Stationary Phased Array Inspection for Non-Linear Cross Sections
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Solution Overview
Problem
Existing inspection systems for components with non-linear cross-sections, such as those in aerospace, maritime, and automotive industries, face challenges in detecting defects and anomalies due to limited inspection coverage and increased complexity, especially with closed-loop structures, leading to frequent scanning stoppages and maintenance issues.
Innovation Solution
A system featuring a stationary sensor element with geometrically complementary phased array sensing units and a drive assembly that moves the part relative to the sensor, allowing for focused ultrasonic inspection beams to be emitted perpendicular to the part's surface, enhancing defect detection and reducing system complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If flat phased arrays are used in Through-Transmission Ultrasonic mode to inspect components, then inspection capability is provided, but foreign material detection becomes difficult and inspection coverage along curved cross-sections is limited
Solution Approach 1:
The patent inverts the traditional inspection approach by making the component rotate through the stationary sensor array instead of moving the sensor array along the component. This inversion allows the phased arrays to maintain a fixed geometric relationship with the component's cross-section, enabling consistent inspection coverage including curved surfaces and radii that were previously difficult to inspect.
Solution Approach 2:
The patent employs curved phased arrays that match the curvature of the component's cross-section. By shaping the sensor arrays to conform to the component's geometry (e.g., circular arcs for tubular structures), the system achieves complete inspection coverage of curved surfaces and radii, eliminating blind spots present in flat array configurations.
2Area of stationary object
If multiple pairs of flat phased arrays are used to enhance inspection coverage along curved cross-sections, then inspection coverage improves, but system complexity increases and maintenance requirements increase
Solution Approach 1:
Instead of adding more sensor arrays to expand coverage, the patent inverts the system by rotating the component through a stationary array. A single pair of curved phased arrays, positioned to span the component's cross-section, achieves complete inspection coverage of the entire component length through rotation, eliminating the need for multiple array pairs.
Solution Approach 2:
The stationary curved phased array system serves multiple functions simultaneously: it inspects the entire length of the component, covers all curved surfaces and radii, and detects all defect types (including foreign materials) in a single configuration, replacing what would otherwise require multiple specialized array pairs.
3Productivity
If the component is clamped to stationary clamps and the phased arrays are moved along the component, then inspection is performed, but closed-loop structures require manual clamp operation and cable twisting occurs causing frequent stoppages
Solution Approach 1:
The patent inverts the motion relationship: instead of moving sensors along a stationary component, the component rotates through stationary sensors. This eliminates cable twisting issues and manual clamp operations for closed-loop structures, as the component's own rotation provides the inspection motion.
Solution Approach 2:
The component itself serves as the moving element by rotating through the inspection zone. This self-rotation eliminates the need for external cable management systems and manual clamp operations, allowing continuous inspection of closed-loop structures without stoppages for cable untangling.
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 solution enables efficient, non-destructive inspection of parts with non-linear cross-sections, improving defect detection and reducing downtime by maintaining consistent inspection coverage and minimizing maintenance needs.
Implementation Method 1
One of the pair of flat phased arrays 201a, 201b transmits an ultrasonic signal and one of the pair of flat phased arrays 201a, 201b receives the ultrasonic signal as the ultrasonic signal passes through the component 203
Implementation Method 2
a stationary sensor element including at least one phased array sensing unit, each of the at least one phased array sensing unit having a shape that is geometrically complimentary to the non-linear cross section of the part
Data Source
AI summary
In accordance with one or more aspects of the present disclosure, an apparatus for inspecting a part having a non-linear cross section includes a stationary sensor element including at least one phased array sensing unit, each of the at least one phased array sensing unit having a shape that is geometrically complimentary to the non-linear cross section of the part, and a support for the part having the non-linear cross section, the support comprising a drive assembly configured to move the part relative to the stationary sensor element, through an inspection beam emitted from the at least one phased array sensing unit.