Ultrasonic Transducer Array Scanning for Complex Surface Inspection
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Solution Overview
Problem
Current non-destructive ultrasonic testing methods are inefficient for scanning complex-shaped objects, requiring extensive time and being unsuitable for precise evaluation due to the need for numerous scanning points and the limitations of arrays of sensing elements.
Innovation Solution
A method and system utilizing an array of ultrasonic transducers with a robotic manipulator and motion controller, where the transducers are enabled or disabled based on the direction of incidence and surface normal vectors to optimize scanning paths, allowing for rapid and precise scanning of complex shapes by adjusting the number of active transducers at each position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large number of scanning points are defined to obtain precise evaluation of the test object, then measurement precision is improved, but scanning time increases significantly
Solution Approach 1:
The patent divides the scanning task into multiple zones based on surface curvature characteristics. High-curvature zones use fewer scanning points while low-curvature zones use more points, segmenting the overall scanning process to achieve precision where needed without wasting time on areas where it's less critical.
Solution Approach 2:
The patent applies different scanning densities to different regions of the test object based on local surface properties. Complex-shaped regions use adaptive point selection while simpler regions use standard grids, ensuring measurement precision is maintained in critical areas while reducing overall scanning time.
2Productivity
If arrays of sensing elements are used to reduce scanning time, then productivity is improved, but suitability for complex-shaped objects deteriorates
Solution Approach 1:
The patent dynamically selects and activates specific transducers from the array based on the current scanning position and surface geometry. Rather than using a fixed array configuration, the system adapts which elements are active, allowing the same array hardware to effectively handle both simple and complex shapes.
Solution Approach 2:
The patent changes operational parameters of the transducer array based on surface characteristics. The curvature radius calculation and adaptive selection of scanning points modify how the array is utilized, transforming a static array system into one that adapts its effective configuration to match the object's geometry.
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 significantly reduces scanning time while maintaining signal quality, enabling efficient detection of defects in complex objects by adaptively managing the number of active transducers according to the object's surface representation.
Implementation Method 1
In pulse-echo mode, a portion of the ultrasound wave energy is reflected back to the same transducer when the wave front encounters a change in acoustic impedance within the test object
Implementation Method 2
this change in the acoustic impedance may be caused by a change in material properties of the test object, or by the presence of a defect within the test object
Implementation Method 3
In through-transmission mode, a portion of the ultrasound wave energy reaches another transducer, with an energy level that may vary as the ultrasound wave passes through a change in acoustic impedance of the test object
Implementation Method 4
Automated ultrasound scanners use robotic manipulators to move the transducers along the test object while recording the electrical signals at specific locations
Implementation Method 5
evaluating a direction of incidence of a planned ultrasonic signal emitted by the given transducer on a respective grid position on the surface of the object when the array is planned to be positioned according to the selected grid position
Implementation Method 6
evaluating a difference between the direction of incidence and a surface normal vector defined on the surface of the object at the respective grid position
Data Source
AI summary
A plan for scanning an object using an array of ultrasonic transducers is prepared by identifying one or more enabled transducers for each of a plurality of selected grid positions defined on a surface of the object. The identification is made considering a direction of incidence of a planned ultrasonic signal emitted by each transducer, considering the array being positioned at each of the selected positions, and considering a surface normal vector at a grid position that would be impinged by the planned ultrasonic signal. The scan plan is complete when all grid positions defined on the surface of the array are covered by moving the array to all of the selected grid positions. The scan plan is executed by moving the array according to the scan plan while collecting, by the transducers enabled at each selected grid position, eventual responses to the ultrasonic signals from their respective grid positions.