Phased Array Transducer for Fastener Hole Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current non-destructive inspection techniques for fastener holes in structural components require the removal of fasteners, leading to damage, high costs, and inefficiency, especially in multi-layer structures and when dealing with various fastener sizes.
Innovation Solution
A phased array transducer system with multiple elements that can align and inspect the entire thickness of a structure around a fastener without removing it, using ultrasonic beams and a magnetic attachment for stability, allowing for versatile inspection of different fastener sizes and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the fastener is removed from the structure for inspection, then the inspection of the fastener hole and adjacent structure can be performed, but the fastener and structure suffer tremendous damage and the process becomes costly and labor intensive
Solution Approach 1:
The patent uses an intermediary inspection probe that can be inserted into the fastener hole without removing the fastener. The probe manipulator allows the inspection tool to reach into the hole through the fastener opening, enabling inspection of the hole and adjacent structure while the fastener remains in place, thus avoiding damage to the fastener and structure.
Solution Approach 2:
The inspection system is segmented into multiple components: the inspection probe, the manipulator mechanism, and the control system. This segmentation allows the inspection function to be separated from the fastener removal process, enabling inspection through the fastener opening without removing the fastener itself.
2Measurement precision
If the fastener is removed from the structure, then the entire thickness of the component can be inspected, but the process requires expensive tooling and special design for each inspection scenario
Solution Approach 1:
The inspection probe and manipulator system is designed as a universal tool that can inspect fastener holes of various sizes and configurations without requiring specially designed tooling for each scenario. The manipulator mechanism can adapt to different fastener types and hole orientations, providing multi-functional inspection capability.
Solution Approach 2:
The inspection system is designed to be self-adjusting and self-positioning. The manipulator mechanism automatically positions the inspection probe within the fastener hole based on the hole's location and orientation, eliminating the need for complex external alignment tools and procedures.
3Object-affected harmful factors
If an automated fastener-hole imaging system is used without removing the fastener, then the fastener remains in place, but the system requires expensive alignment mechanisms and adjustment for each fastener size
Solution Approach 1:
The patent extracts the alignment and positioning functions from complex external alignment mechanisms and integrates them directly into the manipulator system. The manipulator is designed with built-in alignment features that automatically center the inspection probe on the fastener hole axis, eliminating the need for separate expensive alignment equipment.
Solution Approach 2:
The manipulator system incorporates dynamic adjustment capabilities that allow real-time positioning and alignment during the inspection process. The manipulator can adapt its position and orientation dynamically to accommodate different fastener sizes and hole locations, eliminating the need for rigid pre-programmed alignment mechanisms.
4Measurement precision
If the inspection probe is manipulated to inspect the entire thickness, then complete inspection is achieved, but the process is time consuming and labor intensive
Solution Approach 1:
The manipulator system enables continuous inspection motion without interruption. The probe can be manipulated smoothly through the fastener hole and across the structure surface in a continuous motion, maintaining constant inspection contact and eliminating idle time between inspection points, thus improving productivity while maintaining thoroughness.
Solution Approach 2:
The patent replaces manual manipulation of the inspection probe with an automated manipulator mechanism that uses controlled mechanical motion. The manipulator systematically moves the probe through the fastener hole and across the inspection area according to pre-programmed paths, eliminating manual labor and reducing inspection time while maintaining complete coverage.
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 cost-effective, less labor-intensive, and more efficient inspection of fastener holes in place, reducing damage and setup time, while accommodating various fastener sizes and structures without the need for expensive alignment mechanisms.
Implementation Method 1
The AFIS employs a phased array ultrasonic probe
Implementation Method 2
using ultrasonic beams and a magnetic attachment for stability
Data Source
AI summary
A phased array transducer for inspecting a fastener hole and adjacent structure to identify defects and determine hole integrity without removing the fastener from the hole. The phased array transducer includes a plurality of transducer elements, where one of the transducer elements is used to align the transducer to the hole, one group of the remaining transducer elements inspects the entire thickness of the structure at one side of the fastener and another group of the remaining transducer elements inspects the entire thickness of the structure at an opposite side of the fastener.