Ultrasonic Inspection Acoustic Modeling Simulation
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Solution Overview
Problem
Ultrasonic inspection systems often perform suboptimally due to user lack of expertise in selecting appropriate transducer configurations and material properties, leading to degraded inspection quality, especially when dealing with complex objects like semiconductor chips or micro-machined devices with multiple layers.
Innovation Solution
A simulation tool that predicts the response of an object to ultrasound based on estimated material properties and transducer characteristics, allowing users to configure the inspection system by setting time gates, selecting transducers, and optimizing beam focus, and enabling comparison of predicted and actual A-scans to adjust settings for improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a simulation tool is implemented to predict ultrasonic response, then inspection quality and measurement precision are improved, but device complexity and ease of operation are worsened due to the need for users to input material properties and configure parameters
Solution Approach 1:
The patent creates a virtual copy of the inspection system through acoustic modeling and simulation. The software tool replicates the ultrasonic inspection process in a virtual environment, allowing users to predict A-scans and optimize settings before actual inspection. This copying approach improves measurement precision by enabling thorough system configuration and parameter optimization without adding physical complexity to the actual inspection hardware.
2Measurement precision
If acoustic modeling and simulation are used to optimize transducer configuration, then measurement precision and inspection accuracy are improved, but ease of operation is worsened due to the expertise required to use the simulation tool effectively
Solution Approach 1:
The simulation tool performs preliminary actions by allowing users to model acoustic properties, predict A-scans, and optimize transducer configurations before actual inspection. Users can experiment with different material properties, transducer positions, and time gate settings in the virtual environment, thereby improving inspection accuracy while reducing the complexity of the actual inspection operation.
Solution Approach 2:
The simulation tool provides feedback by comparing predicted A-scans with actual measured A-scans. This feedback mechanism allows users to iteratively adjust material properties and transducer configurations to improve the match between simulation and reality, thereby enhancing inspection accuracy while making the system progressively easier to use through learned optimization patterns.
3Productivity
If time gates are optimized using simulation, then productivity and inspection efficiency are improved, but measurement precision may be worsened due to potential oversimplification of complex acoustic interactions
Solution Approach 1:
The simulation tool employs dynamic acoustic modeling that can adapt to different inspection scenarios. The system can model complex acoustic interactions including multiple reflections, mode conversions, and diffraction effects dynamically based on the specific object geometry and material properties. This dynamic approach ensures that productivity gains from optimized time gating do not compromise measurement precision, as the simulation accurately represents the actual acoustic physics.
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
Enhances the quality of ultrasonic inspections by allowing users to accurately model and adjust for material properties and beam focus, reducing interference from internal multiples and improving the alignment of predicted and measured A-scans, resulting in clearer inspection images and more precise material characterization.
Implementation Method 1
An ultrasonic transducer is used to insonify an object
Implementation Method 2
A simulation tool predicts a response of the object to ultrasound from the ultrasonic transducer
Data Source
AI summary
Configuration of an ultrasonic inspection system is facilitated using an ultrasound response predicted by a simulation tool. In one embodiment, estimated material properties of an object to be inspected are input to the simulation tool. Also input to the simulation tool is at least one estimated property of an ultrasonic transducer of the ultrasonic inspection. The simulation tool predicts the response of the object to ultrasound from the ultrasonic transducer. This response is dependent upon the estimated material properties of the object to be inspected and the at least one estimated property of the ultrasonic transducer. The ultrasonic inspection system is then configured dependent upon a feature of the predicted response. The system may be configured, for example, by setting the position of a time gate, selecting an appropriate ultrasonic transducer, selecting the position of the transducer to achieve good focus, or selecting parameters for signal processing.