Modular Ultrasonic Transducer Assembly for Restricted Weld Access
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Solution Overview
Problem
Existing ultrasonic detectors for weld joints in pipework are inconveniently sized, often leaving areas unassessed due to space restrictions from bolt heads, and require cumbersome replacement processes that can lead to inaccuracies.
Innovation Solution
A transducer assembly with integrated transmitter and receiver modules, each comprising a single transducer element securely attached to a wedge portion, allowing for compact design and easy replacement without repositioning, and featuring a couplant delivery system for efficient sound transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional ultrasonic detectors are used with separate transducer elements and wedges, then the detection capability is adequate, but the device size becomes too large for restricted access spaces around pipe bolt heads
Solution Approach 1:
The patent merges the transducer element and wedge into a single integrated module, eliminating the need for separate components. This integration reduces the overall detector size while maintaining the complete detection capability, allowing access to restricted spaces around pipe bolt heads that were previously inaccessible to larger separate-component detectors.
2Ease of repair
If transducer elements are separately mounted in wedges, then replacement is possible, but the replacement process is cumbersome and may lead to repositioning inaccuracies
Solution Approach 1:
By integrating the transducer element permanently with the wedge into a single pre-positioned module, the patent eliminates the need for field replacement while ensuring precise positioning. The module is designed to be replaced as a complete unit, which maintains manufacturing precision and simplifies the replacement process to merely swapping the entire module rather than re-mounting separate components.
Solution Approach 2:
The patent segments the detector into multiple replaceable modules, each containing a transducer element and wedge as an integrated unit. This modular segmentation allows individual modules to be replaced independently without affecting other parts of the detector, improving ease of repair while maintaining positioning accuracy through pre-integrated design.
3Ease of operation
If manual transducer replacement is performed in restricted spaces, then sensor replacement is possible, but the operation becomes inconvenient and time-consuming
Solution Approach 1:
The detector is divided into modular segments where each transducer assembly can be independently replaced. This segmentation allows technicians to replace individual modules in restricted spaces without manipulating multiple separate components, significantly reducing replacement time and improving ease of operation in challenging environments.
Solution Approach 2:
By combining the transducer element and wedge into a single integrated module, the patent reduces the number of manual assembly steps required during replacement. The merged module can be installed as a single unit, eliminating time-consuming alignment and fastening operations that would be required with separate components.
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 complete assessment of weld joints in restricted spaces with improved accuracy and convenience by eliminating the need for manual sensor replacement and ensuring consistent detection, even in challenging environments.
Implementation Method 1
ultrasonic pulse-waves with centre frequencies ranging from 0.1-15 MHz... are transmitted into materials to detect internal flaws
Implementation Method 2
time-of-flight diffraction detectors use the time of flight of the ultrasonic pulse to determine the position and size of the crack defect
Implementation Method 3
time-of-flight diffraction techniques to assess the quality of joints between two parts
Data Source
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AI summary
A transducer assembly for use in determining a health state of a joint (45) between first and second joined parts (42, 44); the transducer assembly comprising a transducer module (50) comprising a transducer element (100) for transmitting or receiving an ultrasonic signal to or from, respectively, the joint, and a mounting part (52) comprising an internal wedge portion (70), formed integrally with the mounting part (52), to which the transducer element (100) is fixed permanently so that the transducer module forms a unitary replaceable module.