Phased Array Probe Beam Steering Eliminates Wedge Changes
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Solution Overview
Problem
Ultrasonic detection assemblies using straight beam probes require multiple test runs and differently sized wedges to detect characteristics at various angles, leading to decreased productivity and increased costs due to the need for multiple probes and complex setups.
Innovation Solution
A phased array probe that transmits and moves sound beams in two or three dimensional directions within a test object, eliminating the need for wedges and allowing for precise detection of characteristics without the need for multiple probes or angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple straight beam probes with different wedge angles are used to detect characteristics at various angles, then detection coverage is improved, but device complexity and cost increase
Solution Approach 1:
The phased array probe integrates multiple transducer elements that can generate sound beams at multiple angles using a single probe body, eliminating the need for multiple probes and wedges. The electronic control system allows the same probe to perform multiple detection functions by adjusting beam steering angles dynamically.
Solution Approach 2:
Multiple transducer elements are combined into a single phased array probe body, merging the functionality of what would traditionally require multiple separate probes and wedges. The array elements work together to produce steerable sound beams through constructive and destructive interference patterns.
2Measurement precision
If multiple test runs with different angles are performed to detect characteristics, then detection accuracy is improved, but productivity decreases
Solution Approach 1:
The phased array probe can continuously steer sound beams through multiple angles during a single test run without requiring the probe to be removed or repositioned. The electronic control system enables seamless transition between different beam angles, maintaining continuous inspection of the test object.
Solution Approach 2:
The sound beam direction is made dynamically adjustable through electronic phase shifting of the transducer elements. This allows the beam angle to be changed rapidly and continuously during inspection, eliminating the static, step-by-step approach required by traditional methods.
3Manufacturing precision
If differently sized wedges are used for each angle to achieve precise beam steering, then beam direction control is improved, but ease of operation and cost worsen
Solution Approach 1:
The mechanical wedge system is replaced with an electronic phase shifting system. Instead of physically changing wedges to alter beam angle, the electronic control system adjusts the phase and timing of excitation signals to each transducer element, achieving precise beam steering without mechanical intervention.
Solution Approach 2:
The beam direction is controlled by changing electrical parameters (phase and timing of excitation signals) rather than mechanical parameters (wedge size and angle). This allows rapid, precise adjustment of beam direction through electronic means without physical manipulation of components.
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
Enables efficient and precise detection of characteristics within test objects by allowing the sound beam to be steered to various positions, reducing the need for multiple test runs and simplifying the setup, thereby improving productivity and reducing costs.
Implementation Method 1
Ultrasonic detection assemblies are used, for example, to inspect a test object and to detect/identify characteristics of the test object
Implementation Method 2
The phased array probe includes a plurality of transducer elements being configured to transmit a sound beam into the test object. The sound beam is movable along at least a two dimensional direction within the test object
Data Source
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AI summary
An ultrasonic detection assembly detects a characteristic in a test object. The ultrasonic detection assembly includes a phased array probe positioned in proximity to a peripheral surface of the test object. The phased array probe includes a plurality of transducer elements. The transducer elements of the phased array probe transmit a sound beam into the test object. The sound beam is movable by the phased array probe within the test object to detect the characteristic. A method of detecting a characteristic in the test object with the ultrasonic detection assembly is also provided.