Flexible Ultrasonic Array Probe for Varying Component Radii

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Solution Overview

Problem

Traditional ultrasonic inspection methods using rigid arrays are ineffective for components with varying radii and opening angles, leading to inaccurate results and the need for multiple probes to accommodate different dimensions, which is costly and inefficient.

Innovation Solution

A flexible ultrasonic array probe with a flexible coupling component that maintains constant contact with the workpiece by deforming to match the component's radius and opening angle, eliminating the need for multiple probes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a rigid curved array of ultrasonic elements is used, then the array can be directed normal to the surface of the component, but the array cannot adapt to variations in component radius and opening angle, leading to inaccurate inspection results

Engineering Contradiction:

Improveinspection accuracyVSAvoidadaptability to varying component dimensions

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent applies the dynamics principle by making the ultrasonic array flexible rather than rigid, allowing it to dynamically adapt its shape to match the varying radius and opening angle of different component geometries. The flexible array can deform to maintain normal orientation with the component surface across different configurations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent directly implements this principle by using a flexible ultrasonic array that can conform to curved surfaces. The flexible nature of the array allows it to adapt to varying component dimensions while maintaining proper orientation for accurate ultrasonic inspection.

Inventive Principle:

Principle #30Flexible shells and thin films

2Measurement precision

If multiple rigid array probes are used to accommodate different component dimensions, then accurate inspection can be achieved for each specific geometry, but the device complexity and cost increase significantly

Engineering Contradiction:

Improveinspection accuracyVSAvoidnumber of probes required

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a single flexible ultrasonic array probe that can inspect multiple component geometries with varying radius and opening angles. This multi-functional probe replaces the need for multiple specialized rigid probes, reducing device complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements parameter changes by allowing the flexible array to change its physical configuration (shape, curvature, orientation) to match different component parameters. This enables a single probe to adapt to various inspection requirements that previously required multiple fixed-geometry probes.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If pressure is applied to maintain contact between the array and workpiece, then consistent ultrasonic coupling is achieved, but rigid arrays cannot deform to maintain contact across varying component geometries

Engineering Contradiction:

Improvecontact consistencyVSAvoidgeometric adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The flexible array dynamically deforms under applied pressure to maintain contact with the workpiece surface across varying geometries. This allows consistent ultrasonic coupling while adapting to different component shapes and angles.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible ultrasonic array acts as a deformable element that can conform to the workpiece surface when pressure is applied, ensuring consistent contact and coupling across different component geometries while maintaining adaptability.

Inventive Principle:

Principle #30Flexible shells and thin films

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

Enables accurate ultrasonic inspection across a wide range of component geometries with consistent pressure, reducing the need for multiple probes and improving inspection efficiency and cost-effectiveness.

Implementation Method 1

a flexible coupling component arranged to ultrasonically couple the flexible ultrasonic array to a workpiece

Methodology Applied

Scientific EffectUltrasonic coupling: Ultrasound

Implementation Method 2

the coupling component deforms and is thereby kept in constant contact with the workpiece

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 3

a loading component arranged to apply a pressure to the loading surface to maintain contact between the workpiece coupling surface and a workpiece in use

Methodology Applied

Scientific EffectMechanical pressure: Pressure Increase

Data Source

PatentUS9372174B2Ultrasonic inspection tool

Publication Date: 2016.06.21 AIRBUS OPERATIONS LTD

AI summary

An ultrasonic inspection probe comprising: a flexible ultrasonic array, a flexible coupling component arranged to ultrasonically couple the flexible ultrasonic array to a workpiece at a coupling boundary surface, a loading component arranged to apply a pressure to the coupling component to a surface opposite the coupling boundary surface to maintain contact between the coupling boundary surface and a workpiece.