Flexible Array Probe for Contoured Surface Inspection
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Solution Overview
Problem
Eddy current array probes face challenges in inspecting contoured surfaces with varying cross-sectional geometry due to limited flexibility and difficulty in maintaining consistent liftoff and orthogonal orientation, particularly on convex, concave, and S-shaped surfaces.
Innovation Solution
A flexible array probe design featuring thin array element mounting fins coupled by pivot mechanisms, allowing elements to rotate in one dimension and inherently align orthogonally with the test surface, providing a robust and pliant solution for varying geometries without mechanical adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a solid, inflexible eddy current array probe is used, then structural stability is maintained, but the ability to adapt to contoured surfaces with varying cross-sectional geometry is lost
Solution Approach 1:
The probe is divided into multiple discrete test heads or modules that can be independently positioned and oriented. Each test head contains array elements that can be separately adjusted, allowing the probe to conform to complex surface geometries while maintaining structural integrity through the modular architecture.
Solution Approach 2:
The probe incorporates movable and adjustable components, including test heads that can rotate and positioners that can adjust the orientation of array elements. This dynamic capability allows the probe to adapt to varying surface contours while maintaining stable electrical connections and orthogonal sensor orientation through active adjustment mechanisms.
2Adaptability or versatility
If array elements are spaced apart to achieve useful probe curvature, then flexibility is improved, but element density and inspection coverage are reduced
Solution Approach 1:
The probe utilizes three-dimensional positioning of array elements through multiple degrees of freedom, including rotation of test heads and adjustment of element orientation. This allows elements to be closely spaced in three-dimensional space while the probe as a whole achieves the necessary curvature and flexibility for contoured surfaces.
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 flexible array probe effectively adapts to multiple curve shapes, maintaining consistent element orientation and liftoff, enhancing the ability to inspect complex surfaces with improved accuracy and ease of use.
Implementation Method 1
thin array element mounting fins coupled by pivot mechanisms, allowing elements to rotate in one dimension and inherently align orthogonally with the test surface
Implementation Method 2
high frequency alternating electrical currents which, in turn, create an alternating magnetic field near the surface of the test piece. This magnetic field induces eddy currents in the conductive surface of the test piece which are sensed and measured
Implementation Method 3
If a flaw or defect is present on the surface of the test piece, the flow of eddy currents will be altered, and this change will be readily detected by the eddy current probe
Data Source
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AI summary
A flexible array probe is disclosed suitable for use in the non-destructive testing and inspection of test pieces with varying cross-sectional geometries. Array elements (103) such as, but not limited to, eddy current sensors, piezoelectric sensor elements, and magnetic flux leakage sensors--are mounted on thin alignment fins (101) and coupled together with pairs of pivot mechanisms along the axis of desired rotation. The pivot mechanisms allow rotation in exactly one dimension and force the flexible array probe to align its elements orthogonally to the surface of the structure under test. Alignment and coupling fixtures arc also disclosed.