Rapid Prototyping Ultrasonic Transducer Array Inspection
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Solution Overview
Problem
Current non-destructive inspection methods for complex structures, such as composite sandwich structures and hat stringers, face challenges in efficiently inspecting multiple-sided and difficult-to-reach features due to the need for specialized devices and manual operation, which are time-consuming and costly to design and maintain.
Innovation Solution
The use of rapid prototyping to create custom inspection devices with integrated matrix pulse echo ultrasonic transducer arrays and fluid coupling systems, allowing for flexible sensor arrangements and efficient inspection of complex structures, including those with multiple sides and corners, using either manual or robotic motion control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If specialized inspection devices are designed for each complex structure, then inspection precision is improved, but device complexity and design time increase
Solution Approach 1:
The patent applies universality by creating a standardized sensor holder platform that can accommodate multiple ultrasonic transducer types and configurations. The holder includes adjustable mounting mechanisms and interchangeable sensor arrays, allowing a single device design to inspect various complex structures (hat stringers, bulkheads, curved surfaces) without requiring custom-designed devices for each structure type, thereby reducing overall device complexity while maintaining inspection precision.
2Adaptability or versatility
If manual inspection methods are used, then flexibility in inspecting complex features is improved, but inspection speed and productivity decrease
Solution Approach 1:
The patent applies dynamics by incorporating adjustable and reconfigurable components in the sensor holder, such as adjustable sensor positions, interchangeable transducer arrays, and adaptable mounting mechanisms. These dynamic features allow the inspection device to be quickly reconfigured for different complex structures and inspection scenarios, maintaining the flexibility of manual inspection while enabling faster automated data collection and processing, thereby improving productivity without sacrificing adaptability.
3Adaptability or versatility
If custom inspection devices are designed for each application, then adaptability to specific structures is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent applies segmentation by dividing the inspection device into modular components: a standardized sensor holder platform, interchangeable sensor arrays, and detachable mounting mechanisms. This segmentation allows the core platform to be manufactured once and reused across multiple applications, while only the sensor arrays need to be customized for specific structures. This significantly reduces manufacturing cost and time compared to designing completely custom devices for each application, while still maintaining adaptability to specific structural requirements.
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 fast and efficient non-destructive inspection of complex structures by allowing for custom-designed inspection devices that can adapt to various shapes and sizes, improving inspection speed and reducing costs associated with device design and maintenance.
Implementation Method 1
the PEU transducer transmits an ultrasonic signal into the structure under inspection and receives the reflection of the ultrasonic signal from the structure
Implementation Method 2
one-sided pulse echo ultrasonic (PEU) testing
Implementation Method 3
facilitate coupling of ultrasonic signals between inspection sensors of apparatus and systems of embodiments of the present invention, such as pulse echo ultrasonic sensors, a couplant may be disposed between the inspection sensors and a respective surface of the structure under inspection
Data Source
AI summary
Apparatus, systems, and methods for inspecting a structure are provided which use a sensor holder constructed from rapid prototyping, such as stereolithography, and which is configured to support a plurality of inspection sensors typically arranged in an ordered matrix array and possibly with one or more additional inspection sensors aligned for inspection of difficult to inspect features of a structure such as radius corner or edge features. Rapid prototype integrated matrix array inspection apparatus, systems, and methods provide fast and efficient methods of constructing custom inspection devices.