Curved Ultrasonic Array Scanner for Multi-Angle Flaw Detection
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Solution Overview
Problem
Phased array ultrasonic scanners require lengthy inspection times due to sequential generation and transmission of ultrasonic waves at different angles, making it time-consuming to detect flaws oriented at various angles within test objects.
Innovation Solution
A rolling ultrasonic scanner with a curved array of transducers aimed at a common point, allowing for simultaneous transmission of ultrasonic beams at multiple angles, reducing the need for sequential steering and enabling sectoral scans, which improves detection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sequential generation and transmission of ultrasonic waves at different angles is used, then detection of flaws at various orientations is achieved, but inspection time increases significantly
Solution Approach 1:
The ultrasonic transducer array is divided into multiple independently controllable element groups, where each group can be activated to transmit ultrasonic waves at specific angles. This segmentation allows simultaneous transmission of multiple ultrasonic beams at different angles, eliminating the need for sequential scanning and significantly reducing inspection time while maintaining comprehensive flaw detection capability
Solution Approach 2:
Multiple ultrasonic transmission functions at different angles are merged into a single simultaneous operation. By combining the capabilities of multiple transducer elements to operate concurrently, the system achieves comprehensive angular coverage in one inspection pass rather than requiring multiple sequential passes, thereby resolving the time versus detection capability contradiction
2Measurement precision
If phased array with delay criteria is used to generate ultrasonic waves at different angles, then flaw orientation detection is improved, but the procedure becomes time consuming
Solution Approach 1:
The system maintains continuous ultrasonic transmission across all required angles simultaneously through the curved array configuration, eliminating the start-stop nature of sequential phased array scanning. This continuous multi-angle transmission preserves precise flaw orientation detection while dramatically improving inspection efficiency by removing temporal gaps between angular measurements
3Productivity
If linear scan is used, then efficient detection of corrosion or delamination is achieved, but detection of flaws at different angles becomes time consuming
Solution Approach 1:
The transducer array is configured in a curved formation that matches the geometry of the inspection surface, allowing simultaneous transmission of ultrasonic beams at multiple angles including perpendicular and oblique directions. This curved geometry enables the system to maintain high detection efficiency for corrosion and delamination while adding the versatility to detect flaws at various orientations without requiring separate scanning procedures
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 approach significantly reduces inspection time by enabling the detection of flaws oriented at various angles with minimal sensitivity loss and maintaining a constant common exit point, enhancing the ability to scan complex surfaces efficiently.
Implementation Method 1
The transducer unit transforms the electrical pulses into ultrasonic waves using one or more ultrasonic transducers (e.g., piezoelectric elements) arranged in an array within the scanner
Implementation Method 2
As the ultrasonic waves pass into the test object, various reflections, called echoes, occur as the ultrasonic waves interact with anomalies and other physical characteristics in the test object
Implementation Method 3
when the reflected ultrasonic waves are received by the piezoelectric surface of the ultrasonic transducers, it causes the transducers to vibrate which generates a voltage difference across the transducer electrodes that is detected as an electrical signal
Data Source
Figure 1~2
Figure 3
AI summary
A rolling ultrasonic scanner comprises a member having an inspection surface for rolling across the surface of an object under test. A plurality of ultrasonic transducers are disposed within the member in a formation such that they are each aimed at a common point that is coincident with the surface of the object.