Single-Channel Ultrasonic Unit with Phased Array Probe
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Solution Overview
Problem
Ultrasonic testing with single channel units is time-consuming due to the need for multiple angle scans with single element probes, and phased array probes are expensive and cumbersome with dense probe cables.
Innovation Solution
A single channel ultrasonic testing unit is retrofitted with firmware and microprocessors to process data from a phased array ultrasonic probe, allowing sequential data transmission over a single conduit, reducing the need for multiple scans and cable complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single element probe with multiple angle scans is used, then the equipment cost is low, but the inspection time increases significantly
Solution Approach 1:
The probe is segmented into multiple independent ultrasonic transducer elements arranged in an array, allowing simultaneous multi-angle inspection without requiring multiple separate single-element probes and multiple scanning operations
Solution Approach 2:
The phased array probe integrates multiple transducer elements with independent control capabilities into a single device, enabling it to perform multiple inspection angles and functions that would otherwise require separate single-element probes and multiple scanning passes
2Productivity
If a phased array ultrasonic probe is used, then the inspection efficiency improves, but the equipment cost and cable complexity increase
Solution Approach 1:
Multiple independent transducer elements and their associated control circuits are integrated into a single probe housing with unified cable connection, combining what would otherwise be multiple separate probes and cables into one manageable unit
Solution Approach 2:
The phased array probe integrates multiple transducer elements with independent control capabilities into a single device, enabling it to perform multiple inspection angles and functions that would otherwise require separate single-element probes and multiple scanning passes
3Productivity
If a phased array ultrasonic probe is used, then the inspection efficiency improves, but the equipment cost increases
Solution Approach 1:
The probe is segmented into multiple independent ultrasonic transducer elements arranged in an array, allowing simultaneous multi-angle inspection without requiring multiple separate single-element probes and multiple scanning operations
Solution Approach 2:
The phased array probe integrates multiple transducer elements with independent control capabilities into a single device, enabling it to perform multiple inspection angles and functions that would otherwise require separate single-element probes and multiple scanning passes
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 ultrasonic inspection with reduced scanning time and cost, producing sector scan images without the need for expensive phased array systems, while simplifying probe cable management.
Implementation Method 1
electrical pulses are fed from the ultrasonic test unit to an ultrasonic probe where they are transformed into acoustic pulses by one or more ultrasonic transducers (e.g., piezoelectric elements) in the ultrasonic probe
Implementation Method 2
when an ultrasonic acoustic wave is reflected from the test object and contacts the surface of the ultrasonic transducer(s), it causes the transducer(s) to vibrate generating a voltage that is detected as a receive signal
Data Source
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Figure 2
AI summary
A device and method for ultrasonic inspection of a test object is disclosed. A plurality of ultrasonic transducer elements and electrical pulser circuits are provided for generating and transmitting electrical pulses. The device has an interface configured to communicate with a single channel ultrasonic testing unit.