Portable Matrix Phased Array Probe for Spot Weld Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current nondestructive testing methods for assessing weld joint quality, particularly resistance spot welds, require skilled operators and are subjective, making it difficult to reliably identify poor-quality joints without human intervention.
Innovation Solution
A portable system equipped with a matrix phased array probe featuring a curved array of ultrasonic transducer elements, a flexible membrane, and a fluid-filled chamber, coupled with a hand-held body containing ultrasonic phased array circuitry, a touch screen computer, and imaging software to generate real-time color-coded C-scan images, allowing for objective characterization of welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If acoustic methods are used for nondestructive testing of weld joints, then both surface and internal information can be obtained with deeper penetration and higher sensitivity, but the requirement for skillful operators and subjective interpretation of data increases
Solution Approach 1:
The patent replaces manual acoustic inspection methods with an automated ultrasonic phased array system that uses computer-controlled transducer arrays and digital signal processing. The mechanical/manual operation of traditional acoustic testing is substituted with automated electronic beam steering and focal law implementation, eliminating the need for skilled operators to manually manipulate testing devices and interpret acoustic data subjectively.
Solution Approach 2:
The system implements automated feedback through real-time processing of ultrasonic signals and generation of visual images (such as S-scans and C-scans) that objectively display weld quality. The feedback loop includes automated defect detection algorithms that analyze ultrasonic echo patterns and provide objective assessments of weld integrity, replacing subjective human interpretation with algorithm-driven decision-making.
2Reliability
If traditional nondestructive testing methods are used, then operator involvement is required for data analysis, but this increases the subjectivity and reduces reliability of identifying poor quality joints
Solution Approach 1:
The patent replaces human operator analysis with automated computer-based ultrasonic phased array processing. The mechanical system of manual inspection and interpretation is substituted with electronic signal processing, automated image generation, and algorithm-based defect identification, thereby eliminating subjectivity and improving reliability of weld quality assessment.
Solution Approach 2:
The system performs self-service through automated data acquisition, processing, and interpretation capabilities built into the ultrasonic phased array system. The equipment automatically adjusts testing parameters, processes ultrasonic signals in real-time, generates visual representations of weld internal structure, and identifies defects without requiring external operator intervention for analysis, thereby achieving objective and reliable quality assessment.
3Measurement precision
If a matrix phased array probe with curved array and flexible membrane is used, then the probe can conform to contoured surfaces and transfer sound energy effectively, but the device complexity increases
Solution Approach 1:
The patent applies curvature to the transducer array by arranging ultrasonic elements in a curved or arc-shaped configuration rather than a flat array. This curved geometry allows the probe to conform to contoured weld surfaces, maintaining optimal acoustic coupling and sound energy transfer efficiency across curved inspection areas, thereby improving measurement precision without requiring multiple rigid probes.
Solution Approach 2:
The system employs a flexible membrane or thin film coupling layer between the transducer array and the weld surface. This flexible interface allows the rigid transducer elements to maintain their precise geometric arrangement while adapting to contoured surfaces through the compliant membrane, enabling effective sound energy transfer across curved geometries without increasing the complexity of the transducer array itself.
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 non-destructive, objective assessment of weld quality by providing accurate, real-time imaging of welds, reducing the need for skilled operators and improving the reliability of identifying stuck or cold welds, thereby enhancing quality control in manufacturing processes.
Implementation Method 1
a plurality of ultrasonic transducer elements arranged in a curved array at one end of the probe that are operative to both generate ultrasonic signals and to receive reflections
Implementation Method 2
a combination of materials for allowing the probe to conform to a contoured surface of the spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions, wherein the combination of materials further includes a flexible membrane mounted on the end of the probe and a fluid filled chamber or solid sound delay material disposed between the membrane and the array
Data Source
AI summary
A portable system for non-destructively characterizing spot welds that includes at least one matrix phased array probe and a body, wherein the body is designed to be hand-held and further includes an ergonomically designed outer casing; at least one input for connecting to the at least one matrix phased array probe; ultrasonic phased array transmitting and receiving circuitry in electrical communication with the at least one input; a touch screen computer that further includes at least one data processor running software that includes at least one imaging algorithm for processing data received from the probe and generating color coded ultrasonic C-scan images of characterized welds; and at least one monitor for displaying the color coded ultrasonic C-scan images of the characterized welds in real time.