Rotating Phased-Array Probe for Pipe Inspection
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Solution Overview
Problem
Conventional non-destructive testing (NDT) systems for elongated objects like pipes and bars face challenges in efficiently inspecting large objects with complex motion control requirements, high maintenance costs, and limited adaptability to varying object sizes, leading to reduced inspection quality and productivity.
Innovation Solution
A rotating phased-array inspection system that moves phased-array probes in an encircling motion around the test object, using small and robust data acquisition units with wireless data transmission, and a stationary source for electricity, couplant fluid, and pressurized air, allowing for high precision and versatility in detecting defects without rotating the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pipe inspection systems use multiple probe heads positioned along the test object's longitudinal axis with complex motion control, then inspection coverage is improved, but system complexity and maintenance costs increase
Solution Approach 1:
Instead of moving multiple probe heads along the test object's longitudinal axis, the patent inverts the approach by rotating a single probe head circumferentially around the stationary test object. This eliminates complex axial positioning mechanisms while achieving complete inspection coverage through rotational motion.
Solution Approach 2:
A single probe head is designed to perform multiple inspection functions by rotating to different angular positions, replacing the need for multiple specialized probe heads. The probe head can inspect various circumferential locations and defect orientations through its rotational capability.
2Adaptability or versatility
If conventional systems rotate large test objects for inspection, then multi-angle inspection is achieved, but motion control requirements and space requirements increase
Solution Approach 1:
Instead of rotating the large test object to achieve multi-angle inspection, the patent rotates the small probe head circumferentially around the stationary test object. This inverts which component moves, dramatically reducing motion control complexity while maintaining the ability to inspect from multiple angles.
Solution Approach 2:
The inspection approach transitions from axial movement along the test object's length to circumferential rotation around the test object. This dimensional change allows multi-angle inspection without requiring the test object to rotate or move axially through complex positioning systems.
3Manufacturing precision
If conventional systems use large probe assemblies to cover all inspection angles, then complete inspection coverage is achieved, but system footprint and space requirements increase
Solution Approach 1:
The probe head transitions from a static, fixed-position assembly to a dynamic, rotating component. This allows a single compact probe head to access all circumferential inspection positions through rotation, eliminating the need for large static probe assemblies that would occupy significant space.
Solution Approach 2:
The rotating probe head assembly is designed to rotate within a compact circumferential path around the test object, with the rotation mechanism nested within a space-efficient configuration. This minimizes the overall system footprint while maintaining full inspection coverage capability.
4Measurement precision
If conventional systems use complex multi-angle probe arrangements, then defect detection capability is improved, but ease of operation and maintenance decrease
Solution Approach 1:
Instead of arranging multiple probes at fixed angles to detect defects, the patent uses a single probe head that rotates to achieve the necessary inspection angles. This simplifies operation as only one probe head needs to be positioned, calibrated, and maintained, while still providing comprehensive defect detection capability.
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 solution simplifies motion control, reduces system complexity and space requirements, enhances inspection quality, and increases productivity by enabling a wide range of incident angles and focal depths, improving the efficiency and cost-effectiveness of NDT processes.
Implementation Method 1
The present disclosure primarily describes exemplary inspection methodologies that employ phased-array or single element UT probes
Implementation Method 2
a probe assembly including phased-array probes, the probe assembly being configured to induce signals in the test object and sense echoes reflected from the test object
Implementation Method 3
a wireless transceiver integrated into the rotating probe assembly and operable to transmit data to and from the user operating station
Data Source
AI summary
A device is disclosed for performing non-destructive inspection and testing (NDT/NDI) of an elongated test object, wherein the inspection system includes: a test object conveyor for conveying the test object along a longitudinal conveyance path; a probe assembly including phased-array probes, the probe assembly being configured to induce signals in the test object and sense echoes reflected from the test object; a probe assembly conveyor configured to movably support the probe assembly, to move the probe assembly on a circumferential path about the test object; and a control system coupled to the test object conveyor and to the probe assembly conveyor and configured to allow data acquisition by and from the phased-array probes while, simultaneously, the test object moves along the longitudinal path and the phased-array probes move on the circumferential path. The test system may include phased-array probes of different types to optimize detecting faults or cracks in the test object which extend in different directions.