Segmented Ultrasonic Probe for Thick Material Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ultrasonic inspection methods for thick materials require multiple probes due to the near-field length and sound field divergence issues, leading to increased technical and cost burdens, as well as unreliable echo evaluations for deep flaws.
Innovation Solution
An ultrasonic test probe with a transducer divided into individually activatable segments forming concentric circles or rings, allowing for controlled sound field adaptation by adjusting the active surface diameter, enabling reliable inspection of thick materials with a single probe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single ultrasonic test probe is used for thick material inspection, then device complexity is reduced, but the near-field length and sound field divergence cause unreliable echo evaluations for deep flaws
Solution Approach 1:
The ultrasonic transducer is divided into multiple independently controllable segments arranged in concentric circles or rings. By selectively activating different segments, the probe can adapt its sound field characteristics to match the inspection depth requirements, enabling reliable evaluation of both shallow and deep flaws with a single probe.
Solution Approach 2:
The probe dynamically adjusts its active surface diameter by controlling which segments are activated. This dynamic adaptation allows the near-field length and sound field divergence characteristics to be optimized for the specific inspection task, maintaining reliability across varying material thicknesses.
2Length of stationary object
If the active surface diameter is increased to reduce sound field divergence for deep inspection, then inspection depth capability is improved, but the near-field length increases causing unreliable evaluations for shallow flaws
Solution Approach 1:
By segmenting the transducer into concentric rings, the system can selectively activate only the inner segments for shallow flaw detection (maintaining short near-field length) or activate all segments for deep inspection (increasing effective aperture). This selective activation resolves the contradiction between deep inspection capability and shallow flaw detection accuracy.
Solution Approach 2:
Different segments of the transducer are activated based on the inspection depth requirement. For shallow flaws, only inner segments are active; for deep flaws, outer segments are also activated. This local quality adjustment optimizes the sound field characteristics for the specific inspection task.
3Adaptability or versatility
If multiple probes with different active surface diameters are used to cover different depth ranges, then inspection coverage is improved, but technical burden and costs increase
Solution Approach 1:
A single ultrasonic test probe is designed with multi-functionality by incorporating multiple independently controllable segments. This universal probe can perform inspections at all depth ranges by dynamically configuring which segments are active, eliminating the need for multiple specialized probes and reducing technical burden and costs.
Solution Approach 2:
The probe transitions from a static, fixed-aperture design to a dynamic, variable-aperture design. The ability to change the effective active surface diameter on-demand allows one probe to replace multiple probes with different fixed diameters, achieving versatility without increasing device complexity.
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 allows for standardized inspections across thick materials using a single probe, improving reliability and reducing costs by satisfying specific inspection criteria and maintaining signal amplitude, thus overcoming the limitations of multiple probe usage.
Implementation Method 1
a short ultrasonic pulse generated by an ultrasonic transducer acting as a transmitter is suitably insonified into a test object so that it propagates in the test object
Implementation Method 2
If the pulse hits a flaw in the test object, for example a discontinuity operated as a receiver, or a geometric structure, the pulse is reflected at least partially
Implementation Method 3
The reflected pulse is detected by means of an ultrasonic transducer
Data Source
Figure 1
Figure 2~4
Figure 3
AI summary
A method and device for the non-destructive inspection of a test object (10) with a great material thickness by means of ultrasound based on an ultrasonic test probe (20) with an ultrasonic transducer (22) divided into a plurality of individually activatable transducer segments (24), wherein the transducer segments (24) are concentric circles or rings, or sections thereof.