Phased-Array Ultrasonic Testing of Angled Hollow Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ultrasonic testing methods are not cost-effective or practical for automated, high-quality assurance testing of elongate, angled hollow profiles, as they require complex adjustments for different geometric conditions and are limited to testing round pipes.
Innovation Solution
A method using a phased-array technique with a probe having multiple transducers, where the transducers are controlled to adjust intromission angles based on their position relative to straight and radius regions, allowing for automated testing of both internal and external defects by determining optimal intromission angles from a reference profile, enabling comprehensive testing of hollow profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional ultrasonic testing methods are used for hollow profiles, then testing coverage is limited, but device complexity and adjustment requirements increase
Solution Approach 1:
The phased array probe with multiple independently controllable transducers serves multiple testing functions simultaneously. The same probe can test both straight regions and radius regions by electronically adjusting the activation pattern and intromission angles of different transducer groups, eliminating the need for multiple specialized probes or complex mechanical adjustments.
Solution Approach 2:
The system dynamically adjusts which transducers are activated and at what intromission angles based on the detected region (straight or radius). The control unit dynamically reconfigures the active transducer subset and their respective intromission angles according to real-time positioning feedback, enabling adaptive testing without manual intervention.
2Reliability
If multiple probes are arranged to test different regions, then comprehensive defect detection is achieved, but testing time and automation complexity increase
Solution Approach 1:
Multiple testing functions that would traditionally require separate probes are merged into a single phased array probe. The probe contains multiple transducers that can be electronically configured to perform different testing tasks (testing straight regions, testing radius regions, different intromission angles) simultaneously or sequentially without physical probe changes or complex mechanical repositioning.
Solution Approach 2:
The system replaces complex mechanical probe arrangement and positioning systems with electronic control of transducer activation. Instead of physically moving or reconfiguring multiple probes mechanically, the control unit electronically activates specific transducer groups and adjusts their intromission angles through phase control, significantly reducing testing time and automation complexity.
3Ease of operation
If fixed intromission angles are used for ultrasonic testing, then device operation is simplified, but detection precision for different regions decreases
Solution Approach 1:
The system changes the intromission angle parameter dynamically based on the testing region. Different transducer groups are assigned different intromission angles (e.g., first angle for straight regions, second angle for radius regions) and the control unit adjusts these parameters electronically according to the detected position, optimizing detection precision for each region while maintaining operational simplicity through automated parameter selection.
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 allows for cost-effective, automated ultrasonic testing of elongate, angled hollow profiles, ensuring high-quality assurance by adapting intromission angles for each region, reducing the complexity and effort required in testing, and enabling detection of longitudinal, transverse, and oblique defects.
Implementation Method 1
a probe provided with piezoelectric transducers is used in a phased array technique
Implementation Method 2
ultrasonic pulses are generated which are introduced into the workpiece via a coupling medium (water or oil). If the ultrasonic pulse generated by an ultrasonic transducer strikes an obstacle, such as e.g. pores or cracks, the original propagation of the ultrasonic signal is influenced at this location by reflection or diffraction
Implementation Method 3
ultrasonic pulses are generated which are introduced into the workpiece via a coupling medium (water or oil)
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a method for ultrasonic testing of angled hollow profiles (5) consisting of sound-conducting material, in particular consisting of metal, comprising an ultrasonic testing device (11), consisting of a probe (1) having transducers (A to G), which are arranged on a transducer ruler (4), in a phased-array technique, wherein ultrasonic signals (10) for detecting external and internal defects on the hollow profile (5) are generated by the transducers (A to G) and are coupled into the surface of the hollow profile (5). In order to implement testing of the test body outer and inner surface for defects, in particular longitudinal defects, including the radius regions, which testing has a greater level of quality assurance and can be automated in a cost-effective manner, it is proposed that for the purpose of detecting external and internal defects in a surface region (5.6) and in radius regions (5.5) of the hollow profile (5), the transducers (A to G) are adjusted in dependence upon their position with respect to the surface region (5.6) and their position with respect to the radius regions (5.5) of the hollow profile (5) such that ultrasonic signals (10) are generated having intromission angles adapted to the external and internal defects in the surface region (5.6) and in the radius regions (5.5) and that prior to the actual ultrasonic testing of the hollow profile (5), ultrasonic testing is performed on a reference profile (5').