Flexible Ultrasound Probe for Complex Geometry Inspection
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Solution Overview
Problem
Existing non-destructive ultrasonic testing techniques face challenges in efficiently inspecting plastic components with complex geometries and small radii of curvature, requiring movement of sensors and generating large amounts of data for visualization, while also posing risks from liquid coupling agents.
Innovation Solution
A conformable device with a flexible envelope containing multiple ultrasonic translator strips sealed in compartments filled with coupling agent, allowing for static positioning and dry inspection without chemical interactions, and enabling the use of advanced techniques like TFM-FMC for improved precision and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid ultrasonic coupling agent is used for conventional ultrasonic testing, then ultrasonic wave transmission is improved, but chemical interaction risks and cleaning requirements increase
Solution Approach 1:
The patent uses a flexible envelope filled with liquid coupling agent as an intermediary between the ultrasonic translators and the workpiece. The envelope makes contact with the workpiece surface while containing the coupling agent, enabling ultrasonic wave transmission without direct chemical contact between the coupling agent and the inspected component.
Solution Approach 2:
The patent employs a flexible envelope (shell) to contain the liquid coupling agent. This flexible shell conforms to the workpiece surface geometry and transmits ultrasonic waves while preventing direct chemical interaction between the coupling agent and the inspected material.
2Adaptability or versatility
If sensors are moved to cover complex geometries with small radii of curvature, then inspection coverage is improved, but inspection time and data complexity increase
Solution Approach 1:
The patent divides the inspection system into multiple ultrasonic translator strips arranged in a matrix configuration within the flexible envelope. Each strip can be independently controlled, allowing simultaneous inspection of multiple areas and eliminating the need to move the entire device for complex geometries.
Solution Approach 2:
The patent transitions from linear array translation to a two-dimensional matrix arrangement of ultrasonic translator strips. This dimensional change enables coverage of complex surfaces without mechanical movement, as the strips can be selectively activated based on their spatial positions in the matrix.
3Productivity
If phased array ultrasonic technique is used to reduce probe movement, then inspection efficiency is improved, but device complexity and data processing requirements increase
Solution Approach 1:
The patent segments the ultrasonic inspection system into multiple independent translator strips arranged in a matrix, where each strip functions as an independent phased array element. This segmentation enables efficient inspection of complex geometries while distributing the computational load across multiple channels.
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 complete and immediate control of complex shapes without moving the device, reducing data complexity and avoiding chemical risks, while providing increased precision and flexibility in ultrasound capture and measurement results.
Implementation Method 1
a flexible envelope provided with a plurality of compartments sealed with a liquid ultrasonic coupling agent and in each of at least two of the compartments, a strip of ultrasonic translators immersed, on at least one face, in said ultrasonic coupling agent
Implementation Method 2
sealed with a liquid ultrasonic coupling agent
Data Source
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Figure 9~11
AI summary
The adaptable instantaneous non-destructive test device (20) using ultrasound for testing at least one solid workpiece comprises: - a flexible covering (21) provided with a plurality of compartments (22, 23, 24, 25), which are sealed with respect to an ultrasound coupling agent; - in each of at least two of the compartments, an array (26, 27, 28, 29) of ultrasonic transducers is immersed, at least on one face, in the ultrasound coupling agent; - a means (35) for sequencing the transmission and/or reception operations of at least two of the arrays of ultrasonic transducers; - and a means (35) for processing the signals that represent the ultrasonic waves received by at least two of the arrays, in order to constitute a representation aggregating the representations of the exploration fields of the arrays.