Double-Focus Immersion Probe for Deep Billet Flaw Detection
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Solution Overview
Problem
Existing flaw inspection methods for large-diameter billets require multiple probes, leading to increased component count and prolonged inspection times, and are unable to effectively detect flaws over a wide wavelength range and deep inside the billet.
Innovation Solution
A double-focus immersion probe with a concave front plate having different radii of curvature for orthogonal imaginary contact lines, allowing ultrasonic waves to focus at two points in water and converge to a single point inside the billet, utilizing a transducer emitting ultrasonic waves above 10 MHz.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple probes are used to detect flaws deep inside large-diameter billets, then the detection capability is improved, but the number of components and inspection time increase
Solution Approach 1:
The front plate is divided into two distinct concave surfaces with different radii of curvature (first concave surface with radius R1 and second concave surface with radius R2), creating two separate focal points in the water medium. This segmentation allows a single probe to function as multiple probes would, achieving deep flaw detection without increasing component count
Solution Approach 2:
The single immersion probe is designed with multi-functionality by incorporating two concave surfaces that create different focal lengths. The probe can detect flaws at multiple depths (shallow and deep) within the billet using the same device, eliminating the need for multiple specialized probes for different detection depths
2Measurement precision
If multiple probes are used to detect flaws deep inside large-diameter billets, then the detection capability is improved, but the inspection time increases
Solution Approach 1:
Multiple detection functions are merged into a single immersion probe by integrating two concave surfaces with different radii of curvature on the same front plate. This allows simultaneous or sequential operation of multiple focal points without the time penalty of switching between separate probes, reducing total inspection time while maintaining comprehensive flaw detection capability
3Device complexity
If a single probe is used with a flat front plate, then the configuration is simple, but the ability to detect flaws deep inside the billet is limited
Solution Approach 1:
The flat front plate is replaced with a curved front plate featuring two concave surfaces with different radii of curvature. This curvature enables the ultrasonic waves to focus at two distinct points in the water medium, extending the detection range to deep interior regions of the billet while maintaining a relatively simple single-probe 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
Facilitates efficient flaw detection deep inside large-diameter billets with a simplified configuration, reducing the number of components and inspection time, while enhancing the detection of small flaws, ensuring material durability for severe environments.
Implementation Method 1
a surface facing the object to be inspected is formed as a concave surface which is curved so as to be gradually depressed toward a center of the concave surface... the ultrasonic wave emitted from the transducer focuses at two points, due to a difference between the first radius of curvature and the second radius of curvature
Implementation Method 2
a transducer configured to emit an ultrasonic wave having a frequency equal to or higher than 10 MHz, to an object to be inspected immersed in a solvent
Data Source
AI summary
An immersion probe includes a front plate having a circular shape in a plan view. A surface of the front plate that faces an object to be inspected is formed as a concave surface that is curved so as to be gradually depressed toward the center. Radii of curvature of a first imaginary contact line and a second imaginary contact line orthogonal to each other at the center of the concave surface and extending so as to curve along the concave surface are defined as a first radius of curvature and a second radius of curvature, respectively. The first radius of curvature and the second radius of curvature are different from each other. When an ultrasonic wave is emitted in a solvent, the ultrasonic wave focuses at two points.