Ultrasonic Shear Wave Sensor Cuff for Permanent Component Monitoring
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Solution Overview
Problem
Current destructive testing methods for components, especially large-format or hard-to-reach components like offshore structures, lack effective non-destructive alternatives for permanent monitoring and are inefficient due to the need for manual guidance and specialist interpretation, particularly in detecting fine cracks and corrosion.
Innovation Solution
A system utilizing pairs of piezoelectric ceramic ultrasound converters with rectangular geometry, aligned parallel to each other's longitudinal axes, emitting shear waves that can be permanently attached to components for continuous monitoring, allowing for improved amplitude and range of operation with minimal thickness and adaptable design for uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection or ACFM methods are used by divers, then defect detection can be performed, but the inspection time and complexity increase significantly
Solution Approach 1:
The sensor cuff automatically performs ultrasonic measurements and stores data without requiring continuous manual operation. The system self-activates when immersed in water, eliminating the need for divers to manually move sensors along the component while maintaining detection capability.
Solution Approach 2:
The patent replaces manual mechanical inspection methods (divers physically moving coils or sensors) with an automated ultrasonic wave-based system. The electronic control unit automatically scans and evaluates the component, substituting human-operated mechanical processes with automated acoustic field methods.
2Area of stationary object
If sensor cuffs are made large enough to cover extensive areas, then more comprehensive monitoring is achieved, but they become impossible for divers to wear
Solution Approach 1:
The monitoring system is divided into multiple small sensor cuffs that can be individually worn by divers or attached to components. Each cuff covers a localized area but multiple cuffs can be deployed to achieve comprehensive coverage, balancing individual wearability with overall monitoring scope.
Solution Approach 2:
The system transitions from requiring large single-unit coverage to achieving coverage through multiple small units distributed in space. The monitoring capability is extended across large areas by deploying multiple compact sensors rather than using one large cumbersome device.
3Reliability
If conventional ultrasonic transducers are used, then defect detection capability is achieved, but they cannot remain permanently attached to components for continuous monitoring
Solution Approach 1:
The ultrasonic transducers are integrated into a flexible sensor cuff made of elastomeric material. This thin-film structure can conform to and remain permanently attached to the component surface, enabling continuous monitoring without requiring complex mounting hardware or structural modifications.
Solution Approach 2:
The sensor cuff combines elastomeric material with piezoelectric transducer elements to create a composite structure. This integration allows the sensing functionality to be permanently embedded in a flexible substrate that can adhere to various component surfaces, achieving both durability and ease of attachment.
4Measurement precision
If multiple measuring points are used to ensure thorough inspection, then detection accuracy improves, but the number of required measurements and time increase
Solution Approach 1:
The sensor cuff continuously scans the component surface as it moves along, performing measurements at numerous points without interruption. This eliminates the need to stop and manually reposition sensors between measurements, maintaining high detection accuracy while significantly improving inspection efficiency through uninterrupted data collection.
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 efficient, automated, and cost-effective long-term monitoring of components, enhancing detection accuracy and safety by allowing for the use of guided shear waves to detect defects without the need for frequent manual inspections or structural changes.
Implementation Method 1
two ultrasonic transducers, which form a pair and each have a piezoelectric ceramic plate-shaped element... The ultrasonic transducers of the pair are connected to a pulsed electrical voltage source... apply electrical voltages in the frequency range from 10 kHz to 1 MHz to the two ultrasonic transducers
Implementation Method 2
at least one of the two ultrasonic transducers in the pair... is/are configured to detect ultrasonic waves reflected from defects in the component and/or shear waves emitted simultaneously by the two ultrasonic transducers in the pair
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The system comprises two ultrasonic transducers (1, 2) forming a pair, each equipped with a rectangular piezoelectric ceramic plate-shaped element (1.1, 2.1) that can be attached to the surface of a component. The two ultrasonic transducers (1, 2) are positioned at a distance from each other such that there is no direct mechanical contact, and they are arranged side by side with their central longitudinal axes aligned parallel to each other. The two elements (1.1, 2.1) have different polarizations along their width b and are connected to an electrical voltage source with the same polarity. Alternatively, the two plate-shaped elements (1.1, 2.1) can have the same polarization along their width b and be connected to an electrical voltage source with opposite polarity.At least one ultrasonic transducer (1 or 2) and/or at least one further ultrasonic transducer is/are designed to detect ultrasonic waves reflected from defects and/or shear waves emitted simultaneously by the two ultrasonic transducers (1, 2) of the pair.