patent replaces radiation-based inspection methods with acoustic emission-based detection. By using elastic wave signals generated during press work instead of ionizing radiation, the system achieves defect detection capability while eliminating harmful radiation exposure to inspectors and the environment.
3Ease of operation
If macroscopic inspection is used to detect surface defects, then inspection simplicity is improved, but dependence on skilled inspectors increases
Solution Approach 1:
The patent enables the inspection system to automatically detect and evaluate defects without human inspectors. The system self-automates the inspection process by measuring elastic wave parameters, comparing them against reference values, and determining defect presence automatically, thereby eliminating dependence on skilled inspectors while maintaining simplicity of operation.
Solution Approach 2:
The patent accelerates the defect detection process by using electronic parameter measurement and automated comparison instead of manual visual inspection. This automation significantly speeds up the inspection process while removing the need for inspector expertise, achieving both simplicity and efficiency.
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 allows for accurate and simple detection of defects in press panels, reducing reliance on skilled inspectors and minimizing radiation exposure, while improving the accuracy of defect determination using signal parameters.
Implementation Method 1
an acoustic emission sensor unit configured to detect at least one elastic wave signal emitted from the press panel as a detection target during press work
Data Source
AI summary
An apparatus for detecting a defect of a press panel includes: an acoustic emission sensor unit configured to detect at least one elastic wave signal emitted from the press panel as a detection target during press work, a period measurer configured to measure a period as a section in which there are consecutive signals with a greater voltage than a threshold voltage among the at least one detected signals, and a defect existence determination unit configured to determine that a defect is generated in the press panel when the measured period is greater than a first reference value, and to determine that the press panel is in a normal state when the measured period is smaller than a second reference value which is smaller than the first reference value.