Flexible 2D TR Probe Array for Pipe Inspection
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Solution Overview
Problem
Ultrasonic sensor assemblies face challenges in accurately and efficiently inspecting tubular pipes with arcuate contours, as single transmitter-receiver probes have limited testing ranges and require extensive time for characterization, leading to inaccurate results.
Innovation Solution
A flexible ultrasonic sensor array with a matrix formation of sensor elements arranged in rows and columns on a supporting material that can bend to conform to the cylindrical shape of the pipe, allowing for extended coverage and improved detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single TR probe is used for pipe inspection, then the device complexity is low, but the testing range is small and detection accuracy is insufficient
Solution Approach 1:
The sensor probe is divided into multiple TR sensor elements arranged in a two-dimensional array pattern, where each element can independently transmit and receive ultrasonic signals. This segmentation allows simultaneous inspection of multiple locations on the pipe, improving detection accuracy and coverage while maintaining manageable system complexity through modular architecture
Solution Approach 2:
The sensor elements are arranged in a two-dimensional array rather than a single linear row, adding spatial dimensionality to the inspection capability. This 2D configuration enables comprehensive coverage of the pipe surface by positioning sensors at multiple radial and axial locations, significantly expanding the testing range and detection precision
2Productivity
If a single TR probe is used, then the device structure is simple, but the inspection time is excessive and coverage is limited
Solution Approach 1:
The probe contains multiple TR sensor elements that can operate simultaneously or in coordinated sequences, enabling parallel inspection of different pipe sections. This multi-element segmentation transforms a single-point inspection into a multi-point concurrent inspection system, dramatically increasing inspection productivity
Solution Approach 2:
Multiple TR sensor elements are combined within a single probe housing, integrating several inspection functions into one unified device. This merging allows the probe to perform comprehensive inspections of the entire pipe circumference and length in a single application, reducing total inspection time and improving productivity
3Adaptability or versatility
If a rigid sensor array is used, then the manufacturing precision is high, but the adaptability to curved pipe surfaces is poor
Solution Approach 1:
The sensor elements are mounted on a flexible substrate or backing material that can be conformally wrapped around curved pipe surfaces. This flexible support structure allows the rigid sensor elements to maintain their precise relative positions while adapting to the contoured geometry of the pipe, achieving both contour matching and positioning precision
Solution Approach 2:
The sensor array incorporates flexible or adjustable mounting mechanisms that allow the probe configuration to dynamically adapt to different pipe diameters and curvatures. This dynamic adaptability enables the same probe design to be used across various pipe sizes while maintaining optimal sensor-to-surface contact and positioning accuracy
Data Source
AI summary
An ultrasonic sensor assembly includes a flexible supporting material that has flexibility configured for allowing bending of the supporting material to conform to a cylindrical shape of a pipe. The assembly includes a plurality of operable sensor elements arranged in a matrix formation upon the flexible supporting material. The matrix formation includes a plurality of rows of the sensor elements and a plurality of columns of the sensor elements. The flexible supporting material is configured for placement of the columns of the matrix formation to extend along the elongation of the pipe and the flexible supporting material is configured for placement of the rows of the matrix formation to extend transverse to the elongation of the pipe. The flexible support material is configured to flex for positioning the sensor elements within each row in a respective arc that follows a curve of the cylinder shape of the pipe.