U-Shaped Stirrup Transducer Support for Flange Ultrasonic Testing
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Solution Overview
Problem
Existing ultrasonic immersion testing installations struggle to access and effectively test the transverse end flanges and connecting regions of tubular parts with complex geometries, such as those found in jet engine fan casings, due to bulky transducer supports that hinder curvature following and require complex robotic arm synchronization, leading to incomplete defect detection and prolonged testing times.
Innovation Solution
A U-shaped or C-shaped stirrup structure bearing controllable transducers is used, allowing for total accessibility to flanges and connecting regions without contact, with a single robotic arm and an immersion container for partial liquid coupling, enabling efficient testing of the entire periphery and reducing the need for oversized tanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bulky transducer supports are used to maintain transducer alignment, then transducer positioning stability is improved, but accessibility to flange regions and connecting regions deteriorates
Solution Approach 1:
The support structure is segmented into multiple articulated components (first support member, second support member, articulation joints) that can independently adjust their positions and orientations. This segmentation allows the structure to navigate complex geometries while maintaining transducer alignment, resolving the contradiction between stability and accessibility.
Solution Approach 2:
The support structure incorporates articulation joints that enable dynamic adjustment of the support members' configurations. This dynamic capability allows the structure to adapt to different regions (cylindrical wall vs. flange vs. connecting region) while maintaining proper transducer positioning, thus achieving both stability and accessibility.
2Measurement precision
If two synchronized robotic arms are used to position transducers, then transducer alignment precision is improved, but device complexity deteriorates
Solution Approach 1:
The invention merges the positioning functions of two separate robotic arms into a single robotic arm that controls an articulated support structure. This consolidation reduces device complexity while maintaining alignment precision through the articulated mechanism's inherent capability to position transducers accurately on complex geometries.
Solution Approach 2:
The single robotic arm is designed with multi-functionality, capable of positioning both the first and second support members that hold the transducers. This universal positioning capability replaces the need for two specialized robotic arms, reducing complexity while maintaining precision through the articulated support structure.
3Reliability
If full immersion testing is used to ensure complete coverage, then testing completeness is improved, but testing time deteriorates
Solution Approach 1:
The invention applies local quality by using partial immersion testing tailored to specific regions being tested. The support structure enables the transducers to maintain proper alignment and coupling with the test piece in both immersed and non-immersed regions, allowing complete coverage without requiring full immersion, thus improving testing speed while maintaining completeness.
4Ease of operation
If oversized tanks are used to accommodate complex geometries, then accessibility to all regions is improved, but device complexity and space requirements deteriorate
Solution Approach 1:
The support structure is segmented into articulated members that can independently position themselves to access different regions. This segmentation eliminates the need for a large tank to accommodate the entire complex geometry, as the articulated structure can reach into flange regions and connecting regions while maintaining a compact overall footprint.
Solution Approach 2:
The dynamic articulation of the support members allows them to adapt their configurations to access various regions of the test piece. This dynamic capability enables complete region accessibility without requiring an oversized stationary tank, thus reducing space requirements while maintaining ease of operation.
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 design allows for optimal testing of material singularities with improved accessibility and reduced testing time, enabling comprehensive inspection of transverse flanges and connecting regions without contact, using a single robotic arm and partial immersion, thus enhancing the quality and efficiency of ultrasonic testing.
Implementation Method 1
ultrasonic immersion testing installation is used... transducers for emitting and receiving ultrasound... testing by a relative movement of the two synchronized robotic transducers
Implementation Method 2
Water jet nozzles 16, 17 are of course provided on the arms, coaxially with the transducers, and make it possible to facilitate the appropriate transmission or propagation of the beam of ultrasound waves by a continuous water jet in order to 'couple' the transducers to the part
Data Source
AI summary
To test transverse flanges terminating at a cylindrical wall of a workpiece, an installation includes a structure in a form of a U-shaped or C-shaped stirrup whose opposite branches carry respectively an ultrasound emitter transducer and receiver transducer, aligned with respect to one another, while leaving between them an internal space for relative passage of the flange to be tested, and whose base is mounted articulated at an extremity of a mobile control arm. The installation also includes an immersion canister including two parts assembled together by a closure mechanism, one of the parts exhibiting cutouts for engaging the transverse flange and for overlapping, with the other part, the flange up to the cylindrical wall of the workpiece.