Phased Array Ultrasonic Weld Seam Tracking

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing weld seam tracking methods for non-destructive testing (NDT) are inefficient and costly, requiring manual operator intervention and additional sensors, which hinders full automation and increases system investment, especially in environments where weld seam position drifts during pipe transport.

Innovation Solution

Integration of phased array (PA) ultrasonic sensors with existing NDT systems to utilize C-scan data for real-time weld seam tracking, eliminating the need for external sensors and allowing simultaneous seam tracking and inspection with enhanced scanning coverage, reducing material and operational costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual tracking method is used, then operator can monitor and adjust weld seam location, but full automation cannot be achieved

Engineering Contradiction:

Improveautomation of weld seam trackingVSAvoidoperator intervention requirement

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The system uses the NDT/NDI sensor's own inspection data to automatically track the weld seam position. The sensor processes C-scan data to identify thickness variations and locate the weld seam without requiring external tracking devices or manual operator intervention, enabling the system to serve itself for both inspection and tracking functions.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If external laser tracking device is used, then weld seam position can be monitored, but system investment increases

Engineering Contradiction:

Improveweld seam position detectionVSAvoidnumber of sensors and hardware

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The NDT/NDI sensor performs dual functions: both inspecting weld integrity and tracking weld seam position. By processing the same C-scan data for both purposes, the system eliminates the need for separate laser tracking devices, reducing hardware complexity and system investment while maintaining tracking precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system combines weld inspection and weld seam tracking into a single integrated process using one sensor. The tracking function is merged with the inspection function by utilizing the same ultrasonic data to identify both defects and weld seam location, thereby reducing the number of devices required.

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If pilot line is painted near welding process, then laser tracking can guide probe, but high temperature causes poor paint adhesion

Engineering Contradiction:

Improveweld seam position guidanceVSAvoidpainting environment temperature

Core Design Contradiction:

Measurement precisionVSTemperature

Solution Approach 1:

The system eliminates the need for external pilot lines by using the NDT sensor's own thickness measurement data to locate the weld seam. The sensor identifies the weld position based on characteristic thickness variations in the C-scan data, removing the requirement for painted guidance lines that would be affected by high temperatures.

Inventive Principle:

Principle #25Self-service

4Productivity

If two separate sensor sets are used, then tracking and inspection can be performed, but material and operational costs increase

Engineering Contradiction:

Improvesimultaneous tracking and inspection capabilityVSAvoidnumber of sensors

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

A single NDT/NDI sensor performs both weld seam tracking and weld integrity inspection functions. The system processes the same C-scan data to achieve both objectives, eliminating the need for two separate sensor sets and thereby reducing material costs, operational costs, and system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The tracking and inspection operations are merged into one unified process using a single sensor. The ultrasonic data collected for inspection purposes is simultaneously utilized for tracking the weld seam position, achieving dual functionality without requiring additional sensors or hardware.

Inventive Principle:

Principle #5Merging (Combining)

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 efficient, automated weld seam tracking and inspection with reduced operational costs and increased efficiency by using PA sensors to process C-scan data for real-time weld seam location identification, allowing for both manual and automated control.

Implementation Method 1

A phased array (PA) ultrasonic sensor is used to scan a test object in an inspection operation

Methodology Applied

Scientific EffectUltrasonic wave propagation: Ultrasound

Implementation Method 2

The PA sensor is fired to produce a C-scan of the test object... the C-scan data is processed to identify a location of the weld seam

Methodology Applied

Scientific EffectTime of flight measurement: Time of Flight

Data Source

PatentUS8365602B2Weld seam tracking system using phased array ultrasonic devices

Publication Date: 2013.02.05 EVIDENT SCIENTIFIC INC

AI summary

A weld seam tracking device for tracking weld seams on pipes or the like uses NDT/NDI sensor(s) in conjunction with an NDT/NDI operation, such as an ultrasonic phased array (PA) inspection. Processing of the weld seam tracking data is integrated or combined with the existing data processing element of the existing NDT/NDI inspection devices. Wide scanning areas of phased array probes allow weld seam tracking and inspection to be performed using a single set of probe and data processing elements to achieve both fault scanning and seam tracking with a single run of the PA scan.