Linear Ultrasonic Array Toppler for Variable Radius Inspection
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Solution Overview
Problem
Conventional ultrasonic inspection methods fail to reliably inspect soft-tooled composite structures with varying radii due to difficulties in maintaining a perpendicular sound path, leading to inadequate inspection rates that cannot meet production requirements.
Innovation Solution
A scanning system that uses a linear ultrasonic array oriented lengthwise down the radius, combined with rotational and translational motions, to maintain normal sound entry and adjust to the changing shape of the radius, ensuring consistent perpendicularity and high inspection rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed position sensor array is used to maintain 90-degree sound entry angle, then inspection reliability is improved for known surfaces, but adaptability to varying radius shapes deteriorates
Solution Approach 1:
The sensor array is mounted on a movable carriage that can translate along the radius and rotate to adjust its orientation. This dynamic positioning system allows the sensor to maintain 90-degree sound entry angles on surfaces with varying radius shapes, resolving the contradiction between inspection reliability and adaptability.
Solution Approach 2:
The system incorporates sensors to detect the actual surface geometry and adjusts the carriage position and sensor orientation accordingly. This feedback mechanism ensures the sound beam remains perpendicular to the surface despite variations in radius shape, maintaining both reliability and adaptability.
2Device complexity
If traditional ultrasonic inspection methods are used, then device complexity is reduced, but inspection rate deteriorates due to inability to maintain perpendicular sound path
Solution Approach 1:
The movable carriage system with rotational and translational capabilities enables traditional ultrasonic sensors to operate effectively on varying surfaces. This dynamic mounting allows the sensor to maintain proper orientation while moving along the radius, achieving high inspection rates without requiring fundamentally complex new sensor technology.
3Productivity
If inspection rate is increased to meet production requirements, then productivity is improved, but measurement precision deteriorates due to inability to maintain normal sound entry
Solution Approach 1:
The dynamically positioned carriage system maintains 90-degree sound entry angles even during high-speed inspection by continuously adjusting sensor orientation relative to the surface normal. This enables both high productivity and measurement precision to coexist.
Solution Approach 2:
Real-time feedback from surface detection sensors allows the system to maintain precise perpendicular orientation during rapid movement along the radius, ensuring measurement precision is preserved even at high inspection rates.
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 system enables efficient and reliable inspection of soft-tooled composite structures by maintaining normal sound entry and covering the entire radius at a high area coverage rate, meeting production inspection requirements.
Implementation Method 1
a linear ultrasonic transducer array (also referred to herein as a 'sensor') is oriented lengthwise down the length of the radius and is mechanically pressed into the 'as inspected' radius at 90 degrees so that sound entering the radius will enter normal to the front surface of the radius
Data Source
AI summary
Method and apparatus for enabling ultrasonic inspection of a changing, insufficiently defined or unknown shape (e.g., a variable radius or a noncircular radius caused by the use of soft tooling) at a rate that meets production requirements. The apparatus comprises a linear ultrasonic array (i.e., sensor) incorporated in a toppler, which in turn is slidably supported by an oscillating sensor mechanism carried by a traveling trailer vehicle. As a result of this arrangement, the sensor can undergo a back-and-forth sweeping motion coupled with motion along the spar radius. The sensor is further able to displace radially relative to a sweep pivot axis and rotate (hereinafter “topple”) about a topple pivot axis. In this manner, the orientation of the sensor can adjust to the contour of the inspected surface as the sensor scans.