Free-Hand Ultrasonic Array With Inertial Positioning
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Solution Overview
Problem
Conventional non-destructive inspection methods, such as X-Y scanners and hand-held probes, are time-consuming, costly, and difficult to use on complex or curved surfaces, particularly when inspecting structures like aircraft wings, and often produce low-quality images.
Innovation Solution
A free-hand inspection apparatus comprising an array of elements and an inertial sensor that measures acceleration and angular rotation, allowing for rapid, low-cost, and versatile non-destructive inspection by correlating inspection data with determined positions and orientations of the array relative to the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single element is scanned across the surface of the structure, then inspection coverage is achieved, but inspection time becomes substantial
Solution Approach 1:
The patent divides the inspection function into multiple independent elements arranged in an array, allowing simultaneous inspection of multiple locations rather than sequential scanning of a single element. This segmentation enables parallel data collection across the structure surface.
Solution Approach 2:
The patent transitions from one-dimensional sequential scanning to two-dimensional array-based simultaneous measurement by adding spatial distribution of multiple elements. This dimensional change allows coverage of the entire inspection area at once rather than point-by-point.
2Measurement precision
If expensive and sophisticated X-Y scanners are used, then C-scan images are produced, but device complexity increases
Solution Approach 1:
The patent extracts the positioning function from complex mechanical X-Y scanners and replaces it with inertial sensors that independently measure position and orientation. This separation eliminates the need for sophisticated mechanical scanning systems while maintaining positioning accuracy.
Solution Approach 2:
The patent replaces mechanical X-Y scanner systems with an array of sensors and inertial measurement units. This substitution transitions from mechanical positioning to sensor-based positioning, significantly reducing device complexity while maintaining inspection capability.
3Ease of operation
If hand-held devices with encoder wheels are used, then portability is maintained, but image quality becomes low
Solution Approach 1:
The patent merges multiple sensor types (inertial sensors, position sensors, and inspection elements) into a single integrated hand-held device. This combination allows the device to maintain portability while achieving high image quality through sophisticated multi-sensor data fusion and correlation.
4Measurement precision
If X-Y bridges are mounted to the surface, then better images are produced, but setup time becomes significant
Solution Approach 1:
The patent enables the inspection device to determine its own position and orientation autonomously using inertial sensors and position sensors, eliminating the need for pre-mounted X-Y bridges or external positioning infrastructure. The device is self-sufficient in positioning itself relative to the structure being inspected.
5Measurement precision
If X-Y bridges are used for manual scanning, then inspection accuracy is improved, but operation becomes time-consuming
Solution Approach 1:
The patent enables continuous inspection across the entire structure surface simultaneously using the array of elements, rather than sequential point-by-point scanning. This continuous parallel measurement maintains high accuracy while dramatically reducing total inspection time.
6Measurement precision
If X-Y bridges are used, then inspection precision is improved, but usability on complex curvatures becomes problematic
Solution Approach 1:
The patent uses dynamic inertial sensors that continuously measure acceleration and angular rotation to adapt to any surface geometry in real-time. This dynamic positioning system can accommodate complex curvatures and varying surface orientations that rigid X-Y bridges cannot handle.
Solution Approach 2:
The patent changes the positioning parameters from fixed mechanical coordinates to dynamic inertial measurements including acceleration and angular rotation. This parameter transformation allows the system to adapt to any surface geometry by continuously updating position and orientation data.
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 rapid collection of high-quality two-dimensional or three-dimensional inspection data without the need for complex mounting or repetitive motion, reducing costs and improving inspection efficiency on various structures, including those with complex curvatures.
Implementation Method 1
The inertial sensor may be for measuring acceleration and angular rotation rate in X, Y, and Z directions of the array
Implementation Method 2
The array may comprise a plurality of elements for transmitting and receiving inspection signals towards and from a structure being inspected
Implementation Method 3
produce C-scan images of ultrasonic or eddy current data of the structure being inspected
Data Source
AI summary
A free-hand inspection apparatus for non-destructively inspecting a structure includes an array and an inertial sensor. The array includes a plurality of elements for transmitting and receiving inspection signals towards and from a structure being inspected. The inertial sensor measures acceleration and angular rotation rate in X, Y, and Z directions of the array.