Linear Phased Array Ultrasonic Defect Sizing
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Solution Overview
Problem
Existing methods for determining the size of defects in high-stress components, such as turbine components, are complex and costly, often requiring reduced transducer sizes or two-dimensional phased arrays to focus sound beams effectively.
Innovation Solution
A method and apparatus using a linear phased array of ultrasonic transducers to propagate a focused ultrasonic beam along a focal line, moving it across the defect to determine its dimension from reflections, with a control unit and processor to analyze the reflections and calculate the defect size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a two-dimensional phased array is used to focus the beam, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts only the essential functionality needed for defect sizing by using a one-dimensional linear phased array instead of a two-dimensional array. By removing unnecessary dimensions and components, the system achieves adequate measurement precision while significantly reducing device complexity and cost.
Solution Approach 2:
The patent applies local quality by concentrating the ultrasonic energy along a specific focal line rather than distributing it across a two-dimensional area. This localized focusing approach provides sufficient measurement precision for defect sizing while simplifying the transducer array configuration.
2Measurement precision
If the transducer size is reduced to focus the sound beam, then measurement precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces an intermediary approach by using software-based beam focusing through phased array signal processing rather than relying solely on physical transducer size reduction. This allows standard-sized transducers to achieve fine focus through electronic control, reducing manufacturing precision requirements while maintaining measurement precision.
Solution Approach 2:
The patent changes the operational parameters of the transducer array by using phased array signal processing to dynamically control beam focusing. This allows the system to achieve precise measurement without requiring extremely small or precisely manufactured individual transducers, as the focusing is achieved through timing and phase adjustments rather than physical dimensions.
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
This approach simplifies the process of defect sizing, providing accurate and cost-effective measurements of defect dimensions in components, enabling efficient inspection of turbine components and other high-stress materials.
Implementation Method 1
propagating a focused ultrasonic beam along a first focal line
Implementation Method 2
focused ultrasonic beam
Implementation Method 3
at least one reflection of the focused ultrasonic beam from the defect
Data Source
AI summary
A method and apparatus for determining a dimension of a defect in a component is disclosed. A linear array of acoustic transducers is used to propagate a focused ultrasonic beam along a first focal line. The focused ultrasonic beam is moved across the defect in a first array direction substantially perpendicular to the first focal line. The dimension of the defect is determined from at least one reflection of the focused ultrasonic beam from the defect as the focused ultrasonic beam moves across the defect.