Non-destructive Pipe Wall Thickness Measurement Using Resonant Frequency
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Solution Overview
Problem
Current methods for measuring pipe wall thickness during the manufacturing process are ineffective at high temperatures, as they require cooling the pipe, leading to delays and increased energy consumption, and are not suitable for real-time feedback in the casting process.
Innovation Solution
A non-destructive thickness measurement system that applies vibrations, specifically white noise, to the pipe to determine its resonant frequency, allowing for accurate thickness calculation without the need for cooling, using a vibration application mechanism, monitoring device, and data processing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the time-of-flight method with couplant is used to measure pipe wall thickness, then measurement can be performed, but the pipe must be cooled to below 1000° F. first, causing measurement delays and increased energy consumption
Solution Approach 1:
The patent replaces the ultrasonic time-of-flight method with a mechanical vibration method. Instead of using ultrasonic waves requiring couplant, the system applies mechanical vibrations directly to the pipe surface and measures resonant frequency to determine wall thickness. This substitution eliminates the temperature limitation and couplant requirement, allowing measurements on hot pipes without cooling.
Solution Approach 2:
The patent changes the measurement parameter from ultrasonic wave travel time to mechanical resonant frequency. By measuring the resonant frequency of the pipe when subjected to mechanical vibration, the system can determine wall thickness without being constrained by temperature-dependent couplant properties, thus enabling in-process measurement of hot pipes.
2Measurement precision
If the pipe is cooled for thickness measurement, then accurate measurement can be obtained, but greater energy is required to reheat the pipe during annealing
Solution Approach 1:
The patent replaces the ultrasonic time-of-flight method with a mechanical vibration method. Instead of using ultrasonic waves requiring couplant, the system applies mechanical vibrations directly to the pipe surface and measures resonant frequency to determine wall thickness. This substitution eliminates the temperature limitation and couplant requirement, allowing measurements on hot pipes without cooling.
Solution Approach 2:
The patent enables continuous thickness measurement during the casting process without interrupting the thermal process. By allowing measurements on hot pipes, the system eliminates the cooling-reheating cycle, maintaining continuous production flow and avoiding the energy waste associated with reheating cooled pipes during annealing.
3Measurement precision
If cooling is required for thickness measurement, then measurement can proceed, but feedback to the casting system is delayed
Solution Approach 1:
The patent replaces the ultrasonic time-of-flight method with a mechanical vibration method. Instead of using ultrasonic waves requiring couplant, the system applies mechanical vibrations directly to the pipe surface and measures resonant frequency to determine wall thickness. This substitution eliminates the temperature limitation and couplant requirement, allowing measurements on hot pipes without cooling.
Solution Approach 2:
The patent performs thickness measurement immediately after casting while the pipe is still hot, rather than waiting for cooling. This preliminary action provides real-time feedback to the casting system, enabling immediate process adjustments without the delay caused by mandatory cooling periods.
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 real-time, accurate measurement of pipe wall thickness at high temperatures, reducing delays and energy consumption, and providing immediate feedback for optimizing the casting process.
Implementation Method 1
a vibration application mechanism configured to apply a vibration to the object having a temperature greater than approximately 1000° F.
Implementation Method 2
a vibration monitoring device configured to gather displacement and frequency data for a discrete location on the outer surface of the object
Data Source
AI summary
The present invention generally relates to improved non-destructive thickness measurement systems and methods. Embodiments of the present invention utilize quarter wave resonant frequency to measure the thickness of high-temperature pipe walls. In one embodiment, an improved non-destructive thickness measurement system is provided that utilizes Gaussian white noise to produce maximum mechanical resonance in the pipe wall and laser vibrometers to detect the pipe wall's maximum displacement.