Phased Array Ultrasonic Probe for Complex Topography Inspection
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Solution Overview
Problem
Conventional ultrasonic tools struggle to accurately measure material thickness in complex topographies, such as welds and curved surfaces in feeder pipes, due to limitations in probe placement, data coverage, and couplant loss, leading to positional uncertainties and missed localized thinning regions.
Innovation Solution
A delivery tool with a phased array ultrasonic probe assembly mounted on a rotating carriage and a flexible membrane transducer shoe, which can conform to complex surfaces, allowing for simultaneous data acquisition from multiple angles and providing precise wall thickness mapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic tools are used for thickness measurement, then the measurement process is simple, but the measurement precision deteriorates due to complex topography
Solution Approach 1:
The inspection system is divided into multiple ultrasonic probes arranged in an array, each probe measuring thickness from a different angle. This segmentation allows comprehensive coverage of complex topography while maintaining measurement precision, as each probe can be optimally positioned for its specific measurement zone.
Solution Approach 2:
The invention transitions from single-point thickness measurement to two-dimensional wall thickness mapping by using multiple probes arranged in an array. This dimensional expansion enables simultaneous measurement across multiple locations and angles, accurately capturing thickness variations over complex surfaces.
2Area of stationary object
If single point ultrasonic probes are used, then the device complexity is low, but the area of inspection coverage is insufficient
Solution Approach 1:
Multiple ultrasonic probes are merged into a single phased array assembly, enabling simultaneous measurement across a large area. The combined array provides comprehensive coverage of complex topography including weld crowns and curved surfaces, eliminating the need for multiple separate measurement points.
Solution Approach 2:
The phased array probe assembly serves multiple functions: it performs thickness measurement, generates two-dimensional maps, and adapts to various complex geometries. This multi-functionality allows a single device to handle diverse inspection scenarios without requiring separate specialized tools.
3Reliability
If conventional probes are used on complex surfaces, then the操作简单性 is maintained, but the reliability of measurement deteriorates due to couplant loss
Solution Approach 1:
A couplant is introduced as an intermediary substance between the ultrasonic probes and the complex surface being measured. This mediator fills gaps and conforms to irregular topography, ensuring reliable acoustic coupling and consistent measurement reliability without requiring complex positioning procedures.
Solution Approach 2:
The system uses a flexible couplant layer that adapts to complex surfaces including weld crowns and curved fittings. This flexible intermediary maintains reliable acoustic contact across irregular topography, eliminating measurement gaps while keeping the system easy to operate.
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
The solution enables comprehensive and accurate wall thickness mapping, reducing gaps in inspection coverage and positional uncertainties, effectively detecting localized thinning regions and corrosion near welds, even in complex geometries.
Implementation Method 1
phased array ultrasonic probe assembly
Implementation Method 2
determining a wall thickness value based on the data set
Implementation Method 3
flexible membrane transducer shoe, which can conform to complex surfaces
Data Source
AI summary
A phased array ultrasonic probe may be mounted to a component to be inspected for wall thickness on an apparatus that includes a split ring adapted to be magnetically held in place on the component. In particular, the probe may be mounted to a carriage connected to the split ring in a manner that allows the carriage to rotate around the split ring while the probe is in operation. Between the probe and the component, a transducer shoe defining, by a flexible membrane, a cavity and an aperture. Conveniently, the construction of the flexible membrane allows wall thickness measurements to be acquired in portions of the component that have complex topography, such as welds. The apparatus is installed on an adaptor assembly for inspection of straight section of pipes. This adaptor assembly is not used in absence of straight section. By acquiring data from multiple output pulse transmitted at multiple incidence angles, processing software may conveniently produce an accurate wall thickness map of the area of interest on the component.