Radiography-Based Braze Bonding Length Quantification
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Solution Overview
Problem
Conventional methods for evaluating braze bonding length in copper parts, especially in narrow gaps, are limited to qualitative assessments, making it difficult to quantify the bonding length and seal function, particularly in complex shapes and defects like bubbles or cracks within the narrow gaps of water-cooling coils.
Innovation Solution
A braze bonding length quantitative evaluation apparatus using radiation, comprising a radiation emission unit, light generator, imaging unit, and calculator, which emits radiation through cut specimens, generates light based on transmissive radiation, and calculates the bonding length using pre-acquired correlations between light amount and bonding length, allowing for precise measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional visual observation or ultrasonic flaw detection is used to evaluate braze bonding, then qualitative determination of defect presence can be performed, but quantitative determination of bonding length cannot be achieved
Solution Approach 1:
The patent introduces radiography images as an intermediary medium to indirectly measure bonding length. By using radiation transmission through the specimen and capturing the resulting image, the system can quantify bonding length without direct physical measurement, thus resolving the contradiction between qualitative inspection capability and quantitative measurement need
Solution Approach 2:
The patent replaces conventional mechanical/visual inspection methods with radiography-based optical measurement. This substitution enables quantitative determination of bonding length by measuring radiation transmission characteristics, transforming the inspection approach from purely visual/ultrasonic to radiographic measurement
2Manufacturing precision
If the gap between copper wires is reduced to 0.05 mm to 0.25 mm for proper solder infiltration, then capillary action is achieved, but defect size becomes smaller than the gap making quantitative evaluation difficult
Solution Approach 1:
The patent uses radiography images as an intermediary to detect defects in narrow gaps. The radiation transmission method provides enhanced contrast and magnification effect that makes small defects within 0.05-0.25 mm gaps visible and measurable, overcoming the limitation of direct visual inspection
Solution Approach 2:
The patent changes the detection parameter from visual/optical reflection to radiation transmission. This parameter change enables detection of defects smaller than the gap size by measuring radiation absorption differences, thus resolving the measurement difficulty in narrow gaps
3Reliability
If cut specimens are used for radiography inspection, then internal defects can be detected, but the inspection process becomes more complex requiring specimen preparation
Solution Approach 1:
The patent performs preliminary cutting of specimens to create cross-sections that can be properly positioned for radiography inspection. This preliminary action enables subsequent quantitative measurement of bonding length and defect detection, accepting the added complexity as necessary for achieving reliable measurements
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 quantitative evaluation of braze bonding length, enhancing the reliability of electrical rotating machines by accurately determining the seal function and bonding length, even in complex geometries and defects within narrow gaps.
Implementation Method 1
a radiation emission unit configured to emit radiation in a braze bonding length direction to each of a plurality of partial specimens
Implementation Method 2
a light generator configured to generate light of an amount corresponding to an intensity of transmissive radiation which is the radiation having passed through each of the partial specimens
Data Source
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AI summary
According to an embodiment, there is provided an apparatus (10) which quantitatively evaluates a braze bonding length. A radiation emission unit (12) emits radiation to each of a plurality of partial specimens which are obtained by cutting a specimen in a plane perpendicular to a braze bonding length direction. A light generator (16) generates light of an amount corresponding to an intensity of transmissive radiation. An imaging unit (18) photographs this light. A calculator (20) calculates a braze bonding length of each of the partial specimens, from a light amount obtained with respect to each of the partial specimens, based on a correlation between a braze bonding length and a light amount. The calculator (20) further calculates the braze bonding length of the specimen by totaling the braze bonding lengths of the respective partial specimens.