Phased Array Ultrasonic Probe for Seamless Pipe Flaw Detection

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Solution Overview

Problem

Conventional ultrasonic testing methods for detecting tilted flaws in tubular objects, such as seamless pipes, are inefficient due to the need for multiple probes and complex setups, leading to reduced testing speed and potential misdetection of flaws due to varying tilt angles affecting echo intensity.

Innovation Solution

An ultrasonic testing method using a phased array probe that sets equivalent external or internal refraction angles for multiple propagation directions, allowing simultaneous transmission and reception of ultrasonic waves, thereby maintaining consistent echo intensity and improving detection precision across various tilt angles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple ultrasonic probes with different tilt angles are arranged to detect tilted flaws with various tilt angles, then detection coverage is improved, but equipment complexity and cost increase significantly

Engineering Contradiction:

Improvedetection coverageVSAvoidequipment complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single ultrasonic probe is designed to perform multiple detection functions by electronically controlling the tilt angle of ultrasonic waves. The probe can detect tilted flaws with various tilt angles (including 0° and non-0° angles) without requiring physical reconfiguration, replacing the need for multiple specialized probes while maintaining comprehensive detection coverage

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mechanical approach of physically arranging multiple probes with different fixed tilt angles is replaced by an electronic control system that dynamically adjusts the ultrasonic wave tilt angle. This substitution eliminates the need for complex mechanical probe arrangements and settings while achieving the same detection capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If the tilt angle of ultrasonic probe is changed each time to detect tilted flaws with different tilt angles, then detection precision is improved, but testing time increases significantly

Engineering Contradiction:

Improvedetection precisionVSAvoidtesting time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The ultrasonic probe system transitions from a static configuration requiring physical repositioning to a dynamic electronic control system. The tilt angle of ultrasonic waves is adjusted in real-time through electronic timing control of transducer elements, allowing rapid switching between different detection angles without mechanical movement, thus maintaining high detection precision while dramatically reducing testing time

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If electronic scanning is used to change tilt angle of ultrasonic waves, then adaptability to various flaw tilt angles is improved, but testing speed decreases due to repeated scanning

Engineering Contradiction:

Improveadaptability to various flaw tilt anglesVSAvoidtesting speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system maintains continuous detection capability by electronically controlling multiple transducer elements to transmit and receive ultrasonic waves simultaneously at different tilt angles. This eliminates the need for repeated sequential scanning, allowing continuous monitoring of tilted flaws with various tilt angles and maintaining high testing speed while achieving comprehensive adaptability

Inventive Principle:

Principle #20Continuity of useful action

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 enables quick and precise detection of flaws with various tilt angles by ensuring equivalent refraction angles, reducing testing time and increasing efficiency while minimizing misdetection, and allowing for high-precision manufacturing of seamless pipes.

Implementation Method 1

respective external refraction angles θr of the ultrasonic wave in the plurality of propagation directions are made to be equivalent and/or respective internal refraction angles θk of the ultrasonic wave in the plurality of propagation directions are made to be equivalent

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentEP1918700B1Ultrasonic flaw detector, ultrasonic flaw detecting method and production method of seamless pipe

Publication Date: 2020.04.15 NIPPON STEEL CORPORATION

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AI summary

The ultrasonic testing method according to the invention includes the steps of arranging an ultrasonic probe 1 having a plurality of transducers 11 so as to face a tubular test object P, and causing the transducers appropriately selected from the plurality of transducers to transmit and receive ultrasonic waves so that the ultrasonic waves are propagated in the tubular test object in a plurality of different propagation directions, wherein a ultrasonic testing condition by the ultrasonic probe is set so that respective external refraction angles θr of the ultrasonic waves in the plurality of propagation directions are approximately equivalent and/or respective internal refraction angles θk of the ultrasonic waves in the plurality of propagation directions are approximately equivalent.