Portable X-ray Backscatter Inspection of Welds
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Solution Overview
Problem
Existing nondestructive inspection methods for welds and joints in complex structures like aircraft and ships face challenges due to access difficulties, sensitivity to local geometry, and limitations in detecting inconsistencies, particularly with x-ray wealth inspection and ultrasonic techniques.
Innovation Solution
A portable x-ray scanning system with a mobility system, sensor panels, and a controller that moves along the joining feature, directing an x-ray beam and adjusting sensor panel angles to enhance backscatter detection, allowing for efficient inspection of welds and joints without damaging the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional transmission x-ray inspection methods are used, then inspection capability is provided, but access difficulty increases and inspection efficiency decreases due to complexity of aircraft structures
Solution Approach 1:
The patent replaces traditional mechanical transmission x-ray inspection systems with a backscatter x-ray inspection system that uses electronic detection and signal processing. The backscatter method uses electronic sensors to detect scattered x-rays, eliminating the need for complex mechanical positioning and providing easier access to difficult-to-reach areas of aircraft structures.
Solution Approach 2:
The patent changes the inspection parameter from transmission mode to backscatter mode. This parameter change allows the inspection system to work from a single side of the structure, significantly improving access ease while maintaining inspection capability through detection of backscattered radiation patterns.
2Reliability
If phase array ultrasound techniques are used, then weld inspection is enabled, but inspection quality decreases due to sensitivity to local geometry
Solution Approach 1:
The patent replaces ultrasound-based mechanical inspection with x-ray backscatter inspection that uses electromagnetic radiation. This substitution eliminates the sensitivity to local geometry and surface conditions that plagues ultrasound methods, providing more consistent and reliable weld inspection quality.
3Ease of operation
If portable inspection systems are used, then access to hard-to-reach areas is improved, but detection precision decreases
Solution Approach 1:
The patent employs a portable inspection system with dynamic positioning capabilities that can adapt to complex aircraft geometries. The system maintains detection precision through real-time adjustment of inspection parameters and use of multiple detection angles, allowing access to hard-to-reach areas without sacrificing weld defect detection capability.
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 effective nondestructive inspection of complex structures by improving detection efficiency and contrast, facilitating faster and higher-quality inspections of welds and joints, even in hard-to-reach areas.
Implementation Method 1
the set of sensor panels generates sensor data in response to detecting backscatter received through the opening, wherein the backscatter is formed in response to the x-ray beam encountering the object
Data Source
AI summary
Method, apparatus, system, and computer program product for inspecting a joining feature on an object. A portable housing with an x-ray system is moved along the joining feature on the object. The x-ray system is controlled to direct an x-ray beam through an opening in the portable housing to scan an area of the object containing the joining feature as the portable housing moves along the joining feature on the object. Sensor data generated from a backscatter detected by a sensor system is received. The backscatter is generated in response to the x-ray beam encountering the area of the object including the joining feature. A determination is made as to whether an inconsistency is present in the area of the object including the joining feature using the sensor data.