PAUT Weld Inspection Visualization for Multi-Weld Reporting
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Solution Overview
Problem
Conventional phased array ultrasonic testing (PAUT) systems face challenges in efficiently inspecting multiple welds on a welded object, as they require tedious and time-consuming processes to generate and interpret ultrasound graphs and reports for each weld individually, making it difficult to manage large numbers of welds effectively.
Innovation Solution
A system comprising an engine with export, transformation, and merger modules, along with a graphical user interface (GUI), to generate graphical representations and compile data from PAUT inspections, allowing for the presentation of multiple weld inspection results in a comprehensive and intuitive format, including 2D and 3D images, and automated reporting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional PAUT systems inspect each weld individually and generate separate reports, then inspection thoroughness is maintained, but inspection time and operational complexity increase significantly
Solution Approach 1:
The patent combines multiple individual weld inspection results into a single comprehensive graphical representation. The system merges ultrasound images and data from multiple welds into one integrated display showing all weld locations with their respective flaw indications, allowing inspectors to evaluate multiple welds simultaneously rather than reviewing separate reports for each weld.
Solution Approach 2:
The patent transitions from two-dimensional individual ultrasound graphs to a three-dimensional graphical representation that displays multiple welds in spatial context. The 3D model shows the welded object's geometry with weld locations positioned in three-dimensional space, enabling inspectors to visualize flaw locations relative to the overall structure and navigate through different viewing angles.
2Loss of information
If conventional PAUT systems generate detailed reports for each weld, then comprehensive evaluation is achieved, but data processing complexity and time consumption increase
Solution Approach 1:
The patent extracts only the essential information needed for weld evaluation from the complete PAUT data set. The system identifies and displays relevant flaw indications, weld geometry, and critical measurements while omitting redundant data, presenting a streamlined view that maintains evaluation completeness without requiring processing of all raw inspection data.
Solution Approach 2:
The patent creates a universal graphical representation framework that can display multiple types of weld inspection data in a single integrated interface. The system handles different weld configurations, flaw types, and inspection parameters through a common visualization methodology, eliminating the need for separate processing routines for each weld type.
3Measurement precision
If conventional systems display traditional ultrasound graphs, then detailed flaw information is provided, but interpretability and ease of use decrease for non-experts
Solution Approach 1:
The patent creates visual copies of flaw indications that represent complex ultrasound data in simplified graphical forms. Instead of displaying raw waveform data requiring expert interpretation, the system generates visual representations such as highlighted regions, color-coded flaw markers, and annotated 3D models that convey the same diagnostic information in an intuitively understandable format.
Solution Approach 2:
The patent employs color coding to indicate different flaw characteristics and severity levels in the graphical representation. Various colors distinguish between different types of discontinuities, flaw sizes, and locations, enabling rapid visual assessment of weld quality without requiring detailed analysis of ultrasound waveforms by non-expert inspectors.
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 solution streamlines the inspection process by enabling efficient graphical representation and data presentation of multiple welds, reducing the time and effort required to analyze and report on weld integrity, facilitating the identification of flaws and generation of detailed evaluation reports for each weld and a master report.
Implementation Method 1
energy propagated into a welded object yields a signal that can be displayed as a waveform image. This waveform image can be instructive of the condition of the welded joint. Such propagated energy may be in the form of electromagnetic waves or acoustic waves.
Implementation Method 2
Upon encountering the welded plane, if a discontinuity is present, the acoustical signals are reflected back towards the transducer where they are converted to electronic-amplitude signals
Data Source
AI summary
A system and method directed to displaying images and presenting the data from the phased array ultrasonic testing (PAUT) inspection of a plurality of welded joints within a welded object. The system includes an engine comprising memory, a graphical user interface (GUI), an export module, a transformation module, and a merger module each operably coupled to one another. The export module is used to extract images and data from the PAUT inspection of the welded joints. The exported information is used by the transformation module to create a multi-dimensional representation of the PAUT inspected welded joint for each joint. The merger module combines the information from the export module and the transformation module into an evaluation report for each PAUT inspected welded joint and assembles the evaluation report into a master report for analysis. The system may be communicatively coupled over a network using a network interface.