Acoustic Weld Scan Drift Tracking for Accurate Flaw Detection
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Solution Overview
Problem
In ultrasonic inspection, probe assembly lateral displacement relative to a weld structure can lead to missed flaws due to incorrect gating of echo data, as the probe may drift laterally, causing geometric echoes to be mistaken for flaws or vice versa.
Innovation Solution
A machine-implemented technique for tracking the lateral displacement of the probe assembly relative to the weld, using index offset tracking to update the presentation of ultrasonic data and compensate for probe drift, ensuring accurate imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the probe assembly is manually scanned along the scan axis, then the inspection process is simple and quick to implement, but the lateral position of the probe assembly drifts relative to the weld structure, causing inaccurate spatial coverage and potential missed flaws
Solution Approach 1:
The system continuously monitors the lateral position of the probe assembly using a transducer array and real-time echo analysis. The processor compares the actual lateral position against the intended scan path and automatically adjusts the probe position or compensates in the imaging data to maintain accurate spatial coverage throughout the inspection process
Solution Approach 2:
The patent replaces manual mechanical scanning with an automated system that uses acoustic echo analysis and digital processing to track and compensate for lateral position drift. The mechanical scanning operation is supplemented by an electronic feedback system that uses sound wave reflections to continuously determine probe position and maintain inspection accuracy
2Measurement precision
If the lateral position of the probe assembly is continuously monitored and adjusted, then the spatial inspection coverage accuracy is improved, but the device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The transducer array serves multiple functions: it performs the primary ultrasonic inspection to detect flaws in the weld structure, simultaneously functions as a position sensing system by analyzing the time-of-flight and amplitude of reflected echoes, and provides data for both imaging and lateral drift compensation without requiring separate dedicated sensors
Solution Approach 2:
The system uses its own inspection echo data to determine the lateral position of the probe assembly. The same acoustic signals used to detect flaws are analyzed to calculate probe position, eliminating the need for external position sensors and reducing overall system complexity
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
Enables accurate differentiation between geometric echoes and defects by maintaining consistent lateral position of the probe, thereby improving the detection of flaws in weld structures.
Implementation Method 1
an acoustic transducer array can be used to transmit acoustic pulses into a structure
Implementation Method 2
obtain data for imaging of features on or within a test specimen. Different imaging modes can be used to present received acoustic signals that have been scattered or reflected by structures
Implementation Method 3
received acoustic signals that have been scattered or reflected by structures
Implementation Method 4
Beamforming can be performed using coherent excitation of ultrasound transducers to provide a desired beam angle and focal location. For example, coherent excitation can include applying specified delay values (or phase shift) to pulses for transmission by individual array elements
Implementation Method 5
beamforming can be performed in reception such as by summing received acoustic echo signals in manner where signals received from individual array elements are delayed (or phase shifted) to provide one or more of a desired beam angle and focal location
Data Source
AI summary
In acoustic inspection, if a probe assembly fails to maintain a controlled lateral position relative to a structure such as a weld being inspected, as the probe assembly is translated along a scan axis, a nearby flaw could be missed or mistaken for an earlier-observed feature. Apparatus and techniques described herein can assist in tracking the lateral displacement of a probe assembly relative to a region of interest such as an edge or centerline of a weld. Such a technique can, for example, be used to gate the received ultrasonic data or to update a presentation to a user, such as for updating an overlay (e.g., a weld template) and ruler position in an S-scan or other image representation.