Spring-Driven Ultrasonic Weld Profiling System
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Solution Overview
Problem
Current methods for inspecting resistance spot welds, such as pry checks and physical tear-downs, are destructive, costly, and not suitable for lightweight or high-strength materials, and traditional ultrasonic spot-weld inspection systems require motorized mechanical systems that are complex and prone to errors in harsh environments.
Innovation Solution
A non-motorized ultrasonic profiling system using a translation element with a spring and encoder to move a sensor over a weld sample, allowing for precise ultrasonic measurements without motorized parts, enabling accurate imaging of welds without physical contact and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If motorized mechanical systems are used to move the ultrasonic probe, then automated scanning and imaging are achieved, but system complexity increases and reliability decreases in harsh environments
Solution Approach 1:
The patent removes the motorized translation mechanism from the probe assembly, extracting the problematic component that caused reliability issues. The probe is now manually positioned and held stationary during scanning, eliminating motors, gears, and moving parts that fail in harsh automotive manufacturing environments.
Solution Approach 2:
The patent replaces the motorized mechanical translation system with a manual positioning system. Instead of using motors to move the probe, an operator manually positions the probe and holds it in place, substituting automated mechanical motion with manual control and eliminating the associated reliability problems.
2Productivity
If motorized systems are used for probe translation, then automated scanning is enabled, but device complexity and maintenance costs increase
Solution Approach 1:
The patent extracts and removes the motorized translation system from the probe assembly, eliminating complex mechanical components including motors, drive mechanisms, and control systems. This simplification reduces device complexity while maintaining scanning capability through manual operation.
Solution Approach 2:
The operator manually positions and holds the probe during scanning operations, making the system self-sufficient without requiring complex automated translation mechanisms. The human operator serves as the positioning mechanism, eliminating the need for motorized systems and reducing overall device complexity.
3Extent of automation
If motorized translation systems are used, then automated probe movement is achieved, but speed irregularities cause measurement inaccuracies
Solution Approach 1:
The patent removes the motorized translation system that caused speed irregularities and measurement inaccuracies. By eliminating the automated translation mechanism, the source of speed variation is removed, and the probe position is controlled manually to ensure accurate positioning during scanning.
Solution Approach 2:
The patent replaces the motorized mechanical translation system with manual positioning control. The operator manually positions the probe and maintains it in the correct position during scanning, substituting automated mechanical motion with human control to eliminate speed irregularities and improve measurement precision.
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
The system provides accurate, non-destructive ultrasonic profiling of welds, reducing costs and enabling the use of lightweight materials by eliminating the need for motorized systems, thus improving inspection efficiency and reliability.
Implementation Method 1
A spring is connected at one end of the translation element. Upon the translation element being moved in the first direction toward the spring such that the translation element and the sensor are at a beginning position relative to the weld sample and the spring is compressed the spring decompresses to push the translation element back along the second direction
Implementation Method 2
Ultrasonic weld profiling is a non-destructive testing technique that allows welds to be sized and discrepant welds to be identified. This technique involves measuring the ultrasonic energy transmitted and reflected at the welded interface.
Data Source
AI summary
A system for ultrasonic profiling of a weld sample includes a carriage movable in opposite first and second directions. An ultrasonic sensor is coupled to the carriage to move over the sample as the carriage moves. An encoder determines the position of the carriage to determine the position of the sensor. A spring is connected at one end of the carriage. Upon the carriage being moved in the first direction toward the spring such that the carriage and the sensor are at a beginning position and the spring is compressed the spring decompresses to push the carriage back along the second direction to move the carriage and the sensor from the beginning position to an ending position. The encoder triggers the sensor to take the ultrasonic measurements of the sample when the sensor is at predetermined positions while the sensor moves over the sample between the beginning and positions.