Flexible Strip Eddy Current Probe for Internal Surface Inspection
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Solution Overview
Problem
Existing eddy current inspection systems for mechanical parts, particularly engine parts with holes, are fragile, expensive, and require frequent reconfiguration for different hole shapes, making them difficult to use and automate, especially when inspecting internal surfaces and complex geometries.
Innovation Solution
A device with eddy current probes arranged on flexible strips, which are compressed to expand transversely and adapt to the surface, allowing for robust, cost-effective, and automated inspection of internal surfaces without the need for multiple probe systems, and includes additional flexible strips for guiding and protecting the probes during insertion and extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional eddy current probe systems with articulated metal arms and springs are used, then measurement capability is achieved, but the system becomes fragile and expensive
Solution Approach 1:
The patent replaces rigid metal arms and springs with flexible strips that can deform to accommodate surface irregularities and hole geometries. These flexible strips eliminate the need for complex articulated mechanisms while maintaining probe contact with the inspection surface, thereby improving reliability and reducing device complexity.
Solution Approach 2:
The patent substitutes the mechanical articulated arm system with a simpler flexible strip mechanism. The flexible strips are deformed by compression in the longitudinal direction, which automatically positions the probes against the inspection surface without requiring complex mechanical linkages, springs, or brushes.
2Measurement precision
If probe systems are designed for specific hole shapes, then measurement accuracy is improved, but reconfiguration is required for different hole shapes increasing complexity and cost
Solution Approach 1:
The patent creates a universal probe system where the flexible strips can adapt to various hole shapes and sizes. The same device configuration can inspect different geometries because the flexible strips deform to match the surface contours, eliminating the need for reconfiguration while maintaining measurement precision across multiple applications.
Solution Approach 2:
The patent introduces dynamic adaptability through flexible strips that can change their configuration based on the inspection geometry. The strips deform elastically to conform to different hole shapes, allowing the system to automatically adapt to various geometries without manual reconfiguration, thereby improving both versatility and measurement accuracy.
3Quantity of substance
If multiple probe systems are used for different inspection zones, then inspection coverage is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple probe functions into a single integrated device. The flexible strips can be configured to inspect various zones including the main surface, end walls, and openings of holes using the same basic structure, eliminating the need for multiple separate probe systems and reducing overall device complexity.
Solution Approach 2:
The patent designs a universal inspection device that can handle multiple inspection zones and geometries with a single configuration. The flexible strips adapt to different surface configurations, allowing one device to perform the work of multiple specialized probes, thereby reducing the quantity of devices needed while maintaining comprehensive inspection coverage.
4Manufacturing precision
If automated positioning protocols are used, then positioning precision is improved, but implementation becomes difficult with robots and complex tooling
Solution Approach 1:
The patent enables the probe system to self-position on the inspection surface through the elastic deformation of flexible strips. When the device is inserted into the hole, the strips automatically deform to conform to the surface geometry and apply the probes to the correct positions without requiring complex automated positioning systems, robotic control, or specialized tooling.
Solution Approach 2:
The patent utilizes the elastic properties of flexible strips to achieve automatic positioning. By changing the physical state of the strips from compressed to relaxed, the system automatically adapts its probe positions to match the inspection surface geometry, eliminating the need for complex automated positioning protocols while maintaining positioning precision.
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 solution simplifies the inspection process, reduces costs, and allows for efficient adaptation to various hole configurations, enabling thorough inspection of both internal surfaces and complex geometries, including the ends of holes, while being robust and easy to handle, both manually and by robots.
Implementation Method 1
a deformable material that, on being compressed along said longitudinal direction, gives rise to expansion transversely to the longitudinal direction, said expansion deforming said strips so as to apply the probes against the surface
Implementation Method 2
One known inspection technique is the eddy current method, consisting in verifying that the material is continuous by measuring currents that have been induced by a magnetic field
Data Source
AI summary
A device for inspecting a surface of an electrically conductive part, the device having a plurality of eddy current probes arranged on a convex surface of the device together with an applicator for applying the probes against the surface to be inspected into which the device is inserted, wherein the probes are fastened on flexible strips extending beside one another in a longitudinal direction of the device, the applicator including a deformable material, that, on being compressed along the longitudinal direction, gives rise to expansion transversely to the longitudinal direction, the expansion deforming the strips so as to apply the probes against the surface.