Ultrasonic Inspection Array Probe Sensor Displacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ultrasonic inspection methods, such as the phased array and synthetic aperture methods, face challenges in achieving high-resolution and high-S/N-ratio imaging efficiently, particularly due to limitations in focal depth control, time-consuming data acquisition, and susceptibility to noise, especially when inspecting thick materials.
Innovation Solution
An ultrasonic inspection method using an array-probe sensor that displaces the transmission/reception position and applies a sectorial scan scheme, generating single images through addition or averaging of inspection results, while adjusting incident angles and correcting for surface inclination, utilizing a combination of piezoelectric vibration elements and computational processing to enhance image resolution and signal quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional single-element ultrasonic sensor is used for transmission and reception, then the equipment is simple and operation is straightforward, but the inspection requires skilled operators and takes tremendous amount of time to complete
Solution Approach 1:
The patent divides the ultrasonic sensor into multiple piezoelectric vibration elements arranged in an array, allowing parallel transmission and reception of ultrasonic waves from different positions. This segmentation enables simultaneous acquisition of multiple reflection signals, dramatically increasing inspection speed while maintaining operational simplicity through automated processing.
Solution Approach 2:
The patent pre-calculates and stores the relationship between sensor positions and defect detection parameters before actual inspection. By preparing reference data in advance, the system can quickly compare real-time measurements against stored parameters, reducing inspection time and eliminating the need for skilled operators to perform complex calculations during inspection.
2Productivity
If phased array method is used to control incident angles and focal depth, then high-speed and high-accuracy inspection is achieved, but the space resolution is lowered at depth positions where focusing is not achieved
Solution Approach 1:
The patent transitions from conventional single-point or linear array scanning to a two-dimensional matrix array configuration. This dimensional expansion allows the system to control ultrasonic wave propagation in multiple directions simultaneously, achieving high resolution at various depth positions without sacrificing inspection speed, as the matrix geometry provides superior spatial sampling.
3Measurement precision
If synthetic aperture method is used to extend reception waveforms in arc-like configuration, then high-resolution imaging is achieved, but the computational operation time is excessive for practical site evaluation
Solution Approach 1:
The patent extracts and utilizes only the essential geometric relationships between sensor positions, defect locations, and ultrasonic propagation paths, discarding unnecessary computational steps of conventional synthetic aperture methods. By focusing on critical parameters and using pre-calculated geometric models, the system achieves high-resolution imaging with minimal processing time suitable for real-time site evaluation.
4Adaptability or versatility
If ultrasonic waves are transmitted to diffuse widely inside inspection target, then the reception waveforms can be extended, but the S/N ratio is lowered due to ultrasonic wave attenuation over long propagation distance
Solution Approach 1:
The patent applies different transmission and reception strategies to different regions of the matrix array based on local requirements. Areas requiring wide coverage use diffused transmission, while regions needing high signal quality utilize focused beams with shorter propagation paths. This localized optimization allows the system to achieve both extensive coverage and high S/N ratio simultaneously by adapting the ultrasonic propagation characteristics to specific inspection needs.
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 approach allows for high-resolution, high-S/N-ratio inspection images to be acquired quickly and easily, overcoming limitations in focal depth control and noise susceptibility, enabling high-accuracy nondestructive inspection without the need for extensive computational processing.
Implementation Method 1
using the so-called array-probe ultrasonic sensor where a plurality of piezoelectric vibration elements are arranged
Implementation Method 2
an ultrasonic signal reflected by a defect or the like inside an inspection target is detected
Implementation Method 3
wavefronts of ultrasonic waves transmitted from the respective piezoelectric vibration elements interfere with each other. Then, the wavefronts will propagate in such a manner that the wavefronts have formed a superimposed wavefront as a result of the interference
Implementation Method 4
by exercising a delay control over ultrasonic-waves transmission timings of the respective piezoelectric vibration elements to shift the respective timings with each other, it becomes possible to control incident angles of the ultrasonic waves and thereby to converge the ultrasonic waves
Implementation Method 5
reflected ultrasonic waves received at the respective piezoelectric vibration elements are added in the manner where the reflected ultrasonic waves are sifted with each other. Similarly to the transmission time, this addition makes it possible to control reception incident angles of the ultrasonic waves, and to receive the ultrasonic waves in the manner where the focusing is achieved
Data Source
AI summary
In the ultrasonic inspection method and equipment, a high-resolution and high-S/N-ratio inspection image can be speedily acquired with ease-of-operability. Inspection of the inside of the inspection target is performed by changing incident angle of the ultrasonic wave oscillated from the array-probe ultrasonic sensor. Then, while performing the inspection, the array-probe ultrasonic sensor is sequentially displaced from the position to the position via the position by using the displacement member. This displacement allows acquisition of inspection images on each position basis. Finally, the inspection images thus acquired are visualized as a processed image by adding or averaging the inspection images by shifting the images by displacement quantity of the array-probe ultrasonic sensor.