Matrix Phased Array Probe for Brazed Weld Inspection
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Solution Overview
Problem
Current nondestructive inspection methods for brazed joints require skilled operators and subjective data interpretation, making it difficult to reliably assess the quality of brazed joints, especially in complex geometries like electrical contacts, and lack automation for on-line inspection.
Innovation Solution
A matrix phased array system with a probe featuring ultrasonic transducer elements, a shaped tip to match specific joint geometries, and software for generating A-scans and color-coded C-scan images, allowing for automated, non-destructive evaluation of brazed welds without the need for skilled operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional acoustic inspection methods are used, then surface and internal information about weld joints can be obtained, but skilled operators and subjective data interpretation are required
Solution Approach 1:
The patent replaces traditional mechanical/acoustic inspection methods with electromagnetic imaging technology. The electromagnetic imaging system captures and processes signals to generate visual images of weld joints, eliminating the need for skilled operators to interpret acoustic data subjectively. The system automatically processes inspection data through image generation algorithms, transforming the inspection process from operator-dependent to system-automated while maintaining high measurement precision.
2Extent of automation
If traditional inspection methods are used, then weld joint quality can be assessed, but automated on-line inspection is not available
Solution Approach 1:
The electromagnetic imaging system performs self-service by automatically capturing, processing, and generating images of weld joints without human intervention. The system includes automated image generation algorithms that process inspection data and produce visual representations of weld quality. This self-service capability enables reliable automated on-line inspection while maintaining consistent inspection standards without relying on operator skill levels.
3Adaptability or versatility
If inspection of complex geometries like electrical contacts is performed, then quality assessment is needed, but strong geometry and edge effects make inspection difficult
Solution Approach 1:
The electromagnetic imaging system applies local quality by using specifically designed probes and inspection configurations tailored to different geometric features. The system can adjust its imaging parameters and probe positioning to accommodate various weld joint geometries, including complex shapes like electrical contacts. This localized approach optimizes the inspection process for each specific geometry, reducing the impact of edge effects and geometric complexities on inspection difficulty.
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
Enables reliable, automated inspection of brazed joints by generating visual images that indicate areas of lack of braze, improving the efficiency and accuracy of quality control without requiring skilled operators, and accommodating various joint geometries.
Implementation Method 1
a plurality of ultrasonic transducer elements, arranged in an array at one end of the probe, that are operative to both generate ultrasonic signals and to receive reflections thereof
Data Source
AI summary
A system for non-destructively inspecting brazed joints that includes at least one matrix phased array probe that further includes plurality of ultrasonic transducer elements arranged in an array at one end of the probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections thereof; and at least one tip adapted to be removably mounted over the array of ultrasonic transducer elements, wherein a region of the at least one tip has been shaped to correspond to the geometric characteristics of an item or a specific portion of an item that includes a brazed joint to be inspected; and a processor running software that includes at least one imaging algorithm for processing data received from the at least one matrix phased array probe and generating color coded ultrasonic C-scan images of inspected brazed joints.