Power Cable Lead Sheath Imaging With Ultrasonic Scanning
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Solution Overview
Problem
Existing methods for inspecting power cable lead sheath quality, such as Gamma-Ray and X-ray imaging, are inefficient and pose health risks to operators, failing to provide comprehensive images due to high reflectivity and requiring cumbersome safety measures.
Innovation Solution
An ultrasonic testing apparatus and method using phased array ultrasonic probes with Total Focusing Method (TFM) and Adaptive Ultrasonic Imaging (ATFM) techniques, combined with a probe guiding device, to inspect the lead sheath for thickness, defects, and uniformity, providing detailed images without radiation exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Gamma-Ray or X-ray imaging is used to inspect lead sheath, then imaging capability is provided, but operator safety is compromised due to radiation exposure
Solution Approach 1:
The patent replaces electromagnetic radiation-based imaging (Gamma-Ray/X-ray) with ultrasonic wave-based imaging. The ultrasonic testing apparatus uses acoustic waves to penetrate and image the lead sheath, eliminating ionizing radiation while maintaining non-destructive testing capability. This substitution resolves the contradiction by providing imaging functionality without harmful radiation exposure to operators.
2Measurement precision
If high energy Gamma-Ray or X-ray Source is used, then imaging is achieved, but image quality is insufficient due to high reflectivity of cable core
Solution Approach 1:
The patent changes the physical parameter of the imaging waves from electromagnetic radiation (Gamma-Ray/X-ray) to mechanical ultrasonic waves. Ultrasonic waves have different interaction characteristics with the cable core and lead sheath interface, allowing them to penetrate through the high reflectivity barrier that blocks electromagnetic radiation. This parameter change enables adequate image quality by overcoming the reflectivity issue.
3Measurement precision
If traditional imaging methods are used, then inspection is performed, but inspection time is excessive
Solution Approach 1:
The patent implements continuous ultrasonic scanning along the cable length, allowing inspection to proceed without interruption. The ultrasonic probe continuously emits and receives waves as it moves along the cable, providing real-time imaging and eliminating the need for repeated positioning and setup required by traditional methods. This continuous operation significantly reduces inspection time while maintaining comprehensive coverage.
4Measurement precision
If radiation sources are used for inspection, then imaging is achieved, but safety procedures and equipment complexity increases
Solution Approach 1:
The patent extracts and removes the radiation source from the inspection system, replacing it with a non-ionizing ultrasonic transducer. By eliminating the radiation source entirely, the system no longer requires complex radiation safety procedures, shielding, licensing, or specialized safety equipment. The ultrasonic apparatus uses standard non-destructive testing safety protocols, dramatically simplifying the overall system complexity.
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 confident, high-resolution inspection of power cable lead sheath quality, ensuring operator safety while offering comprehensive information about thickness, defects, and uniformity.
Implementation Method 1
Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the propagation of ultrasonic waves in the object or material tested
Implementation Method 2
Very short ultrasonic pulse-waves are transmitted into materials to detect internal flaws
Data Source
Figure 1a~1b
Figure 2a~2b
AI summary
Ultrasonic testing apparatus for inspection of power cable lead sheath comprises an ultrasonic probe for emitting ultrasound waves towards the power cable lead sheath and recording ultrasound waves reflected from the power cable lead sheath, a probe guiding device configured to move the ultrasonic probe along an inspection path, and a processing device connected to the ultrasonic probe for receiving signals from the ultrasonic probe and processing the signals to provide an image representing the lead sheath along the inspection path. A method for ultrasonic imaging of power cable lead sheath comprises emitting ultrasound waves towards the power cable lead sheath, moving the ultrasonic probe along an inspection path, and processing signals reflected from the power cable lead sheath to provide an image representing the lead sheath along the inspection path.