Mirror Connecting Unit for Industrial Ultrasonic Testing Alignment
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Solution Overview
Problem
Industrial Ultrasonic Testing (UT) systems require manual alignment of mirrors and probes each time a mirror is assembled, leading to inefficiencies and the need for duplicate probes for direct and angled inspections.
Innovation Solution
A connecting unit for UT systems that includes a probe side adjustable unit with a first connector and an alignment element, and a mirror side unit with a second connector and a locking element, allowing for quick and automatic alignment of the US beam with the mirror surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment of mirror and probe is performed each time a mirror is assembled, then alignment accuracy can be achieved, but time consumption and operational complexity increase significantly
Solution Approach 1:
The alignment element is pre-adjusted to a predetermined location on the probe side unit before assembly with the mirror. This preliminary positioning ensures that when the mirror and probe are connected, the alignment is automatically established without requiring manual adjustment during assembly, thus maintaining alignment accuracy while reducing time consumption
Solution Approach 2:
The connecting unit is designed with self-aligning features where the pre-adjusted alignment element on the probe side automatically interfaces with the mirror side unit. The system self-aligns through the mechanical connection of these elements, eliminating the need for external manual alignment operations while preserving measurement precision
2Adaptability or versatility
If duplicate probes are used for direct and angled inspections, then inspection versatility is improved, but system cost and complexity increase
Solution Approach 1:
The connecting unit enables a single probe to perform multiple inspection functions by allowing interchangeable attachment of different mirrors with varying angles. The standardized connecting unit with alignment elements provides universal compatibility, enabling one probe to serve multiple purposes that previously required duplicate specialized probes, thus reducing system complexity while maintaining versatility
Solution Approach 2:
The system transitions from a static configuration requiring fixed duplicate probes for different inspection angles to a dynamic system where mirrors can be interchangeably attached and detached. The adjustable and lockable connecting unit enables the probe assembly to adapt its inspection angle dynamically by swapping mirrors, reducing the need for multiple permanent probe configurations
3Adaptability or versatility
If adjustable alignment element is implemented on probe side, then alignment flexibility is improved, but device complexity increases
Solution Approach 1:
The connecting unit is segmented into distinct functional components: the probe side unit with the adjustable alignment element, and the mirror side unit with the locking element. This segmentation allows the alignment functionality to be isolated to a specific component, making the adjustment mechanism more manageable and less complex than integrating all alignment features into a single monolithic structure
Solution Approach 2:
The alignment element acts as an intermediary component between the probe and mirror assembly. It provides the necessary alignment functionality by interfacing with the locking element on the mirror side, mediating the connection and alignment process without requiring complex integrated systems. This intermediary approach simplifies the overall device complexity while maintaining alignment flexibility
Data Source
AI summary
An industrial ultrasound (US) system is disclosed. The US system comprising: at least one US probe; at least one mirror; and at least one connecting unit comprising: a probe side adjustable unit comprising a first connector connectable to a US probe and an alignment element, wherein a location of the alignment element is adjustable with respect to the US prob; and a mirror side unit comprising a second connector connectable to a mirror and locking element located at a fixed position with respect to a reflecting surface of the mirror. In some embodiments, the alignment element is configured to be locked by the locking element, to secure a fixed relation between a direction of a US beam emitted from the probe and the reflecting surface of the mirror.