Phased Array Probe Ultrasonic Inspection Down Hole Drilling Systems
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Solution Overview
Problem
Current methods for inspecting down hole drilling systems are inefficient, inaccurate, and pose safety risks due to the need for extensive scanning and potential obstruction by particulate, lacking the ability to provide detailed inspections of small areas and multiple angles.
Innovation Solution
The method employs a phased array probe with multiple elements that can steer, focus, and scan ultrasonic signals using a sound carrying wedge to form-fittingly couple with down hole drilling systems, allowing for simultaneous inspection at various angles and depths, and uses a wave coupling medium to enhance signal transmission, enabling efficient and accurate flaw detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional ultrasonic inspection methods are used, then inspection coverage can be achieved, but inspection efficiency is low and extensive scanning is required
Solution Approach 1:
The patent employs a phased array probe with multiple ultrasonic elements that can dynamically steer, focus, and scan inspection signals electronically without physical movement of the probe. This dynamic beam steering capability allows rapid inspection of multiple angles and depths from a single probe position, dramatically improving inspection efficiency while reducing scanning time
Solution Approach 2:
The invention adds the dimension of angular diversity by providing ultrasonic inspection signals at multiple predetermined angles (e.g., 45°, 60°, 75°) simultaneously through the phased array. This multi-angular approach enables comprehensive inspection of the inspection area without requiring extensive lateral scanning, thus improving productivity while minimizing time loss
2Measurement precision
If sound carrying wedges are used to couple with down hole drilling systems, then inspection accuracy is improved, but the inspection area must be sufficiently large to accommodate the wedge
Solution Approach 1:
The patent divides the ultrasonic inspection system into multiple independent phased array elements that can be selectively activated. This segmentation allows the inspection function to be concentrated on small specific areas of the down hole drilling system, eliminating the need for large surface areas while maintaining high flaw detection sensitivity through focused ultrasonic beams
Solution Approach 2:
The patent uses a wave coupling medium as an intermediary between the phased array probe and the down hole drilling system surface. This coupling medium enhances ultrasonic signal transmission efficiency, allowing accurate flaw detection even when the probe contacts small or irregular surfaces, thus improving measurement precision without requiring large inspection areas
3Measurement precision
If multiple inspection angles are provided, then flaw detection accuracy is improved, but the complexity of the inspection system increases
Solution Approach 1:
The phased array probe integrates multiple ultrasonic elements into a single multi-functional device that can generate inspection signals at various angles, focus beams at different depths, and steer beams electronically. This universal probe design provides multiple inspection capabilities without requiring separate probes for each angle, thus improving flaw detection accuracy while managing system complexity through integration
Solution Approach 2:
The patent replaces mechanical steering mechanisms with electronic beam steering through phased array technology. Instead of physically moving probes or changing their orientation mechanically, the system uses electronic phase delays across multiple elements to steer and focus ultrasonic beams at different angles and depths, improving measurement precision while reducing mechanical complexity
4Reliability
If extensive scanning is performed to ensure coverage, then inspection thoroughness is improved, but safety risks increase due to inspector exposure
Solution Approach 1:
The phased array probe performs self-steering and self-focusing of ultrasonic beams through electronic control, automatically covering the required inspection volume without requiring manual repositioning or extensive scanning operations by inspectors. This self-service capability maintains inspection thoroughness while minimizing inspector exposure to hazardous down hole environments
Solution Approach 2:
The system performs preliminary electronic beam steering and focusing to pre-establish complete inspection coverage before inspector exposure. By pre-calculating and executing the necessary beam paths and angles, the system ensures thorough inspection while allowing inspectors to remain at a safe distance, thus improving reliability while reducing safety risks
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 provides safe, efficient, and accurate inspection data by reducing the need for extensive scanning, improving flaw detection sensitivity, and allowing for real-time monitoring, enhancing the safety and efficiency of down hole drilling operations.
Implementation Method 1
transmitting a plurality of inspection signals to an area of interest
Implementation Method 2
employing a phased array probe with multiple elements that can steer, focus, and scan ultrasonic signals
Implementation Method 3
uses a wave coupling medium to enhance signal transmission
Data Source
AI summary
A method for inspecting down hole drilling systems for identifying indications of flaws in material. The method can include removing particulate, disposing a wave coupling medium on an area of interest, attaching a probe to a sound carrying wedge, engaging the sound carrying wedge over the wave coupling medium, transmitting inspection signals to the area of interest, manipulating the probe to produce detection signals, transmitting the detection signals to a data storage, presenting the detection signals and a known reference level to a user, and comparing the detection signals to the known reference level to determine if the detection signals are within a standard deviation of the known reference level. The method can include adapting a sound carrying wedge to form-fittingly couple to an area of interest of a down hole drilling system.