Multi-Sensor NDI Instrument with Shared Data Acquisition
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Solution Overview
Problem
Current non-destructive inspection (NDI) instruments are often bulky, costly, and require multiple units for different sensor technologies, making them impractical for time-critical inspections, especially in remote or hard-to-reach locations, due to the lack of shared data acquisition and processing elements and high power consumption.
Innovation Solution
A compact, economical NDI instrument that integrates multiple sensor technologies, such as eddy current, acoustic bond testing, ultrasonic flaw detection, and magneto-acoustic corrosion measurement, using common hardware, software, and mechanical parts to minimize size, weight, and cost, with a user-friendly interface and automatic sensor recognition for seamless switching between technologies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate NDI instruments are used for different sensor technologies, then each instrument can be optimized for its specific function, but the overall system becomes bulky, heavy, and requires multiple units to be carried
Solution Approach 1:
The patent combines multiple NDI technologies (ultrasonic, acoustic bond, eddy current, magneto-acoustic) into a single integrated instrument housing, merging previously separate instruments into one unified device that can perform all inspection functions
Solution Approach 2:
The instrument is designed with universal multi-functionality, allowing a single device to operate with multiple types of sensors and perform various NDI functions through software configuration and sensor recognition, eliminating the need for multiple specialized instruments
2Adaptability or versatility
If multiple separate NDI instruments are maintained for different inspection technologies, then each technology can be performed with dedicated equipment, but the cost of acquiring and maintaining multiple instruments becomes prohibitive
Solution Approach 1:
The instrument employs universal hardware and software architecture that can accommodate multiple NDI technologies, reducing manufacturing costs by eliminating the need to produce and maintain separate dedicated instruments for each inspection type
3Adaptability or versatility
If multiple NDI instruments are carried to remote inspection sites, then all inspection needs can be met, but the logistical burden of transporting multiple heavy units to hard-to-reach locations becomes impractical
Solution Approach 1:
By merging multiple NDI technologies into one portable instrument, the system becomes feasible for transport to remote and difficult-to-access inspection sites, improving ease of operation in field conditions
4Measurement precision
If conventional separate NDI systems are used for each sensor type, then each system can be optimized for its specific sensor, but the data acquisition and processing requirements become complex and power-consuming
Solution Approach 1:
The instrument uses a universal data acquisition and processing system that can handle multiple sensor types, reducing power consumption by eliminating redundant processing capabilities while maintaining measurement precision through software configuration and automatic sensor recognition
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
The solution provides a versatile, lightweight, and cost-effective NDI instrument that can switch between multiple sensor technologies while maintaining calibration integrity, reducing the need for multiple instruments and enabling efficient operation in various inspection scenarios.
Implementation Method 1
eddy current instruments to detect cracks in metal surfaces of airplanes
Implementation Method 2
ultrasonic instruments to measure pipe and vessel wall conditions and detect flaws
Implementation Method 3
acoustic bond testing instruments to detect the composite material delamination
Data Source
AI summary
A non-destructive inspection (NDI) instrument includes a sensor connection system configured to receive test signals from at least two different types of NDI sensors which are configured to obtain test signals from an object being tested. The sensor connection system has sensor-specific connection circuits and at least one common sensor connection circuit. A data acquisition circuitry is coupled to the sensor connection and has sensor-specific data acquisition circuits and at least one common data acquisition circuit. It is further coupled to a common digital data processor which executes sensor-specific processing modules and at least one common processing module. A common display screen and user interface is coupled to the data processor and enables programs including sensor-specific user interface modules and at least one common user interface module. The sensor types preferably include all of or any combination of an ultrasound sensor, an eddy current sensor and acoustic sensor.