Piezoelectric Sensor Array Geometry for Structural Defect Detection

Solution Overview

Problem

Conventional methods for detecting abnormalities in structures, such as cracking and corrosion in aircraft, are burdensome due to the need for disassembly and time-consuming ultrasonic testing, which is inefficient and costly.

Innovation Solution

A piezoelectric sensor apparatus with specific geometric configurations of transducers and sensors is attached to the structure to generate and sense acoustic waves, allowing for continuous monitoring without disassembly, and provides accurate abnormality detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional ultrasonic testing methods are used to detect abnormalities in structures, then measurement precision is improved, but loss of time and ease of operation deteriorate due to disassembly requirements

Engineering Contradiction:

Improveabnormality detection accuracyVSAvoidtesting time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The piezoelectric sensor apparatus is pre-configured with multiple transducers and sensors in specific geometric arrangements before deployment. This preliminary setup allows the system to immediately begin monitoring and detecting abnormalities without requiring time-consuming disassembly or reconfiguration during the testing phase.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces conventional mechanical ultrasonic testing methods with an electrical field-based piezoelectric sensor system. The piezoelectric transducers generate electrical signals that are converted to mechanical vibrations in the structure, and the resulting acoustic waves are detected by piezoelectric sensors, eliminating the need for mechanical contact and disassembly associated with traditional ultrasonic testing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If conventional ultrasonic testing methods are used to detect abnormalities in structures, then measurement precision is improved, but device complexity and ease of operation worsen due to disassembly requirements

Engineering Contradiction:

Improveabnormality detection accuracyVSAvoidaccessibility to structure

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The piezoelectric sensor apparatus is pre-configured with multiple transducers and sensors in specific geometric arrangements before deployment. This preliminary setup allows the system to immediately begin monitoring and detecting abnormalities without requiring time-consuming disassembly or reconfiguration during the testing phase.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces conventional mechanical ultrasonic testing methods with an electrical field-based piezoelectric sensor system. The piezoelectric transducers generate electrical signals that are converted to mechanical vibrations in the structure, and the resulting acoustic waves are detected by piezoelectric sensors, eliminating the need for mechanical contact and disassembly associated with traditional ultrasonic testing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If piezoelectric sensor apparatus with specific geometric configuration is used, then productivity is improved by eliminating disassembly, but device complexity increases

Engineering Contradiction:

Improvedetection efficiencyVSAvoidsensor array configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The piezoelectric sensor apparatus is divided into multiple independent piezoelectric transducers and sensors, each positioned at specific locations according to geometric configurations. This segmentation allows the system to achieve comprehensive coverage and high detection efficiency while maintaining modular simplicity, as each element can be independently configured and replaced if needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The piezoelectric sensor apparatus is designed with multiple transducers and sensors that can detect various types of abnormalities including cracks, corrosion, and delamination. The same basic apparatus configuration can be applied to different structural components and inspection scenarios, providing universal functionality that reduces overall system complexity despite the multi-element arrangement.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The apparatus enables prompt, efficient, and accurate detection of abnormalities in structures by generating and sensing acoustic waves, eliminating the need for disassembly and providing reliable results at accessible locations.

Implementation Method 1

piezoelectric transducers configured to generate waves through the structure

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

piezoelectric sensors configured to sense the waves generated by the piezoelectric transducers

Methodology Applied

Scientific EffectPiezoelectric effect: Converse Piezoelectric Effect

Data Source

PatentUS20250327715A1Apparatus, system, and method for detecting an abnormality in a structure

Publication Date: 2025.10.23 THE BOEING CO

AI summary

An apparatus for detecting an abnormality in a structure includes a base, configured to be attached to the structure, and piezoelectric transducers, configured to generate waves through the structure, coupled to the base, spaced apart from each other, and aligned with each other along a transducer plane. The apparatus additionally includes piezoelectric sensors configured to sense the waves generated by the piezoelectric transducers, coupled to the base, spaced apart from each other, and aligned with each other along a lateral sensor plane. A distance between adjacent ones of the piezoelectric sensors is the same. A size of each one of the piezoelectric transducers is greater than a size of each one of the piezoelectric sensors. A distance between the transducer plane and the lateral sensor plane is greater than a distance between adjacent ones of the piezoelectric transducers and greater than a distance between adjacent ones of the piezoelectric sensors.