Adaptive Ultrasonic Inspection for Variable Radius Joints
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Solution Overview
Problem
Conventional ultrasonic inspection methods struggle with inspecting composite structures with irregular and variable radii, as they fail to maintain a perpendicular sound path over the entire inspection area, leading to inefficient and unreliable data collection due to the need for manual probe adjustments.
Innovation Solution
A self-adjusting ultrasonic inspection system with a chassis, shoe assembly, and transducer array that mechanically adapts to changing radii along the length of the joint, ensuring the ultrasonic energy enters the composite part close to the local perpendicular, thereby maintaining data quality and speeding up the inspection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fixed-position sensor array is used to maintain 90-degree entry angle, then measurement precision is improved, but adaptability deteriorates when inspecting surfaces with varying radii
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a fixed-position sensor array to a movable sensor array that can dynamically adjust its position along the inspection surface. The sensor array is mounted on a movable carriage or rail system that allows it to follow the contour of variable radius surfaces while maintaining the 90-degree entry angle requirement through continuous positional adaptation.
Solution Approach 2:
The patent implements feedback by using sensors to detect the actual surface geometry and radius variations in real-time, then using this information to automatically adjust the sensor array position and orientation. This closed-loop feedback system ensures the 90-degree entry angle is maintained despite surface variations, resolving the contradiction between measurement precision and adaptability.
2Adaptability or versatility
If manual probe readjustment is performed to adapt to changing radii, then adaptability is improved, but productivity deteriorates due to slowed inspection process
Solution Approach 1:
The patent applies self-service by designing an automated system that performs the alignment and adjustment functions previously requiring manual operator intervention. The sensor array automatically detects surface geometry changes and adjusts its own position and orientation without human input, eliminating the need for manual probe readjustment and maintaining high inspection rates while adapting to variable radii.
Solution Approach 2:
The patent replaces manual mechanical adjustment operations with an automated electromechanical system. Sensors, motors, and control systems substitute for human operators who manually repositioned probes, enabling continuous automated inspection at high speed while maintaining proper alignment with varying surface geometries.
3Adaptability or versatility
If multiple probes are used to cover different radius configurations, then adaptability is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by designing a single sensor array system that can perform multiple inspection functions across different radius configurations. The movable sensor array with automated positioning and orientation control serves as a universal inspection tool that replaces multiple specialized probes, each designed for specific radius values, thereby reducing overall system complexity while maintaining versatility.
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
The system significantly accelerates the inspection process by automatically adjusting to varying radii, enabling reliable data collection and potentially replacing multiple probes with a single adaptive device, reducing inspection time, cost, and maintenance.
Implementation Method 1
For ultrasonic inspection of composite structure, the ultrasound beam should ideally enter at 90 degrees to the local surface of the composite part being inspected
Implementation Method 2
If it does not enter at 90 degrees, it will be refracted off normal and a return echo from any possible internal structure or anomaly will not be optimum
Data Source
AI summary
A system and method for inspecting a joint fillet having a surface whose radius varies along the length of the joint fillet. In one embodiment, the inspection apparatus comprises: a chassis; a shoe assembly supported by the chassis and comprising an axle; a transducer array assembly translatably coupled to the shoe assembly; biasing means for urging the transducer array assembly to translate relative to the shoe assembly in a first direction; and a lever assembly pivotably coupled to the axle of the shoe assembly and in contact with the transducer array assembly over a range of angular positions of the lever assembly. The transducer array will translate in a second direction opposite to the first direction when the net force exerted by the lever assembly is greater than the biasing force exerted by the biasing means. The lever assembly is used to automatically adjust the array position to the varying fillet radius.