Matrix Array Probe Ultrasonic Flaw Detection for Welded Steel Pipe
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Solution Overview
Problem
The vertical incidence method for ultrasonic flaw detection in welded steel pipes is sensitive to changes in incidence angle and manual adjustments, leading to variability in defect detection sensitivity due to mechanical wobbling and operator errors, and has limited range and sensitivity at high refraction angles.
Innovation Solution
An ultrasonic flaw detection device using a matrix array probe with a wedge, where the probe transmits and receives ultrasonic waves focused in the pipe axis direction, and adjusts the refraction angle to optimize defect detection sensitivity by selecting the appropriate wedge for the closest desired refraction angle, reducing the impact of incidence angle changes and manual errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the vertical incidence method is used for ultrasonic flaw detection, then the defect detection sensitivity is improved, but the detection sensitivity becomes sensitive to changes in incidence angle due to mechanical wobbling and operator adjustments
Solution Approach 1:
The patent applies dynamics by making the probe assembly movable and adjustable along the pipe surface. The probe can be dynamically positioned and angled to achieve optimal ultrasonic wave incidence on planar defects, allowing adaptation to different defect locations and orientations while maintaining stable detection sensitivity through controlled movement rather than fixed positioning
Solution Approach 2:
The patent changes the incidence angle parameter of ultrasonic waves by adjusting the probe's angular position. By varying the incidence angle within a specific range, the system can optimize detection sensitivity for different defect orientations and positions, reducing the adverse effects of mechanical wobbling and operator adjustment variations
2Measurement precision
If the tandem probe method is used for defect detection, then the S/N ratio is improved and planar defects can be detected sensitively, but the setting work becomes complicated due to the need to adjust angles and positions of multiple probes
Solution Approach 1:
The patent segments the ultrasonic detection function into multiple independent probes arranged in a specific configuration. Each probe can be independently positioned and angled, allowing flexible adjustment to achieve optimal detection conditions while simplifying the overall setting process through modular arrangement rather than requiring complex coordinated adjustment of probe pairs
Solution Approach 2:
The patent creates a multi-functional probe system that can detect various types of defects (planar defects, volumetric defects, defects at different positions) using a single configured probe assembly. The probes are arranged to perform multiple detection functions simultaneously, eliminating the need for separate angle and position adjustments required by traditional tandem probe methods
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 enhances defect detection sensitivity by at least 12 dB at high refraction angles and reduces variability, providing a wider detection range and improved quality control for welded steel pipes by stabilizing the defect detection sensitivity.
Implementation Method 1
transmitting ultrasonic waves focused in a pipe axis direction to a welding root surface
Implementation Method 2
adjusts a refraction angle of ultrasonic waves in a predetermined angle range around a predetermined center angle
Implementation Method 3
receive ultrasonic waves reflected at the welding root surface
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An ultrasonic flaw detection device 1 includes: a matrix array probe 2 that is arranged, via a wedge 3, at a position on a outer peripheral surface of a welded steel pipe S, the position enabling ultrasonic waves to be vertically incident on a welding root surface, transmits ultrasonic waves focused in a pipe axis direction, to the welding root surface, and receives ultrasonic waves reflected at the welding root surface; an ultrasonic wave transmitting and receiving unit 4 that controls the matrix array probe 2 such that the matrix array probe 2 receives the reflected ultrasonic waves reflected at the welding root surface; and an evaluation unit 5 that detects a planar defect based on the reflected ultrasonic waves received by the ultrasonic wave transmitting and receiving unit 4.