Real-Time Augmented Reality Ultrasonic Testing for 3D Defect Positioning
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Solution Overview
Problem
Existing methods for non-destructive testing using ultrasound struggle to provide a realistic 3D visualization of internal defects in mechanical parts, as simple holograms fail to convey depth and spatial positioning effectively.
Innovation Solution
A method and device for real-time visualization in augmented reality, using an optical motion tracking system, a sensor holder, and a non-destructive testing sensor, which superimposes holographic 3D representations on a real view, creating occlusions and signal viewing surfaces aligned with the sensor's paths, allowing precise 3D positioning of ultrasonic signals within the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a simple hologram display is used to visualize 3D-positioned data, then the data can be displayed in 3D space, but the user cannot perceive depth and spatial positioning effectively
Solution Approach 1:
The patent introduces a virtual cutout plane as an intermediary element between the user and the 3D holographic data. This cutout plane acts as a reference surface that provides spatial context, allowing users to understand the depth and position of internal defects relative to the external surface of the mechanical part. The cutout plane serves as a mediator that translates abstract 3D coordinates into perceptible spatial relationships.
Solution Approach 2:
The patent adds a fifth dimension to the visualization by introducing the virtual cutout plane that intersects the 3D holographic model. This additional dimensional element (the cutting plane orientation and position) transforms the visualization from a static 3D display into a dynamic multi-planar representation, enabling users to perceive internal structures at different depths and angles simultaneously.
2Reliability
If the entire examination area is scanned to ensure complete coverage, then all defects can be detected, but the testing time increases
Solution Approach 1:
The patent implements real-time feedback visualization that continuously displays the sensor's position, the scanned area coverage, and detected defects during the examination process. This feedback mechanism allows operators to monitor scanning progress and make immediate adjustments, ensuring complete coverage while optimizing the scanning path to reduce unnecessary movements and testing time.
Solution Approach 2:
The system performs preliminary planning of the scanning path before the actual examination begins. By pre-calculating the optimal scanning trajectory that ensures complete coverage of the examination area, the system minimizes redundant movements and testing time while maintaining 100% coverage reliability.
3Measurement precision
If multiple holographic elements are superimposed to create occlusion effects, then realistic depth perception is achieved, but the device complexity increases
Solution Approach 1:
The patent segments the visualization into distinct functional layers: the external surface model, the virtual cutout plane, and the internal defect holograms. Each layer is independently rendered and then composited together, allowing the system to achieve realistic occlusion effects without requiring a completely complex monolithic visualization system. This segmentation enables modular development and optimization of each component.
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 the operator to perceive ultrasonic signals as if inside the mechanical part, providing a realistic 3D immersion and accurate spatial understanding of defects through augmented reality visualization.
Implementation Method 1
A suitable sensor emits ultrasound at a frequency (usually between 500 kHz and 100 MHz) chosen according to the nature of the part to be tested
Implementation Method 2
The waves are reflected on the acoustic interfaces encountered: contours of the room, interior defects
Implementation Method 3
an optical motion tracking system to which a reference frame is linked
Implementation Method 4
Visualization, on the augmented reality visualization device, of a real view of the mechanical part, of the sensor holder and of the non-destructive testing sensor, a holographic 3D representation of the mechanical part, of the sensor holder and of the non-destructive testing sensor, superimposed on the real view
Data Source
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AI summary
The invention relates to a method for displaying in real time a signal emitted by a non-destructive testing device comprising a rigid body, a non-destructive testing sensor connected to the rigid body, and an augmented reality display device, the method comprising the following steps: - emitting (210) and receiving (220) the signal by the sensor; - determining (230) a cut-out of an occlusion inside the mechanical part; - determining (240) a signal display surface constructed from the paths of the signal; and - displaying (250) - a superimposed real view and holographic 3D representation of the mechanical part, from the non-destructive testing sensor, and - a holographic representation of the cut-out of the occlusion and of the signal display surface, superimposed on the real view.