Flexible Magnetostrictive Pipe Inspection System
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Solution Overview
Problem
Current non-destructive testing (NDT) and structural health monitoring (SHM) techniques for tubes and pipes face challenges in efficiently and accurately detecting defects without causing damage, particularly in long-range inspections where traditional ultrasonic methods are limited by their localized nature and inability to provide 100% volumetric inspection.
Innovation Solution
The system employs a segmented magnetostrictive inspection system with a collar comprising a magnetostrictive material, sensor coil arrays on flexible printed circuit boards, and strategically placed magnets to induce a bias magnetic field, allowing for the generation and reception of guided waves that can inspect long distances and distinguish between structural features and defects through axisymmetric and flexural wave modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional ultrasonic methods are used for pipe inspection, then the inspection can be performed with simple equipment, but the inspection range is limited and cannot provide 100% volumetric coverage
Solution Approach 1:
The collar is divided into multiple discrete sensor segments arranged circumferentially around the pipe. Each segment contains magnetostrictive material and coil circuits that can be independently controlled. This segmentation enables the system to perform synthetic focusing and active focusing of guided wave energy at specific axial and circumferential locations, achieving 100% volumetric inspection coverage while maintaining high defect detection accuracy through targeted energy concentration
Solution Approach 2:
The system transitions from traditional one-dimensional linear array inspection to two-dimensional circumferential coverage by arranging sensor segments around the pipe circumference. This dimensional expansion enables simultaneous inspection of multiple circumferential positions and axial locations, providing comprehensive 100% volumetric coverage of the pipe structure
2Area of stationary object
If magnetostrictive segmented collar design is used, then long-range inspection with 100% volumetric coverage is achieved, but the device complexity increases
Solution Approach 1:
Each sensor segment in the collar is designed to perform multiple functions: it can both transmit guided wave energy and receive reflected signals, and can operate in different modes (active focusing, synthetic focusing, full-circumference inspection). This multi-functionality reduces the need for separate specialized components, thereby managing device complexity while achieving comprehensive inspection coverage
Solution Approach 2:
The system combines the pulser and receiver functions into integrated coil circuits within each sensor segment. The magnetostrictive material serves dual purposes as both the sensing element and the coupling medium to the pipe. This merging of functions reduces the number of separate components needed, managing complexity while maintaining long-range inspection capability
3Length of stationary object
If guided waves are used for long-range inspection, then inspection distance is increased, but the ability to distinguish between structural features and defects becomes more challenging
Solution Approach 1:
The segmented collar design enables localized excitation and reception of guided waves at specific circumferential positions. By controlling which segments are active, the system can target specific regions of interest along the pipe, improving the ability to distinguish defects from structural features through spatially selective inspection and synthetic focusing at predetermined locations
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 enables efficient, cost-effective, and accurate long-range inspection of pipes and tubes, providing 100% volumetric coverage and improved sensitivity by using guided waves to detect defects and structural features with enhanced signal-to-noise ratio and penetration power.
Implementation Method 1
The at least one strip of magnetostrictive material is configured to be induced with a bias magnetic field... The plurality of coil circuits and the plurality of magnets are configured to be disposed adjacent to the at least one magnetostrictive strip
Implementation Method 2
The plurality of coil circuits and the plurality of magnets are configured to be disposed adjacent to the at least one magnetostrictive strip. At least one of the plurality of coil circuits is individually controllable by a number of channels to at least one of excite or detect guided waves
Data Source
AI summary
A system includes a magnetostrictive strip configured to be wrapped at least partially around an outer surface of a structure. A plurality of coil circuits are disposed on at least one flexible PCB that is configured to be disposed adjacent to the magnetostrictive strip. Each coil circuit is individually controllable by a plurality of channels to at least one of excite or detect guided waves in the structure. A plurality of magnets are configured to induce a magnetic field in the magnetostrictive strip. A connector is configured electrically connect at least one of the plurality of coil circuits and at least one the plurality of channels. A body constructed from a flexible material is sized and configured to at least partially encapsulate at least one other component of the system.