Adjustable Ultrasonic Probe for Aircraft Corner Radii
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Solution Overview
Problem
The existing ultrasonic probes for inspecting corner radii of stiffened aircraft parts require a large inventory of customized probes to accommodate various sizes and angles, leading to high costs due to the need for multiple probes and transducers.
Innovation Solution
An ultrasonic probe with a curved sensor array and an adjustable shoe mechanism that ensures all ultrasonic beams have the same water path distance and pass through the center of the corner radius, allowing for scanning of a wide range of angles and sizes with fewer probe types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If different shoes are customized to match different radii sizes and angles, then the inspection accuracy for various corner radii is improved, but the inventory cost and device complexity increase significantly
Solution Approach 1:
The patent applies universality by designing a single ultrasonic probe with an adjustable sensor array that can accommodate multiple corner radius sizes and angles. The sensor array can be repositioned along the arc of the corner radius, allowing one probe to perform the function of multiple customized probes, thereby reducing inventory complexity while maintaining inspection accuracy across different geometries
Solution Approach 2:
The patent implements dynamics by making the sensor array adjustable and reconfigurable rather than fixed. The sensor array can be dynamically repositioned to match different corner radius geometries, enabling the probe to adapt to various inspection requirements without requiring separate static probes for each configuration
2Measurement precision
If different shoes are customized to match different radii sizes and angles, then the inspection accuracy for various corner radii is improved, but the cost of maintaining probe inventory increases
Solution Approach 1:
The patent reduces inventory quantity by creating a universal probe design that can inspect multiple corner radius types. Instead of maintaining separate probes for each radius size and angle, a single probe with adjustable sensor array positioning can serve all inspection needs, directly reducing the quantity of probes required in inventory while preserving measurement precision
3Device complexity
If a single probe design is used for all corner radii, then the device complexity and inventory cost are reduced, but the inspection accuracy for specific geometries deteriorates
Solution Approach 1:
The patent resolves the accuracy issue with a single probe design by implementing dynamic adjustability. The sensor array can be repositioned along the arc to match specific corner radius geometries during inspection, ensuring that the probe maintains high measurement precision for each specific geometry while still being part of a simplified single-probe inventory system
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 solution reduces the number of required probes and transducers, lowering costs while enabling effective non-destructive inspection of corner radii with varying sizes and angles, thereby improving operational efficiency and reducing inventory needs.
Implementation Method 1
the transducer operates in pulse/echo mode to generate sound pulses, which are transmitted through the corner radius. Reflected sound pulses indicate whether the corner radius contains a crack, void, delamination, etc.
Data Source
AI summary
An ultrasonic probe performs non-destructive inspection of a corner radius of a part. According to one embodiment, an ultrasonic probe includes an ultrasonic sensor array, and a shoe for holding the sensor array and moving the sensor array along the radius of the part. The shoe includes means for adjusting the sensor array so all ultrasonic beams from the sensor array have the same water path distance to a center of the radius, and for adjusting the sensor array so that all beams pass through the center of the radius.