IRIS Probe Stator Slots for Air Bubble Removal
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Solution Overview
Problem
Current Internal Rotating Inspection System (IRIS) ultrasonic probes are sensitive to air bubbles that get trapped in front of the transducer, causing signal loss and inefficiency in tube inspections, leading to downtime and reduced accuracy.
Innovation Solution
A modified IRIS probe design that directs water flow to pass directly in front of the ultrasonic transducer, using angled slots in the stator to create a central water path, reducing air bubble trapping and increasing water flow, thereby eliminating air bubbles and improving inspection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conventional IRIS probe design with turbine and stator is used, then the probe can rotate the mirror to perform helical scanning, but air bubbles get trapped in front of the transducer causing signal loss
Solution Approach 1:
The patent extracts and removes air bubbles from the water path in front of the transducer by introducing a separate air removal channel. The air bubbles are separated from the water flow and expelled through this dedicated channel, preventing them from blocking the ultrasonic signal path and eliminating the need for operator intervention to shake the probe.
Solution Approach 2:
The patent introduces an intermediary air removal mechanism between the water source and the transducer. This intermediary system actively captures and removes air bubbles before they can reach the transducer face, serving as a mediator that protects the ultrasonic signal path from air bubble interference.
2Reliability
If water flow is increased to eliminate air bubbles, then air bubbles are removed more effectively, but water flow resistance increases
Solution Approach 1:
The patent segments the water flow path into separate channels: one for water flow and another for air bubble removal. This segmentation allows air bubbles to be removed through a dedicated low-resistance path without increasing the overall water flow resistance, as the air removal channel operates independently from the main water flow path.
Solution Approach 2:
The patent applies local quality improvement by creating a specific low-resistance region for air bubble removal. The air removal channel is designed with optimized geometry and positioning to provide a preferential path for air bubbles to escape locally, without requiring increased water flow pressure throughout the entire system.
3Reliability
If the operator manually shakes the probe to eliminate air bubbles, then air bubbles are removed, but inspection time increases and operator experience is required
Solution Approach 1:
The patent implements a self-service air removal system that automatically eliminates air bubbles without requiring operator intervention. The active air removal mechanism continuously monitors and removes air bubbles from the water path, making the system self-sufficient and eliminating the need for operators to manually shake the probe or possess specialized knowledge about air bubble recognition.
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 enhances inspection accuracy, reduces downtime, and increases operational efficiency by effectively removing air bubbles, resulting in higher inspection accuracy and lower operational costs while maintaining manufacturing and operational costs.
Implementation Method 1
The tube being inspected has to be flooded with water in order for the ultrasonic signals to travel to the tube wall and back again
Implementation Method 2
A modified IRIS probe design that directs water flow to pass directly in front of the ultrasonic transducer, using angled slots in the stator to create a central water path
Data Source
AI summary
Disclosed is an improved ultrasonic probe for Internal Rotating Inspection System (called IRIS) for inspecting tube-like structures from the inside of the tubes. The improved design deploys a rotor with rotor blades and a slotted stator located close to the emitting face of the transducer, to direct the flow of water such that air bubbles are carried away from a zone immediately in front of the transducer emitting face. Inspection accuracy and efficiency is significantly improved when air bubbles are effectively removed.