Curved Phased Array Probe for Spot Weld Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current nondestructive testing methods for assessing spot weld quality, particularly resistance spot welding, require skilled operators and are subjective, making it difficult to reliably identify poor quality joints without human intervention.
Innovation Solution
A three-dimensional matrix phased array spot weld inspection system using a curved array of ultrasonic transducer elements with a flexible membrane and fluid-filled chamber, coupled with a phased array excitation unit and computerized controller, generates a two-dimensional, color-coded image characterizing the integrity of spot welds by transmitting and receiving ultrasonic signals, allowing for objective analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If acoustic methods are used for nondestructive testing of spot welds, then deeper penetration and higher sensitivity to small discontinuities are achieved, but the requirement for skillful operators and subjective interpretation increases
Solution Approach 1:
The patent replaces manual acoustic inspection with an automated ultrasonic phased array system that uses computer-controlled transducer elements to generate and analyze acoustic signals. The system substitutes operator skill with automated signal processing and imaging algorithms, eliminating subjective interpretation while maintaining high sensitivity to weld discontinuities
Solution Approach 2:
The patent introduces a flexible membrane as an intermediary between the ultrasonic transducer array and the contoured weld surface. This membrane enables effective acoustic coupling and signal transmission while adapting to irregular geometries, allowing automated inspection without requiring manual positioning or interpretation skills
2Area of stationary object
If a curved array of ultrasonic transducer elements is used, then improved coverage area and sensitivity are achieved, but device complexity increases
Solution Approach 1:
The patent transitions from a traditional one-dimensional linear array of transducers to a two-dimensional curved matrix array. This dimensional expansion enables broader coverage area and improved sensitivity to discontinuities at various orientations, while the systematic arrangement of elements manages the increased complexity through structured signal processing
Solution Approach 2:
The patent employs a curved array geometry that conforms to the contoured surface of spot welds. This curvature optimizes acoustic beam penetration and reflection detection across the weld interface, improving coverage and sensitivity while the flexible membrane enables adaptation to various weld geometries without requiring custom rigid probes for each configuration
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 enables reliable, non-destructive characterization of spot welds, reducing operator dependency and subjectivity, and providing accurate imaging of weld integrity, including detection of stuck or cold welds, with improved sensitivity and coverage area compared to two-dimensional designs.
Implementation Method 1
an acoustic probe having a plurality of ultrasonic transducer elements arranged in a curved array at one end of the acoustic probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof
Implementation Method 2
a phased array excitation unit in electrical communication with the array of transducer elements for ultrasonically exciting transducer elements
Data Source
AI summary
A system for characterizing a spot weld including an acoustic probe that further includes a plurality of ultrasonic transducer elements arranged in a curved array, wherein the transducer elements are operative to generate ultrasonic signals and to receive reflections thereof; and a combination of materials for allowing the probe to conform to a contoured surface of the spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions; a phased array excitation unit coupled to the array of transducer elements for ultrasonically exciting transducer elements; and a controller coupled to the phased array excitation unit for controlling the operation of the phased array unit, gathering and processing information from the ultrasonic transducers, and generating a two-dimensional, color coded image that characterizes the integrity of the spot weld.