Acute-Angle Ultrasonic Array for Complex Geometry Inspection
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Solution Overview
Problem
Conventional ultrasonic test heads with linear transducer arrays are inefficient for non-destructive material testing of components with complex geometries or hard-to-reach areas, as they require multiple arrays and complex positioning, leading to reduced sensitivity and increased image artifacts due to insufficient sound wave coupling and interference effects.
Innovation Solution
An ultrasonic test head with a two-dimensional array of transducers arranged at acute angles to the support surface, allowing for preferred direction coupling of sound waves oblique to the surface normal, enhancing intensity and reducing interference, and featuring uneven distribution and stochastic arrangements to improve signal-to-noise ratio and access to difficult areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple linear arrays are combined in a phased beam configuration to inspect complex geometries, then coverage of different defect types is improved, but device complexity and positioning requirements increase significantly
Solution Approach 1:
The patent transitions from linear one-dimensional transducer arrays to two-dimensional arrays arranged in a phased beam configuration. This dimensional change allows the system to achieve coverage of multiple defect types and complex geometries within a single array structure, eliminating the need for multiple separate linear arrays and complex positioning mechanisms while maintaining adaptability to various inspection requirements
2Ease of manufacture
If transducers are arranged in a regular matrix pattern, then manufacturing is simplified, but image artifacts increase due to interference effects
Solution Approach 1:
The patent employs asymmetric and irregular arrangements of transducers within the two-dimensional array, specifically using stochastic distributions and spiral-arm-shaped patterns instead of regular matrix patterns. These asymmetric arrangements disrupt the constructive interference that causes image artifacts while maintaining manufacturability through defined geometric patterns, thereby reducing harmful interference effects in the inspected component images
3Use of energy by moving object
If transducers are spaced closely together, then sound wave coupling intensity is maintained, but access to hard-to-reach areas is limited
Solution Approach 1:
The patent segments the two-dimensional transducer array into multiple independently controllable groups or subsets. This segmentation allows different portions of the array to be activated selectively and independently, enabling the system to adapt sound wave coupling to specific geometric features and hard-to-reach areas while maintaining sufficient intensity through coordinated activation of appropriate transducer segments
4Use of energy by moving object
If sound waves are coupled perpendicular to the surface, then coupling efficiency is maximized, but detection sensitivity in complex geometries decreases
Solution Approach 1:
The patent implements dynamic control of sound wave propagation directions through electronic phase control of the two-dimensional transducer array. This allows the system to adaptively change the angle and direction of sound wave coupling in real-time, transitioning from perpendicular coupling for efficiency to oblique coupling for enhanced defect detection sensitivity in complex geometries, without requiring physical repositioning of the probe
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 enables more reliable and efficient non-destructive material testing by increasing sound wave intensity in relevant areas, reducing image artifacts, and improving detection sensitivity, particularly in components with holes or complex geometries, allowing for better detection of defects in previously inaccessible regions.
Implementation Method 1
at least one of the individual transducers of the array is arranged at a predefinable acute angle with respect to a contact surface of the array such that the sound waves emitted by the at least one individual transducer can be coupled to the component in a preferred direction
Implementation Method 2
phased array transducers are known, featuring a multitude of individual transducers arranged directly adjacent to one another in linear or two-dimensional arrays. Such ultrasonic transducer arrangements enable phase-controlled adjustment of the angle of incidence and the focusing depth of the sound waves
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
An ultrasonic test head (1) for the non-destructive materials testing of a component (7) has an ultrasonic transducer arrangement (2) which is designed to be coupled to the component (7) and comprises a multiplicity of individual transducers (3) arranged at a distance from one another in a two-dimensional array (4); at least one of the individual transducers (3) in the array (4) is arranged at a predefinable acute angle (13) with respect to a supporting surface (8) of the array (4) such that the sound waves which can be emitted by the at least one individual transducer (3) can be coupled in in a preferred direction (11), which differs from a surface normal (12) running perpendicular to the coupling surface (8), when the ultrasonic test head (1) is placed onto the component (7).