Curved Transducer Array for Non-Planar Ultrasonic Inspection
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Solution Overview
Problem
Inspecting composite structures with non-planar surfaces is challenging due to the difficulty in achieving desired responses from signal transmissions, as conventional transducer arrays do not conform to complex shapes, requiring multiple passes and potentially failing to provide effective through-transmissions or response signals.
Innovation Solution
A curved transducer array configured to cover non-planar surfaces, with a controller managing sound signal transmission and reception to ensure through-transmission via an undeflected path, allowing for efficient inspection of composite structures with complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional transducer arrays are used on non-planar surfaces, then the inspection process requires multiple passes and complex positioning, but this increases inspection time and reduces productivity
Solution Approach 1:
The transducer array is formed into a curved configuration that matches the non-planar surface geometry of the test object. This curvature allows the transducer elements to maintain proper acoustic coupling and orientation across the entire surface, enabling complete inspection in a single pass without requiring multiple repositioning operations while maintaining accurate defect detection
2Measurement precision
If conventional transducer arrays are used on complex geometries, then positioning and achieving desired signal responses becomes difficult, but this increases device complexity and operation difficulty
Solution Approach 1:
The curved transducer array geometry is designed to conform to the test object's surface curvature, which simplifies positioning by eliminating the need for complex alignment procedures. The curved configuration naturally maintains optimal acoustic paths and signal responses across the entire inspection area, reducing operational complexity while improving signal quality consistency
3Measurement precision
If multiple inspection passes are performed on non-planar surfaces, then coverage is improved, but this increases inspection time and reduces productivity
Solution Approach 1:
The curved transducer array is designed with a geometry that enables complete surface coverage in a single inspection pass. The curvature allows all transducer elements to simultaneously access and inspect the entire non-planar surface area, eliminating the need for multiple passes and significantly reducing inspection time while maintaining comprehensive coverage
4Measurement precision
If transducers are positioned to account for geometry variations, then measurement accuracy is improved, but this requires automated positioning systems that increase device complexity
Solution Approach 1:
The curved transducer array is manufactured with a predetermined geometry that inherently accounts for the test object's surface variations. This fixed curved configuration eliminates the need for automated positioning systems or real-time geometry compensation mechanisms, achieving accurate measurements across complex geometries while maintaining simple device architecture
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 comprehensive inspection of composite structures with complex shapes without the need for multiple passes, effectively identifying inconsistencies such as delamination, voids, or porosity, improving inspection efficiency and accuracy.
Implementation Method 1
send a sound signal from a first portion of the curved transducer array through the test object to a second portion of the curved transducer array
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A method and apparatus for inspecting a test object. A sound signal is sent from a first portion of a curved transducer array through the test object in a direction towards a second portion of the curved transducer array. The curved transducer array has a shape that is configured to cover a non-planar surface of the test object. A response signal in response to the sound signal is received at the second portion of the curved transducer array.