Phased Array Transducer Selection for Weld Inspection
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Solution Overview
Problem
Ultrasonic weld inspection using phased-array probes is inefficient due to the unnecessary operation of all transducer elements, which results in inefficiency as not all elements can effectively scan the weld root and cap simultaneously.
Innovation Solution
A method is developed to select the optimal transducer elements based on material thickness, wedge angle, and geometric relationships to ensure efficient scanning of welds by determining the appropriate elements for scanning the weld root and cap during a single pass, utilizing an iterative algorithm to identify the correct elements for signal emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all transducer elements are operated during scan movement, then complete weld inspection coverage is achieved, but inspection efficiency deteriorates due to unnecessary element operation
Solution Approach 1:
The transducer array is segmented into multiple independent elements, each capable of being selectively activated. The system divides the inspection task by assigning specific elements to scan specific regions (weld root, weld cap, or both), rather than operating all elements simultaneously. This segmentation allows efficient utilization of only the necessary elements for each scanning scenario.
Solution Approach 2:
Different transducer elements are assigned to different functional roles based on their position in the array. Elements at specific locations are designated for root scanning, cap scanning, or dual scanning based on their geometric relationship to the weld. This local quality assignment ensures that each element operates only when and where it can effectively contribute to inspection coverage.
2Reliability
If sequential operation of all transducer elements is performed, then weld inspection coverage is maintained, but inspection time increases due to redundant scanning
Solution Approach 1:
The system performs preliminary calculations using geometric relationships (wedge angle, material thickness, offset distance) to pre-determine which transducer elements should be activated for each scanning scenario. This preliminary action avoids the need to sequentially test all elements during inspection, thereby reducing inspection time while maintaining complete coverage.
Solution Approach 2:
Instead of operating all transducer elements (excessive action), the system activates only the specific subset of elements needed for each scanning task (partial action). This approach maintains sufficient inspection coverage while eliminating redundant scanning operations that would increase inspection time.
3Productivity
If multiple transducer elements are operated simultaneously, then simultaneous scanning of weld root and cap is achieved, but element selection complexity increases
Solution Approach 1:
The system uses changes in geometric parameters (wedge angle, material thickness, offset distance) to determine element selection. By establishing mathematical relationships between these parameters and transducer element positions, the system automatically identifies which elements should operate simultaneously for root scanning, cap scanning, or combined scanning, thereby managing complexity through parameter-based decision rules.
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 enhances the efficiency of weld inspection by optimizing the operation of transducer elements, allowing for simultaneous scanning of the weld root and cap with reduced unnecessary element operation, thereby improving inspection coverage and reducing inefficiency.
Implementation Method 1
Each transducer element is capable of emitting a signal that proceeds though the one of the connected portions and into the weld itself
Data Source
AI summary
A method of selecting one element among a plurality of elements of a phased-array ultrasonic weld inspection arrangement during inspection of a weld to obtain optimum weld inspection coverage. The weld connects portions of material having a known thickness. The elements extend along an ultrasonic transmission wedge of the arrangement that supports the extent of the elements at a wedge angle relative to the welded material. The method includes utilizing material thickness, offset distance of an edge of the wedge from a weld centerline and number of elements within calculation that yields the selection.