Curved Delay Line Ultrasonic Probe for High-Resolution Inspection
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Solution Overview
Problem
Conventional non-destructive inspection methods for structures with curved surfaces, such as composite shear ties, face challenges in achieving high resolution due to the size and spacing of traditional ultrasonic transducers, leading to low resolution and increased energy consumption, as well as the need for excessive couplant like water for efficient signal transmission.
Innovation Solution
An inspection probe with a phased array of transducers configured in an arcuate fashion, paired with a curved delay line matching the workpiece's curvature, allows for efficient ultrasonic signal transmission and reception, reducing couplant requirements and improving resolution without increasing energy consumption by concurrently or sequentially triggering transducers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional ultrasonic transducers are used with wide angular spacing to inspect curved surfaces, then the inspection probe can cover the curved surface, but the resolution of the inspection results deteriorates
Solution Approach 1:
The inspection probe divides the curved surface inspection task into multiple discrete transducer elements arranged in an arcuate pattern, with each transducer responsible for a specific angular sector. This segmentation allows precise positioning of multiple small transducers to achieve high resolution without requiring wide spacing between individual elements.
Solution Approach 2:
The patent transitions from linear transducer arrays to arcuate/trans spherical coordinate system, allowing transducers to be positioned along a curved path that matches the workpiece geometry. This dimensional change enables dense packing of transducers along the arc while maintaining appropriate spacing for resolution, solving the contradiction between coverage and resolution.
2Measurement precision
If additional transducers are added to improve resolution, then the inspection resolution improves, but the inspection probe becomes more difficult to maneuver
Solution Approach 1:
The inspection probe adopts a curved/arcuate geometry that conforms to the spherical or cylindrical surfaces being inspected. This curved design allows the probe to follow the workpiece contour smoothly, improving maneuverability while accommodating multiple transducers along the arc. The curved form factor reduces the probe's effective width when navigating tight spaces compared to a linear array of the same transducer count.
3Reliability
If traditional transducers are used with individual firing to increase energy transfer, then the depth and quality of inspection improves, but the energy consumption increases
Solution Approach 1:
The patent implements phased array technology with electronic scanning that enables continuous inspection without the need to reposition or re-fire individual transducers. By using phased array signal processing, the system maintains continuous ultrasonic coverage of the inspected region, eliminating gaps and reducing the need for repeated high-energy transmissions, thereby improving inspection quality while reducing overall energy consumption.
4Measurement precision
If more transducers are added to improve resolution, then the inspection resolution improves, but the amount of couplant required increases
Solution Approach 1:
The curved surface is divided into multiple discrete transducer positions along an arc, with each transducer requiring only a small localized amount of couplant at its specific contact point. This segmentation of the couplant requirement along the curved arc dramatically reduces the total couplant volume needed compared to a linear array where all transducers would require continuous couplant coverage across a larger linear distance.
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 solution enhances inspection resolution and quality while minimizing couplant usage and energy consumption, enabling reliable and efficient non-destructive testing of curved surfaces with improved detail and speed.
Implementation Method 1
a curved delay line that is also carried by the housing. The curved delay line has an outer arcuate surface having a predefined radius of curvature that matches the predefined radius of curvature of the plurality of elements. The curved delay line also has an inner arcuate surface exposed to the workpiece
Implementation Method 2
a plurality of transducer elements, typically configured in a phased array, carried by the housing and positioned in an arcuate configuration... introduce ultrasonic signals into the structure and to receive ultrasonic signals returning from the workpiece
Data Source
AI summary
A non-destructive inspection method, apparatus and system are provided for inspecting a workpiece having a curved surface with at least one predefined radius of curvature. The apparatus, such as an inspection probe, includes a plurality of transducer elements positioned in an arcuate configuration having a predefined radius of curvature and a curved delay line. The curved delay line has an outer arcuate surface having a predefined radius of curvature that matches the predefined radius of curvature of the transducer elements. The curved delay line also has an inner arcuate surface that has at least one predefined radius of curvature that matches the at least one predefined radius of curvature of the curved surface of the workpiece. In addition to the inspection probe, the system includes an excitative source for triggering the transducer elements to emit signals into the workpiece and a computing device to receive the return signals.