2D Ultrasonic Array Profiling for Rapid Dent Assessment
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Solution Overview
Problem
Current methods for evaluating surface depressions on aerospace structures, such as dents, are inefficient and time-consuming, particularly in scenarios like hail damage, where rapid assessment is needed to minimize downtime and ensure compliance with manufacturer or regulatory standards.
Innovation Solution
A non-destructive ultrasonic system utilizing a two-dimensional transducer array and a delay line material, coupled with a processor, which measures surface properties by transmitting and receiving ultrasonic pulses to determine the depth and contour of depressions, enabling quick classification as acceptable or requiring repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual measurement methods (scale and dial indicator gauge) are used, then measurement precision can be maintained, but productivity is significantly reduced due to time-consuming manual evaluation
Solution Approach 1:
The patent replaces manual mechanical measurement tools (scale and dial indicator gauge) with an automated ultrasonic measurement system. The system uses ultrasonic transducers to automatically measure depression depth and generate contour maps, eliminating the need for manual operation while maintaining measurement precision and significantly reducing inspection time.
Solution Approach 2:
The measurement system performs self-evaluation by automatically acquiring ultrasonic signals, processing the data, generating contour maps, and determining whether repairs are needed. The system autonomously completes the entire inspection workflow without requiring manual intervention at each step, thereby improving productivity and reducing time loss.
2Measurement precision
If laser line gauges or laser profilometry systems are used, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces a couplant as an intermediary medium between the ultrasonic transducer and the object surface. This couplant ensures efficient ultrasonic wave transmission and improves measurement precision while keeping the overall system relatively simple and cost-effective compared to laser-based systems.
3Measurement precision
If interferometric devices operating on moiré effect are used, then measurement precision is achieved, but ease of operation is reduced due to complex setup and operation requirements
Solution Approach 1:
The patent replaces complex optical interferometric devices with a simpler ultrasonic measurement system. The ultrasonic system maintains measurement precision while significantly improving ease of operation, as it requires minimal setup and can be easily applied to various surfaces without complex optical alignment requirements.
4Productivity
If rapid evaluation methods are implemented, then productivity is improved, but measurement precision may be compromised
Solution Approach 1:
The patent performs preliminary scanning of the surface to identify potential depressions before conducting detailed measurements. This preliminary action allows the system to quickly survey large areas and then focus measurement resources on specific areas of interest, thereby maintaining both high productivity and measurement precision.
Solution Approach 2:
The ultrasonic measurement system continuously acquires signals across the surface without interruption, generating comprehensive contour maps in real-time. This continuous measurement approach ensures that no data is missed and maintains measurement precision while enabling rapid evaluation of entire surfaces.
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 allows for rapid and accurate evaluation of surface depressions, reducing downtime and costs compared to traditional methods, while providing automatic classification and the ability to assess internal damage, thus facilitating quicker aircraft return to service.
Implementation Method 1
transmitting from each of a plurality of ultrasonic transducers of the two-dimensional ultrasonic transducer array an ultrasonic pulse toward the surface of the object. Additionally, the method includes receiving by one or more of the plurality of ultrasonic transducers one or more ultrasonic echoes resulting from the transmitting of the ultrasonic pulses
Implementation Method 2
a two-dimensional ultrasonic transducer array and a delay line material coupled to the two-dimensional ultrasonic transducer array
Data Source
AI summary
Example systems and methods for non-destructive evaluation of depressions on a surface of an object are provided. One example system includes a measurement apparatus having a two-dimensional ultrasonic transducer array, a delay line material, a sealing member position such that the sealing member forms a cavity between the delay line material and a surface of the object, and a liquid inlet for injecting a liquid into the cavity. The example system also includes a processor configured to determine, using ultrasonic signals received from the two-dimensional ultrasonic transducer array, at least one property of a depression such as a dent on the surface of an object. The example system may also be configured to provide an output that is indicative of whether the at least one property of the depression satisfies a predetermined criterion. Another example system includes a compressible elastomeric delay line material that conforms to a surface of an object.