Offset Transducer Wedge Assembly for Single-Pass Weld Inspection

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Solution Overview

Problem

Conventional transducer wedges for phased array ultrasonic testing are limited in steering capabilities, requiring multiple scans for full coverage and are time-consuming to position, leading to unwanted interactions between beam waves when inspecting welds in multiple directions.

Innovation Solution

A transducer wedge assembly with a central spacer wedge, preferably made of insulating materials like cork, is used to create an offset angle between two transducer wedges, allowing for reliable normal and transverse scanning in a single pass, enhancing the steering capabilities and reducing the need for multiple scans.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple transducer wedges are used to inspect welds in multiple directions, then the inspection coverage is improved, but the time required for positioning and the complexity of the scanning process increases

Engineering Contradiction:

Improveinspection coverageVSAvoidpositioning time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent combines multiple transducer wedges (first and second transducer wedges) into a single integrated assembly with a central spacer wedge, allowing simultaneous inspection of welds in multiple directions without requiring separate positioning operations for each wedge

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The transducer wedges are pre-positioned at specific angles (e.g., 15 degrees offset) relative to each other in the assembly, so that when the assembly is placed on the weld, the correct angular orientation is already established, eliminating the need for time-consuming field positioning

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If multiple transducer wedges are used to inspect welds in multiple directions, then the inspection coverage is improved, but the complexity of the scanning process increases

Engineering Contradiction:

Improveinspection coverageVSAvoidscanning process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges multiple transducer wedges into a single integrated assembly with a central spacer wedge, allowing simultaneous inspection of welds in multiple directions without requiring separate positioning operations for each wedge

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The transducer wedge assembly is designed to perform multiple inspection functions (normal and transverse scanning) simultaneously through a single placement operation, making the device multi-functional and reducing procedural complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If multiple transducer wedges are placed close together to inspect welds in multiple directions, then the inspection coverage is improved, but unwanted interactions between beam waves occur

Engineering Contradiction:

Improveinspection coverageVSAvoidbeam wave interactions

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The central spacer wedge acts as an intermediary element positioned between the first and second transducer wedges, physically separating them to prevent unwanted acoustic interactions between the ultrasonic beams while maintaining the required angular orientation for multi-directional inspection

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The central spacer wedge extracts or removes the harmful interaction between the two transducer wedges by introducing a physical barrier that prevents acoustic coupling while preserving the functional relationship between the wedges

Inventive Principle:

Principle #2Taking out (Extraction)

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 improved transducer wedge assembly enables efficient and accurate inspection of welds in both normal and transverse directions, reducing the time and complexity of scanning processes while minimizing unwanted interactions between beam waves.

Implementation Method 1

the back side of the spacer wedge producing an offset angle between the first transducer wedge and the second transducer wedge

Methodology Applied

Scientific EffectGeometric offset angle: Geometry

Implementation Method 2

the transducer generates high frequency ultrasonic energy. The sound energy is introduced and propagates through the materials in the form of waves

Methodology Applied

Scientific EffectUltrasonic wave propagation: Ultrasound

Implementation Method 3

The reflected wave signal is transformed into an electrical signal by the transducer

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS11986908B1System and apparatus for inspecting welds in normal and transverse directions

Publication Date: 2024.05.21 VALMONT INDUSTRIES INC

AI summary

The present invention includes an improved transducer wedge assembly for inspecting welds and other formations. According to a first preferred embodiment, the transducer wedge assembly includes a central spacer wedge fixed between a first transducer wedge and a second transducer wedge. The central spacer wedge is preferably formed from cork or other insulating material. Additionally, the central spacer wedge preferably includes a wave direction side and a back side, with the back side of the spacer wedge producing an offset angle between the first transducer wedge and the second transducer wedge.