Single-Angle Wedge Phased Array for CR Wave Inspection
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Solution Overview
Problem
Existing methods for inspecting plate structures in high-end equipment, such as aerospace and automobiles, face challenges in detecting defects and damages due to the difficulty in exciting and receiving critically refracted longitudinal waves, which requires multiple wedges with specific inclination angles, leading to poor adaptability and increased costs.
Innovation Solution
A multi-material inspection system using single-angle wedges and a phased array ultrasonic system, where a transmitting and receiving wedge with the same inclination angle are designed, allowing for the calculation of longitudinal wave velocity without relying on thickness information, enabling efficient and reliable detection of critically refracted longitudinal waves across various materials and ultrasonic velocity changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple wedges with different inclination angles are designed for different materials, then the inspection accuracy for each material can be improved, but the device complexity and inspection cost increase
Solution Approach 1:
The patent applies universality by designing a single wedge that can inspect multiple materials with different ultrasonic velocities. The wedge is equipped with multiple piezoelectric crystal elements that can be selectively activated based on the material being inspected, allowing one wedge to perform the function of multiple material-specific wedges, thereby reducing device complexity while maintaining inspection accuracy
Solution Approach 2:
The patent changes the controllable parameter from physical wedge geometry (inclination angle) to electrical parameter (delay time of piezoelectric crystal elements). By adjusting the delay time electronically, the system can adapt to different materials and ultrasonic velocities without physically changing the wedge, thus resolving the contradiction between measurement precision and device complexity
2Measurement precision
If multiple wedges with different inclination angles are designed for different materials, then the inspection accuracy for each material can be improved, but the inspection cost increases
Solution Approach 1:
The patent reduces inspection cost by making the wedge universal - a single wedge with multiple piezoelectric crystal elements can inspect multiple materials, eliminating the need to purchase and maintain multiple material-specific wedges, thereby reducing the quantity of substances (materials) required while maintaining inspection accuracy
3Adaptability or versatility
If multiple wedges are used for different materials, then the adaptability to various materials is improved, but the ease of operation deteriorates due to wedge replacement requirements
Solution Approach 1:
The patent improves ease of operation by designing a universal wedge that works with multiple materials, eliminating the need for wedge replacement operations. The system achieves adaptability through electronic control of piezoelectric crystal elements rather than physical wedge changes, making the inspection process more convenient and easier to operate
Solution Approach 2:
The patent replaces the mechanical system of physical wedge replacement with an electrical/electronic system. Instead of mechanically changing wedges for different materials, the system uses electronic delay time adjustments of piezoelectric crystal elements to adapt to different materials, significantly improving ease of operation
4Adaptability or versatility
If phased array ultrasonic method is used to excite critically refracted longitudinal wave, then the adaptability to various materials is improved, but the difficulty of detecting and measuring increases due to complex delay law calculation
Solution Approach 1:
The patent replaces complex mechanical angle adjustments with electronic delay time control of piezoelectric crystal elements. This substitution simplifies the detection and measurement process by using electronic parameters instead of mechanical configurations, reducing the difficulty while maintaining adaptability to various materials
Solution Approach 2:
The patent changes the controlling parameter from mechanical inclination angle to electrical delay time. This parameter change simplifies the system because delay time can be precisely controlled and adjusted electronically without physical reconfiguration, reducing the difficulty of detection and measurement while maintaining adaptability
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 significantly improves detection efficiency and reliability, reduces costs, and enhances the characterization technology for high-end equipment by allowing single wedges to handle multiple materials and ultrasonic velocity changes, facilitating early defect detection and damage evaluation.
Implementation Method 1
Critically refracted longitudinal wave is a longitudinal wave incident at the first critical angle, parallel to the surface of a material and propagated along subsurface
Implementation Method 2
a certain number of piezoelectric crystal elements are selected from a phased array ultrasonic probe
Data Source
AI summary
A multi-material inspection system and velocity measurement method of critically refracted longitudinal wave based on single-angle wedges belong to the field of nondestructive testing of high-end equipment. The method includes the following steps: designing a transmitting wedge and a receiving wedge with the same inclination angle, and building phased array ultrasonic-based inspection systems of critically refracted longitudinal wave; estimating a longitudinal wave velocity range of a material to be tested, calculating and optimizing a phased array ultrasonic delay law, and building a relation between a longitudinal wave velocity and an amplitude of critically refracted longitudinal wave; reading and interpolating the arrival time of a received signal, and calculating a longitudinal wave velocity of the material to be tested; determining an optimal delay law, and exciting and receiving a critically refracted longitudinal wave.