Phased Array Probe Impedance Calibration for Pulse Rate Optimization
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Solution Overview
Problem
Phased array ultrasonic inspection systems are limited by suboptimal pulse rates due to assumed static transducer impedance, leading to reduced inspection efficiency and accuracy, as the actual adaptive impedance is not accurately measured.
Innovation Solution
A method to calibrate and measure the adaptive transducer impedance, using SPICE modeling and curve fitting to determine the relationship between transducer and pulser impedance, allowing for on-site measurement of voltage and current to optimize pulse rate within power consumption limits, thereby increasing scan rate and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed static transducer impedance (e.g., 50 Ohms) is used to limit maximum pulse rate, then the pulser circuit protection is simplified, but the pulse rate is reduced below optimal values
Solution Approach 1:
The patent applies dynamics by transitioning from a static fixed impedance value to a dynamic adaptive impedance measurement system. The system continuously measures the actual transducer impedance during operation and adjusts the pulse rate accordingly, allowing the pulse rate to vary based on real-time conditions rather than being limited by a conservative fixed value.
Solution Approach 2:
The patent implements feedback by measuring the actual transducer impedance during pulser operation and using this information to adjust the pulse rate. The system monitors power consumption and impedance variations, then modifies the pulse rate to optimize inspection efficiency while staying within power limits, creating a closed-loop control system.
2Productivity
If the pulse rate is increased to improve inspection efficiency, then scan rate and productivity increase, but power consumption increases beyond acceptable limits
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the pulse rate based on measured transducer impedance and power consumption conditions. Instead of using a fixed maximum pulse rate, the system modifies the pulse rate parameter in real-time according to actual operating conditions, optimizing the balance between inspection efficiency and power consumption.
Solution Approach 2:
The system dynamically determines the maximum allowable pulse rate based on real-time power consumption measurements and impedance variations. This dynamic adjustment allows the pulse rate to increase when power availability permits and decrease when power limits are approached, optimizing productivity within power constraints.
3Productivity
If adaptive impedance measurement is implemented, then pulse rate optimization is achieved, but measurement and calibration complexity increases
Solution Approach 1:
The patent applies self-service by having the system measure its own impedance characteristics during normal operation. The transducer impedance is measured using the existing pulser circuitry and signal processing capabilities without requiring external measurement equipment or separate calibration procedures, allowing the system to self-optimize its pulse rate.
Solution Approach 2:
The patent implements universality by using the existing multi-functional pulser circuitry for both driving the transducer and measuring its impedance characteristics. The same signal processing capabilities used for inspection are also utilized for impedance measurement and pulse rate optimization, avoiding the need for dedicated measurement hardware.
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
This approach significantly increases the pulse rate to its maximally allowed value, enhancing inspection accuracy and productivity without enlarging the high voltage power supply, enabling higher scan rates and more efficient inspections.
Implementation Method 1
a phased array ultrasonic inspection system... a transducer assembly with from 16 to as many as 256 small individual piezoelectric elements that can each be pulsed separately... Pulse rate, commonly known as pulse repetition frequency, is the rate at which an electrical pulse is applied to a piezoelectric element producing an ultrasound through a testing material
Implementation Method 2
A pulser circuitry is usually employed to perform the pulsing tasks to energize each PA probe's element
Data Source
AI summary
Disclosed is a method and a phased array inspection device enabling calibration of the device with an optimized pulse rate, the pulse rate is derived based on the true adaptive value of the impedance of the specific phased array probe circuit or the pulser circuit and the circuit energy consumption limitations. The energy consumption limitations include the total energy made available by the power supply to the pulser and probe circuit and the pulser energy consumption with limitation due to pulser circuit's physical limit such as thermal limitation.