Flexible Ultrasonic Array for Radiused Component Inspection
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Solution Overview
Problem
Traditional ultrasonic inspection tools face challenges when dealing with radiused components due to variability in dimensions, leading to inaccurate results and the need for multiple probes, and existing flexible array probes require a separate water supply and can be difficult to load, affecting signal quality and usability.
Innovation Solution
An ultrasonic inspection probe with a flexible array that conforms to the shape of the workpiece, using a deformable chassis and neoprene sealing material to maintain contact and direct liquid couplant, eliminating the need for a separate water supply and simplifying probe loading and unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rigid curved array of ultrasonic elements is used to detect features in radiused components, then the array can maintain fixed geometric relationships between elements, but it cannot accommodate variations in component radius and opening angle, leading to inaccurate results
Solution Approach 1:
The patent applies the dynamics principle by making the array probe flexible rather than rigid, allowing it to adapt its shape to match different radiused component geometries. The flexible array can dynamically conform to varying radii and opening angles while maintaining proper ultrasonic coupling, thereby achieving both measurement precision and adaptability to varying component dimensions.
Solution Approach 2:
The patent employs parameter changes by modifying the physical state of the array from rigid to flexible, enabling it to change its geometric parameters (curvature radius, opening angle) to match the inspected component. This allows the same probe to accurately inspect components with different dimensional parameters without sacrificing inspection accuracy.
2Adaptability or versatility
If a flexible array probe is used to accommodate varying component shapes, then the probe can conform to different radii and opening angles, but it requires a separate water supply system which degrades signal quality
Solution Approach 1:
The patent merges the coupling component and the array into a single integrated unit, eliminating the need for a separate water supply system. The coupling component itself provides the necessary ultrasonic coupling through its material properties and direct contact with the workpiece, thereby maintaining signal quality while preserving adaptability to varying component dimensions.
Solution Approach 2:
The patent uses the coupling component as an intermediary between the array and the workpiece, where this intermediate layer provides both mechanical coupling and ultrasonic coupling. The coupling component's material (such as rubber or polymer) serves as an effective ultrasonic medium, eliminating the need for additional water film coupling and reducing signal degradation at material boundaries.
3Ease of operation
If the flexible array is positioned near the top of the coupling component for easy access, then loading becomes simpler, but local pressure on piezoelectric elements detrimentally affects their signal properties
Solution Approach 1:
The patent segments the probe into distinct functional components: a coupling component that interfaces with the workpiece and an array component that contains the piezoelectric elements. This segmentation allows the array to be loaded from the end of the coupling component rather than from the top, providing ease of operation while protecting the piezoelectric elements from detrimental local pressure by positioning them away from the high-pressure contact zone.
4Measurement precision
If multiple array probes are kept in store to inspect different radiused components, then each component can be inspected with optimal geometry, but the device complexity and cost increase significantly
Solution Approach 1:
The patent applies universality by designing a single flexible array probe that can function for inspecting multiple types of radiused components with different radii and opening angles. The flexible array adapts its shape to match each specific component geometry, providing inspection accuracy comparable to dedicated rigid probes for each component type, thereby eliminating the need to maintain multiple specialized probes in inventory.
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 improves ease of use and signal quality by ensuring consistent contact and coupling between the ultrasonic array and the workpiece, reducing the need for multiple probes and minimizing signal degradation, while accommodating varying component dimensions.
Implementation Method 1
A typical ultrasonic array comprises a series of piezoelectric transducers attached to a substrate to maintain their relative positions
Implementation Method 2
In order to effectively ultrasonically couple the array to the workpiece, a separate water supply is required to create a water film between the coupling component and the workpiece
Data Source
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AI summary
An ultrasonic inspection tool (100; 200) has a chassis (102; 202) with a two part body (116; 216), an aperture (130; 230) for providing a clear line of sight between an array (146; 246) and a workpiece, and a series of feet (134, 136: 272, 274, 276, 278., 280, 282) for sliding along the workpiece.