Ultrasonic Bolt Tester Calibration via Reference Data Comparison

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Solution Overview

Problem

Ultrasonic measurement devices used for calibrating bolted connections in wind turbines face challenges in maintaining accurate and comparable readings due to wear and variations in hardware, leading to potential errors in clamping force measurement.

Innovation Solution

A method of calibrating ultrasonic measurement devices that involves using a reference object to generate reference-measurement-data, which is then compared to verification-measurement-data to adjust the device, thereby reducing the burden of data entry on operators and minimizing errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual data entry of calibration rod parameters is required, then operator flexibility is maintained, but error risk increases

Engineering Contradiction:

Improvecalibration accuracyVSAvoidoperator burden

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The measurement device automatically retrieves and uses calibration rod parameters from its own memory without requiring operator intervention for data entry. The device serves itself by storing reference measurement data during manufacturing and autonomously accessing this data during calibration operations, eliminating manual parameter input while maintaining measurement precision.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent introduces an intermediary data storage mechanism (memory device) that holds calibration rod parameters and reference measurement data. This intermediary allows the system to automatically access required parameters without direct operator involvement, reducing errors while maintaining operational flexibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If calibration parameters are pre-stored in the device, then data entry errors are eliminated, but device complexity increases

Engineering Contradiction:

Improvemeasurement consistencyVSAvoiddata storage requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The calibration rod parameters and reference measurement data are pre-stored in the device's memory during manufacturing before the device is deployed. This preliminary action ensures that when calibration is performed, the device can automatically access accurate reference data without requiring external input, thereby eliminating data entry errors and ensuring measurement consistency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates a copy of the calibration rod's reference measurement data and stores it within the measurement device's memory. This copying approach allows the device to have access to accurate reference data without requiring the physical presence of the calibration rod or external data sources during measurement operations.

Inventive Principle:

Principle #26Copying

3Measurement precision

If frequent re-calibration is performed, then measurement accuracy is maintained, but productivity decreases

Engineering Contradiction:

Improvereading accuracyVSAvoidmeasurement throughput

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The device incorporates a verification measurement function that automatically checks measurement accuracy against pre-stored reference data. This feedback mechanism allows the device to self-verify its calibration status without requiring full re-calibration procedures, maintaining measurement precision while minimizing interruptions to productivity.

Inventive Principle:

Principle #23Feedback

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 method ensures accurate and reliable calibrations by shifting the measurement origin based on comparison results, thereby maintaining consistent measurement accuracy throughout the device's lifetime.

Implementation Method 1

measuring the reference object via an ultrasonic measurement device to determine reference-measurement-data representative of the ultrasonic length of the reference object

Methodology Applied

Scientific EffectUltrasonic wave propagation: Ultrasound

Implementation Method 2

measuring the reference object with the same, or another, ultrasonic measurement device to determine verification-measurement-data representative of the ultrasonic length of the reference object

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Data Source

PatentUS20250130038A1Method of calibrating an ultrasonic measurement device

Publication Date: 2025.04.24 NIELSEN FLEMMING SELMER

AI summary

A method of calibrating an ultrasonic measurement device, particularly an ultrasonic bolt testing device, comprising: a) providing a reference object; b) measuring the reference object via an ultrasonic measurement device to determine reference-measurement-data representative of the ultrasonic length of the reference object; c) storing the reference-measurement-data; d) measuring the reference object with the same, or another, ultrasonic measurement device to determine verification-measurement-data representative of the ultrasonic length of the reference object; e) comparing a reference length of the reference object determined on the basis of the reference-measurement-data to a verification length of the reference object determined on the basis of the verification-measurement-data; f) adjusting the ultrasonic measurement device on the basis of a comparison result between the reference-measurement-data and the verification-measurement-data.