Dry-Coupled Magnetostrictive Guided Wave Scanning System
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Solution Overview
Problem
Conventional long-range ultrasonic testing (LRUT) and medium-range ultrasonic testing (MRUT) systems face limitations such as uninspectable regions around transducers, axial and lateral resolution issues, and complex, costly setups for guided wave inspection of pipes and cylindrical structures, which hinder effective detection of corrosion and flaws in inaccessible areas.
Innovation Solution
A dry-coupling magnetostrictive guided wave scanning system using a ferromagnetic strip and a magnetostrictive receiver coil, with mechanical pressure coupling and a processor to generate and detect guided waves, allowing for improved axial and lateral resolution and reduced dead zones, enabling two-dimensional imaging of anomalies in pipes and cylindrical structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional transducers are used for guided wave inspection, then long-range inspection capability is achieved, but uninspectable regions and poor resolution occur around the transducers
Solution Approach 1:
The patent replaces conventional piezoelectric transducers with a magnetostrictive sensor system consisting of a ferromagnetic strip and receiver coil. This substitution eliminates the need for complex segmented transducer collars and multiple channels, achieving improved axial and lateral resolution while simplifying the overall system architecture for guided wave inspection of pipes and cylindrical structures.
2Reliability
If conventional LRUT/MRUT systems are used, then guided wave inspection is achieved, but dead zones and inspection limitations occur around transducers
Solution Approach 1:
The magnetostrictive sensor system replaces complex conventional transducer assemblies with a simplified ferromagnetic strip and coil configuration. This substitution eliminates dead zones around transducers by providing continuous contact along the ferromagnetic strip, improving detection reliability while simplifying the inspection process through a single sensor unit that can be moved around the structure.
Solution Approach 2:
The patent employs a movable sensor assembly that can be dynamically positioned around the circumference of pipes and cylindrical structures. The ferromagnetic strip maintains continuous contact with the structure surface while the sensor moves to different locations, enabling comprehensive inspection without fixed transducer limitations and simplifying operation through movable rather than fixed positioning.
3Power
If complex segmented transducer collars are used, then guided wave generation is achieved, but system complexity and cost increase
Solution Approach 1:
The patent replaces complex segmented piezoelectric transducer collars with a simplified magnetostrictive system using a ferromagnetic strip and receiver coil. This substitution maintains guided wave generation and detection capabilities while significantly reducing system complexity, eliminating the need for multiple segments and channels, and lowering overall system cost.
Solution Approach 2:
The patent merges the functions of multiple segmented transducers and channels into a single integrated magnetostrictive sensor unit. The ferromagnetic strip and receiver coil combination consolidates guided wave generation and detection capabilities that would traditionally require separate transducer segments and multiple channels, thereby reducing device complexity while maintaining full inspection functionality.
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 enhances axial and lateral resolution, reduces the dead zone, and simplifies the inspection process by using mechanical pressure coupling for dry attachment, facilitating efficient detection of corrosion and flaws over short to medium ranges without the need for complex segmentation or additional channels.
Implementation Method 1
at least one magnetostrictive receiver coil... detecting guided wave reflections using said receiver coil
Implementation Method 2
the at least one ferromagnetic strip in the magnetostrictive sensor is temporarily coupled to the structure using mechanical pressure coupling
Implementation Method 3
The at least one magnet, which may be a permanent magnet or an electromagnet, is configured to apply a biasing magnetization to the at least one strip
Data Source
AI summary
A system includes a scanner body, a sensor package, a magnet, an actuator mechanism, and a retention mechanism. The sensor package includes a ferromagnetic strip and a flexible coil configured to at least one of transmit and detect a guided wave. The magnet is for applying a biasing magnetic field to the ferromagnetic strip. The actuator mechanism is configured to provide a mechanical pressure coupling between the magnetostrictive strip and a structure, and the retention mechanism is configured to counteract a force applied by the actuator mechanism. A processor is in communication with the sensor package and is configured to record guided wave signals detected by the flexible sensor coil, record scanner body location data provided by a position encoder, and generate two-dimensional image data of an anomaly in the structure based on the guided wave signals and location data. Methods of use and operation also are disclosed.