3D Visualization of Solid Rotor Flaws via Ultrasonic Phased Array
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Solution Overview
Problem
Current boresonic inspection systems for solid rotors rely heavily on conservative assumptions due to the complexity of analyzing ultrasound data, leading to inaccurate flaw size estimation and a need for more accurate and user-friendly methods for non-destructive examination.
Innovation Solution
A method and apparatus for automatic non-destructive examination using three-dimensional visualization of solid rotors, achieved by associating two-dimensional ultrasound scan sample points with a regular 3D grid, determining kernel functions for each sample point, assigning weights based on their values, and interpolating values for overlapping image points to reconstruct a 3D volume, allowing for more accurate flaw detection and analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conservative assumptions are used in data analysis, then reliability of rotor integrity assessment is improved, but measurement precision of flaw size estimation deteriorates
Solution Approach 1:
The patent transforms the analysis approach by changing from conservative assumption-based parameters to actual measured ultrasound data parameters. The system uses measured flaw echo amplitudes and time-of-flight data to directly calculate flaw characteristics, replacing conservative estimation parameters with precise measurement parameters.
Solution Approach 2:
The patent replaces the manual engineering judgment system with an automated computer-based analysis system. The computer automatically processes ultrasound data, applies appropriate analysis methods, and generates flaw assessments, eliminating the need for conservative assumptions that arise from manual analysis limitations.
2Reliability
If manual analysis with engineering know-how is used, then reliability of assessment is improved, but ease of operation deteriorates
Solution Approach 1:
The system enables self-service analysis where the computer automatically performs flaw characterization without requiring operator expertise. The automated system selects appropriate analysis methods, processes ultrasound data, and generates assessments independently, making the system easy to operate while maintaining high reliability.
Solution Approach 2:
The patent replaces the manual expert analysis system with an automated computer-based system that encapsulates engineering know-how in software algorithms. This substitution maintains assessment reliability through sophisticated automated analysis while dramatically improving ease of operation by eliminating the need for specialized manual expertise.
3Measurement precision
If three-dimensional visualization is implemented, then measurement precision of flaw detection is improved, but device complexity increases
Solution Approach 1:
The patent transitions from two-dimensional ultrasound scan data to three-dimensional visual化 representation of rotor flaws. By adding the spatial dimension through 3D visualization, the system improves measurement precision by providing comprehensive spatial context of flaw locations, sizes, and orientations while managing complexity through automated processing.
Solution Approach 2:
The patent uses computer-based automated processing to generate three-dimensional visualizations from ultrasound data. This computational approach manages the complexity of 3D reconstruction and analysis, providing high measurement precision without requiring complex manual analysis procedures or specialized equipment operations.
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 reduces conservatism in data analysis, providing more accurate and user-friendly visualization and analysis of solid rotor integrity, enabling better flaw detection and estimation of remaining life cycles.
Implementation Method 1
ultrasound is used to detect defects and flaws in a rotor
Data Source
AI summary
A method and apparatus for three-dimensional visualization and analysis for automatic non-destructive examination of a solid Rotor using ultrasonic phased array is disclosed. Data is acquired by scanning a solid rotor with a phased array ultrasound transducer producing a plurality of two dimensional ultrasound scans. Each of a plurality of sample points of a plurality of two dimensional ultrasound scans are associated with a corresponding 3D image point of a regular grid. A kernel function for each of the plurality of sample points defining a size and shape of a kernel located at the corresponding image point is determined. A weight is assigned to each kernel which, in one embodiment, is based on the sample point value. A value for each image point of the regular 3D grid is determined based on kernels overlapping each image point. A three-dimensional volume representing the solid rotor is then visualized.