Portable Sensor Array Probe for Ultrasonic Testing
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Solution Overview
Problem
Existing phased array ultrasonic testing systems lack a portable, adaptable housing that enables omnidirectional articulation and effective sectoral scanning, leading to increased noise from side lobes and grating lobes, which complicates high-resolution scans on complex surfaces.
Innovation Solution
A sensor array housing device with a stem, transducer housing section, and couplant housing section filled with coupling fluid, featuring omnidirectional wheels and an articulating section that allows for omnidirectional movement, along with a robotic arm for precise positioning and a user device for command transmission, ensuring the ultrasonic waves have a wavelength less than double the groove height to mitigate noise and enhance scan clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phased array ultrasonic testing systems are used to scan complex surfaces, then nondestructive inspection capability is improved, but noise from side lobes and grating lobes increases
Solution Approach 1:
The patent converts the harmful noise from side lobes and grating lobes into useful information by designing grooves into the couplant housing section. These grooves are positioned to receive and redirect the stray ultrasonic energy that would otherwise create noise, transforming it into beneficial scan coverage on complex surfaces.
Solution Approach 2:
The patent applies local quality by creating specific groove structures in predetermined locations on the couplant housing section. These grooves are strategically positioned to address local noise problems in specific scan regions, allowing targeted noise reduction while maintaining overall inspection capability.
2Adaptability or versatility
If omnidirectional articulation is implemented for sectoral scanning, then scanning adaptability is improved, but device complexity increases
Solution Approach 1:
The patent implements dynamics by making the couplant housing section movable relative to the transducer housing section through the articulating section. This allows the scanning device to dynamically adjust its orientation and articulation to adapt to complex surfaces, enabling omnidirectional scanning without requiring a completely complex overall structure.
Solution Approach 2:
The patent applies segmentation by dividing the housing into distinct sections: transducer housing section, articulating section, and couplant housing section. This modular segmentation allows each section to perform its specific function independently, simplifying the overall design while achieving omnidirectional articulation capability.
3Measurement precision
If robotic arm positioning is used for precise scanning, then positioning accuracy is improved, but system complexity increases
Solution Approach 1:
The patent uses the articulating section as an intermediary mechanism between the robotic arm positioning system and the couplant housing section. This intermediary allows precise positioning to be achieved through a series of controlled articulations and movements, breaking down the complex positioning task into manageable stages while maintaining accuracy.
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
The solution enables high-resolution, omnidirectional scanning with reduced noise interference, allowing for accurate detection of features on complex surfaces by effectively managing side lobes and grating lobes, and facilitating precise positioning of the scanning device during the scan.
Implementation Method 1
an articulating section, attached to a bottom end of the couplant housing section, including a plurality of omnidirectional wheels extending downwardly from the articulating section
Implementation Method 2
a couplant housing section, wherein the couplant housing section is filled with at least one coupling fluid
Implementation Method 3
a bottom end of the couplant housing section includes an acoustic window
Implementation Method 4
wherein the couplant housing section includes a plurality of grooves extending inwardly from an interior surface of an interior chamber of the couplant housing section, wherein the ultrasonic waves have a wavelength equal to less than double a height of each of the plurality of grooves
Data Source
AI summary
A sensor array housing device includes an enclosed couplant housing section between a linear array of transducers or coils and a test object. The linear array is particularly suited for sectoral scanning of a test object. Interior surfaces of the couplant housing section include a plurality of ridges for mitigating the impact of reflected side lobes on scan data. The sensor array housing device includes a plurality of retained articulating balls, configured to allow the sensor array housing device to move omnidirectionally across a surface of the test object.