Multi-layer Ultrasonic Transducers for Composite Inspection
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Solution Overview
Problem
Current ultrasonic imaging equipment for detecting inconsistencies in composite parts is complex and expensive, limiting its accessibility for effective inspection in mission-critical applications.
Innovation Solution
The use of multiple layers of transducers, each rotated at different angles, allows for precise determination of the ultrasonic wave's location upon reflection by intersecting transducers in different layers, enabling effective and affordable ultrasonic imaging systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current ultrasonic imaging equipment is used to detect inconsistencies in composite parts, then detection capability is achieved, but device complexity and cost increase
Solution Approach 1:
The ultrasonic imaging system is segmented into multiple independent planar layers, each containing a grid of transducers. Each layer can be independently configured and rotated to different angles, allowing the system to achieve comprehensive detection capability through modular segmentation rather than a single complex monolithic structure.
Solution Approach 2:
The patent transitions from traditional single-plane or simple array transducer configurations to a multi-layer three-dimensional arrangement. By stacking multiple planar layers and rotating them at different angles, the system adds spatial dimensions to the detection capability, enabling precise localization of inconsistencies through triangulation from multiple viewing angles.
2Measurement precision
If current ultrasonic imaging equipment is used to detect inconsistencies in composite parts, then detection capability is achieved, but cost increases
Solution Approach 1:
The system divides the imaging function into multiple independent planar layers that can be manufactured separately using standard transducer fabrication processes. This segmentation allows for easier manufacturing and assembly compared to building a single complex imaging system, thereby reducing overall cost while maintaining detection capability.
Solution Approach 2:
Each planar layer serves multiple functions: it can act as both a transmitting and receiving array, and by rotating layers to different angles, the same physical transducers can detect inconsistencies from multiple orientations. This multi-functionality reduces the total number of transducers needed compared to traditional systems, lowering cost.
3Measurement precision
If multiple layers of transducers are used to pinpoint ultrasonic wave location, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent uses multiple planar layers rotated at different angles to create a three-dimensional transducer arrangement. This dimensional approach enables precise location determination through geometric intersection of detection paths, achieving high measurement precision while maintaining a relatively simple modular structure compared to more complex phased array systems.
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 configuration enhances the ability to pinpoint and quantify inconsistencies within composite parts, providing detailed maps of inconsistencies and reducing the complexity and cost of ultrasonic imaging systems.
Implementation Method 1
transmitting an ultrasonic wave via a transmitting ultrasonic transducer
Implementation Method 2
detecting a returning ultrasonic wave at a receiving ultrasonic transducer
Implementation Method 3
ultrasonic transducers that are each configured to conduct electricity across their length
Data Source
AI summary
Systems and methods for multi-layer ultrasonic imaging are provided. One embodiment is an apparatus that includes linear ultrasonic transducers that are each configured to conduct electricity across their length. The apparatus includes a first planar layer that comprises a first set of the transducers arranged in parallel. The apparatus also includes a second planar layer that comprises a second set of the transducers arranged in parallel, and that is oriented such that each transducer of the second set overlaps at least two transducers of the first set. Furthermore, the apparatus includes a third planar layer that comprises a third set of the transducers arranged in parallel, and that is oriented such that each transducer of the third set overlaps at least two transducers of the first set and at least two transducers of the second set.