Flexible Ultrasonic Probe Wedge for Complex Shape Inspection
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Solution Overview
Problem
Conventional ultrasonic probes struggle with high-resolution thickness mapping of complex shapes due to rigidity, requiring custom designs with long lead times and high costs, and existing flexible wedge solutions are complex and inconvenient to use.
Innovation Solution
A flexible ultrasonic phased array probe with a slidable acoustic module inserted into a water wedge with modular slots, allowing the probe to conform to various shapes without the need for tools and quick interchange between different wedges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rigid phased array probe is used for high-resolution inspection, then measurement precision is improved, but the probe cannot conform to complex shapes requiring custom designs with long lead times and high costs
Solution Approach 1:
The patent employs a flexible acoustic module that can dynamically change its shape to match different test object geometries. The module includes a flexible substrate with piezoelectric elements that can be bent and positioned at various angles, allowing the same probe to adapt to flat surfaces, curved pipes, and complex geometries without requiring custom rigid probe designs for each application.
Solution Approach 2:
The acoustic module is constructed with a flexible substrate (such as flexible PCB or thin film technology) that allows the probe to conform to complex surfaces. This flexible construction enables the probe to bend and wrap around curved surfaces like pipes while maintaining the integrity and positioning of the piezoelectric elements, eliminating the need for custom rigid probes for different geometries.
2Adaptability or versatility
If a custom probe array geometry is manufactured for each part shape, then adaptability is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent creates a universal flexible acoustic module that can serve multiple inspection applications. The same module can be configured for inspecting flat plates, curved pipes of various diameters, and complex geometries by simply changing its bending configuration rather than manufacturing different custom probes. This multi-functional design dramatically reduces manufacturing lead time while maintaining adaptability.
Solution Approach 2:
The probe adapts to different geometries by changing physical parameters such as the bending radius, curvature, and angular orientation of the flexible substrate. Rather than manufacturing different probes, the system varies these parameters to match the test object geometry, enabling rapid adaptation without additional manufacturing time.
3Adaptability or versatility
If a two-part detachable wedge is used for flexible array inspection, then adaptability is improved, but device complexity and ease of operation worsen due to assembly requirements
Solution Approach 1:
The patent merges the wedge structure into a single integral piece rather than using two detachable parts. The flexible acoustic module is inserted into a slot within the monolithic wedge, which provides both support and shaping functions. This unified design eliminates the need for separate assembly and disassembly operations while maintaining the ability to inspect curved surfaces.
Solution Approach 2:
The flexible acoustic module is extracted as a separate insertable component that can be placed into the wedge slot without requiring the wedge itself to be disassembled. This allows the flexible module to be changed or replaced while the wedge remains intact, providing adaptability without increasing wedge structural complexity or requiring tool-based assembly.
4Measurement precision
If conventional ultrasonic probes are held perpendicular to the surface at every point, then measurement precision is maintained, but productivity decreases due to slow acquisition process
Solution Approach 1:
The flexible acoustic module can be dynamically positioned and oriented to maintain perpendicular beam propagation across complex surfaces. The module's flexibility allows it to conform to the surface geometry while the phased array electronics dynamically adjust the beam direction to remain perpendicular to the local surface, enabling rapid scanning without sacrificing measurement accuracy.
Solution Approach 2:
The patent replaces the mechanical approach of manually positioning rigid probes at each point with an electronic beam steering system. The phased array technology uses electronic delays and phase shifts to steer the ultrasonic beam perpendicular to the surface at multiple points simultaneously, dramatically increasing inspection speed while maintaining 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
Enables efficient, high-resolution inspections of complex shapes with reduced manufacturing costs and time, allowing the same probe to be used across various part shapes by forming the acoustic module into a shape that matches the test object surface.
Implementation Method 1
a flexible acoustic module comprising a flexible substrate and a plurality of piezoelectric elements mounted on the flexible substrate
Implementation Method 2
in which water is used as the coupling medium between the probe and the test object
Data Source
AI summary
Disclosed is an ultrasonic inspection probe assembly comprising a water wedge and a flexible probe array assembly having a flexible acoustic module. The wedge is machined to match a test surface to be inspected and is configured to shape the acoustic module so that the active surface of the acoustic module is parallel to the test surface. Different wedges may be machined to match different test surfaces, but the same flexible probe array assembly may be used for all such surfaces.