Ultrasonic Array Probe Sector Scanning Surface Shape Compensation
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Solution Overview
Problem
Existing linear-scan ultrasonic inspection methods struggle to achieve effective scanning over a wide range due to limitations in the number of elements in the array probe, leading to inadequate image evaluation.
Innovation Solution
A linear-scan ultrasonic inspection apparatus and method that utilize an ultrasonic array probe with a delay-time calculator to adjust delay times based on the test object's surface shape, an overlapping-region adjustor to set conditions for generating images in overlapping regions, and an integrated-image generator to produce expanded image data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the array probe has a small number of elements due to limited probe-setting position, then the device complexity is reduced, but the linear scanning cannot attain a large enough scanned area for adequate image evaluation
Solution Approach 1:
The patent transitions from conventional linear scanning to sector scanning, where the ultrasonic beam is transmitted in a fan-shaped pattern covering a wide angular range. This dimensional change in scanning geometry allows a single probe with limited elements to cover a larger inspection area by utilizing angular dispersion rather than linear extension.
Solution Approach 2:
The patent employs dynamic adjustment of delay times for each ultrasonic element based on the measured surface shape of the test object. By changing the temporal parameters (delay times) rather than the spatial configuration of elements, the system compensates for the limited number of elements and achieves accurate focusing and imaging across the expanded scanned area.
2Area of stationary object
If sector scanning is used to expand the scanned area, then the area of stationary object is increased, but the sound speed changes in accordance with the beam-scanning angle if the object material has anisotropy, affecting measurement accuracy
Solution Approach 1:
The patent performs preliminary measurement of the surface shape of the test object before conducting the ultrasonic inspection. This advance information about the surface geometry is then used to calculate and set appropriate delay times for each ultrasonic element, enabling the system to pre-compensate for variations in sound path lengths and anisotropic effects across different beam angles.
Solution Approach 2:
The system uses the measured surface shape as feedback to dynamically adjust the delay times for ultrasonic beam transmission and reception. This closed-loop approach allows the system to adapt to the specific geometry and anisotropic properties of each test object, maintaining measurement accuracy across the expanded sector scanning area.
3Measurement precision
If linear scanning is used to maintain measurement at the same angle, then the measurement precision is improved, but the area of stationary object remains limited and insufficient for adequate image evaluation
Solution Approach 1:
The patent extends the scanning approach from one-dimensional linear scanning to two-dimensional sector scanning by introducing angular variation. The ultrasonic beam is transmitted at multiple angles forming a fan pattern, allowing the system to cover a broader area while maintaining measurement quality through delay time compensation for each angular position.
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
Enables effective linear scanning over a wide range by improving image evaluation precision and expanding the depth and width of the scanned area, even with array probes having a small number of elements.
Implementation Method 1
piezoelectric elements, which are used as small ultrasonic elements for transmitting and receiving ultrasonic waves
Implementation Method 2
calculate, referring to the surface shape of the test object, values of delay time of at least one of transmitting and receiving the ultrasonic wave
Implementation Method 3
the sound speed changes in accordance with the beam-scanning angle if the object material has anisotropy
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
According to an embodiment, a linear-scan ultrasonic inspection apparatus (100) comprises: an ultrasonic array probe (10) having a plurality of ultrasonic elements (11) aligned in a first direction; a delay-time calculator (33) configured to calculate, referring to the surface shape of the test object (1), values of delay time of at least one of transmitting and receiving ultrasonic wave; an overlapping-region adjustor (36) configured to set conditions for generating an image of an overlapping region; and an integrated-image generator (35) configured to generate first image data of a region including the overlapping region. The overlapping-region adjustor (36) is configured to set the conditions of the surface shape to be referred to the delay-time calculator (33) in calculating the values of the delay time at either the first-probe setting position or the second-probe setting position as both of a first acquired shape obtained at the first-probe setting position and a second acquired shape obtained at the second-probe setting position.