Phased Array Probe Origin Time Adjustment for Welded Pipe Defect Detection
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Solution Overview
Problem
Existing defect detection methods for welded steel pipes, such as those using phased array probes, face accuracy issues when the position of the welded portion deviates from the expected position, leading to decreased detection accuracy.
Innovation Solution
The implementation of a defect detection device that utilizes a phased array probe with a control and processing unit, storage unit, and input unit to adjust the origin time of ultrasonic waveform data using multiple origin time adjustment patterns, allowing for accurate defect evaluation even with positional deviations of the welded portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a phased array probe is used for defect inspection of a welded portion, then the detection capability is improved, but the detection accuracy decreases when the welded portion position deviates from the expected position
Solution Approach 1:
The patent applies dynamics by making the origin time adjustable and adaptable based on the actual position of the welded portion. The system dynamically adjusts the origin time for each ultrasonic element according to the measured position, allowing the detection system to adapt to position deviations while maintaining high detection accuracy. This resolves the contradiction by enabling the system to be both precise and tolerant of position variations.
Solution Approach 2:
The patent changes the parameter of origin time for each ultrasonic element based on the position of the welded portion. By calculating and adjusting the origin time according to the actual position (which may deviate from the expected position), the system maintains accurate defect detection despite position variations. This parameter adjustment resolves the contradiction between detection accuracy and position deviation tolerance.
2Ease of manufacture
If the position of the welded portion is fixed at an expected position, then the detection setup is simplified, but the detection accuracy decreases when position deviation occurs
Solution Approach 1:
The patent performs preliminary action by measuring the position of the welded portion before conducting the defect inspection. Based on this pre-measured position information, the system calculates and sets the appropriate origin time for each ultrasonic element. This preliminary position measurement and adjustment enables the system to maintain high detection accuracy without complicating the overall setup process.
Solution Approach 2:
The system performs self-service by automatically adjusting the origin time based on the measured position of the welded portion. The defect detection device itself compensates for position deviations by calculating the appropriate origin time adjustments, eliminating the need for external complex adjustment mechanisms and maintaining both simplicity and accuracy.
3Measurement precision
If multiple origin time adjustment patterns are used to compensate for position deviation, then the detection accuracy is maintained, but the system complexity increases
Solution Approach 1:
The patent changes the origin time parameter for each ultrasonic element based on the measured position of the welded portion. By calculating the position deviation and adjusting the origin time accordingly, the system maintains detection accuracy without requiring multiple physical adjustment mechanisms. This parameter-based approach resolves the contradiction by achieving high precision through software/calibration adjustments rather than hardware complexity.
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 approach effectively suppresses the decrease in accuracy of defect detection by adjusting the origin time of ultrasonic waveform data, enabling reliable detection of defects in welded steel pipes with positional deviations.
Implementation Method 1
ultrasonic beams are transmitted toward a welded portion through an outer surface of a welded steel pipe from a flaw detection ultrasonic element group
Implementation Method 2
the ultrasonic beams reflected on the welded steel pipe including the welded portion are received via the flaw detection ultrasonic element group
Data Source
Figure 1
Figure 2A~2B
Figure 2C
AI summary
There are provided an ultrasonic waveform data generation unit (123) that generates ultrasonic waveform data representing amplitudes of reflected ultrasonic beams received by a reception unit (132) in time series for each of ultrasonic elements (111) forming reception ultrasonic elements (114), an ultrasonic waveform data processing unit (124) that uses a plurality of origin time adjustment patterns, each being an origin time adjustment pattern for adjusting an origin time of the ultrasonic waveform data for each of the ultrasonic elements (111) forming the reception ultrasonic elements (114), in which a plurality of relative positional relationships between a phased array probe (110) and a welded portion (210) are set, and performs processing to synthesize pieces of the ultrasonic waveform data each having the adjusted origin time to generate synthesized ultrasonic waveform data according to each of the origin time adjustment patterns, and a defect evaluation unit (125) that evaluates whether or not a defect (211) is present in the welded portion (210) based on the synthesized ultrasonic waveform data.