Magnetostrictive Pipe Inspection System with High-Temperature Coupling
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Solution Overview
Problem
Current long-range guided wave pipe inspection systems face limitations in ease of use, cost, and operating temperature range, particularly in efficiently coupling magnetostrictive sensors to pipes across varying temperatures without disrupting functionality.
Innovation Solution
The system employs a segmented magnetostrictive collar with a tensioner mechanism for mechanical pressure coupling, utilizing a jacket assembly with inner and outer layers for even pressure distribution and high-temperature resistance, allowing for effective ultrasonic coupling and extended temperature operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional magnetostrictive sensor coupling methods are used, then the inspection system can operate at lower temperatures, but the coupling becomes disrupted at high temperatures reducing inspection effectiveness
Solution Approach 1:
The patent changes the physical state and properties of the coupling medium by using a high-temperature resistant gel compound that maintains its viscoelastic properties at elevated temperatures up to 500°F, allowing the magnetostrictive sensor to maintain reliable mechanical coupling with the pipe surface across a wide temperature range without disruption
Solution Approach 2:
The patent employs a composite coupling system combining the magnetostrictive sensor element, a high-temperature resistant gel compound, and a flexible collar assembly. The gel compound acts as a viscoelastic intermediary that maintains consistent mechanical contact and magnetic coupling efficiency across varying temperatures, enabling reliable operation from -40°F to 500°F
2Adaptability or versatility
If segmented collar design is used for guided wave inspection, then the inspection coverage and focusing capability improve, but the device complexity and cost increase
Solution Approach 1:
The patent divides the circumferential sensor array into multiple discrete segmented elements arranged around the pipe circumference. Each segment can be independently controlled to generate and receive guided waves, enabling synthetic focusing and improved inspection coverage while maintaining manageable complexity through modular design
Solution Approach 2:
The segmented collar assembly serves multiple functions: it provides mechanical support for the magnetostrictive sensors, applies uniform pressure distribution around the pipe circumference, enables both active and synthetic focusing of guided waves, and maintains coupling integrity across varying temperatures, thereby reducing the need for separate specialized components
3Reliability
If pressure coupling is applied to ensure good ultrasonic contact, then the coupling efficiency improves, but the mechanical stress on the sensor and pipe increases potentially causing damage
Solution Approach 1:
The patent employs a flexible viscoelastic gel compound that acts as a compliant intermediary between the magnetostrictive sensor and the pipe surface. This flexible coupling medium distributes mechanical pressure uniformly across the contact interface, ensuring good ultrasonic coupling efficiency while preventing localized stress concentrations that could damage the sensor or pipe
Solution Approach 2:
The high-temperature resistant gel compound serves as a viscoelastic intermediary material that transmits mechanical pressure and acoustic energy efficiently while protecting both the sensor element and pipe surface from direct mechanical stress. The gel's viscoelastic properties allow it to maintain consistent coupling pressure without causing damage
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 configuration enhances ease of use, reduces costs, and significantly extends the operating temperature range, enabling efficient and sensitive guided wave inspections across a wide temperature spectrum.
Implementation Method 1
The at least one magnetostrictive strip is configured to be induced with a bias magnetic field
Implementation Method 2
The plurality of coil circuits are configured to be disposed adjacent to the at least one magnetostrictive strip
Implementation Method 3
The tensioner is configured to provide a mechanical pressure coupling between said at least one magnetostrictive strip and said structure
Data Source
AI summary
A system for non-destructive inspection of a structure includes at least one magnetostrictive strip, a plurality of coil circuits, a jacket having at least one component layer, and a tensioner. The at least one magnetostrictive strip is configured to be induced with a bias magnetic field and be wrapped at least partially around an outer surface of the structure. The plurality of coil circuits are configured to be disposed adjacent to the at least one magnetostrictive strip, and the jacket is configured to be disposed adjacent to at least one of the plurality of coil circuits. The tensioner is configured to provide a mechanical pressure coupling between said at least one magnetostrictive strip and said structure. At least one of the plurality of coil circuits is individually controllable by a number of channels to at least one of excite or detect guided waves in said structure.