Sheet Metal Joint Diagnosis Device Using Delay Material Ultrasonic Signal Ratio
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Solution Overview
Problem
Conventional ultrasonic testing methods for evaluating joint integrity in sheet metal are limited by the need for direct contact or immersion, which is impractical for complex shapes or objects that cannot be submerged, leading to inaccurate assessments due to variable contact force and state.
Innovation Solution
A diagnosis device that uses a detector to irradiate ultrasonic waves through a first and second medium with a delay material to distinguish and calculate the amplitude ratios of reflection signals, allowing for accurate joint defect diagnosis regardless of ultrasonic wave irradiation conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If direct contact method is used between ultrasonic sensor and test object, then detection can be performed without water medium, but accurate contact cannot be maintained due to complex shapes leading to measurement inaccuracy
Solution Approach 1:
The patent introduces a delay material as an intermediary substance between the ultrasonic sensor and the test object. This delay material fills the gaps caused by complex shapes and ensures consistent acoustic coupling without requiring direct contact or water immersion, thereby maintaining measurement precision while simplifying operation.
2Extent of automation
If immersion testing method is used, then automatic detection is enabled, but test objects that cannot be dipped into water or have complicated shapes cannot be examined
Solution Approach 1:
The delay material provides a universal solution that works for all test object shapes and sizes without requiring immersion. It enables the ultrasonic detection system to handle both simple and complex geometries, making the method universally applicable while maintaining automation capability.
3Adaptability or versatility
If water circulation device is used to maintain contact, then detection can be performed on various shapes, but contact force and contact state cannot be maintained under predetermined condition leading to inaccurate evaluation
Solution Approach 1:
The delay material serves as a reliable intermediary that maintains consistent acoustic coupling regardless of test object shape or position. Unlike water circulation systems that struggle to maintain predetermined contact conditions, the delay material inherently provides stable contact force and state, ensuring reliable and accurate evaluation.
4Device complexity
If amplitude of reflection signal is used to evaluate joint integrity, then simple evaluation is possible, but accurate diagnosis cannot be achieved due to variable ultrasonic wave irradiation conditions
Solution Approach 1:
The delay material acts as a standardized intermediary that eliminates variable irradiation conditions by ensuring consistent ultrasonic wave transmission. This allows the simple amplitude-based evaluation method to achieve high measurement precision, as the delay material compensates for shape variations and maintains uniform acoustic coupling.
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 more accurate and convenient joint defect diagnosis by calculating and displaying signal ratios, improving detection accuracy and applicability to various shapes and objects, regardless of ultrasonic wave conditions.
Implementation Method 1
a detector for irradiating an ultrasonic wave to a diagnosis object including a first medium and a second medium having a joint, and for sensing a reflection signal reflected from the joint and a reflection signal reflected from the joint and thereafter, reflected toward the joint on an inner surface of the first medium
Implementation Method 2
a delay material positioned between the detector and the diagnosis object to delay the reflection signal
Data Source
AI summary
There is provided a diagnosis device of a joint of sheet metal, including: a detector that irradiates an ultrasonic wave to a diagnosis object including a first medium and a second medium having a joint, and senses a reflection signal reflected from the joint and a reflection signal reflected from the joint and thereafter, reflected toward the joint on an inner surface of the first medium; a delay material positioned between the detector and the diagnosis object to delay the reflection signal; and a diagnoser that calculates and displays a signal ratio by receiving the reflection signals sensed by the detector.