Fluid Chamber Bellows for Ultrasonic Inspection
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Solution Overview
Problem
Ultrasonic inspection methods face challenges with the use of gel or large water tanks, which are costly and inefficient, especially for inspecting structures with complex curvatures, leading to air gaps and poor data collection.
Innovation Solution
An inspection system with a fluid chamber using a bellows with a flexible lip to create a fluid coupling environment between a sensor array and a structure, allowing for fluid flow without the need for gel or large tanks, and featuring a corrugated skirt that conforms to curved surfaces to maintain contact and reduce fluid loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If gel is used as coupling medium for manual ultrasonic inspection, then inspection can be performed on complex curved surfaces, but cost increases and inspection time increases
Solution Approach 1:
The patent replaces manual application of gel with an automated fluid delivery system that uses a pump to deliver water through a nozzle to the inspection area, eliminating the need for manual gel application and removal while maintaining effective coupling on curved surfaces
Solution Approach 2:
The patent changes the coupling medium from gel to water, and delivers it in a controlled fluid stream rather than as a static layer, allowing for continuous inspection without the time-consuming steps of applying and removing gel
2Extent of automation
If large water tank is used for automated ultrasonic inspection, then entire structure can be submerged for inspection, but tank size and maintenance cost increase
Solution Approach 1:
The patent extracts the fluid coupling environment from a large tank setting and delivers it locally to the inspection area through a nozzle, providing automated inspection capability without requiring a large water tank
Solution Approach 2:
The patent introduces a fluid delivery nozzle as an intermediary that brings the coupling fluid directly to the inspection area, eliminating the need for a large tank while maintaining automated inspection capabilities
3Reliability
If gel is used as coupling medium, then ultrasonic inspection can be performed, but residual gel affects surface characteristics
Solution Approach 1:
The patent changes the coupling medium from gel to water, which does not leave residual material on the surface, eliminating the harmful effect of gel residue while maintaining inspection quality
Solution Approach 2:
The patent uses a continuous stream of water that flows away after use, rather than a reusable gel that remains on the surface, effectively disposing of the coupling medium without leaving residue
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 ultrasonic inspection of structures with complex curvatures without the need for gel or large tanks, reducing inspection time and improving data quality by maintaining a consistent fluid coupling environment.
Implementation Method 1
a fluid chamber configured to provide a fluid coupling environment between the sensor array and the surface of the structure
Implementation Method 2
In ultrasonic inspection, ultrasonic waves are sent through a coupling medium and into the surface of the structure
Data Source
AI summary
An inspection system comprises a sensor array and a fluid chamber. The fluid chamber is configured to provide a fluid coupling environment between the sensor array and a structure. The fluid chamber comprises a bellows having a first side and a second side opposite the first side, wherein the first side is a flexible lip.