Ultrasonic Double-Wave Bolt Measurement Without Temperature Sensors
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Solution Overview
Problem
Existing ultrasonic methods for measuring pre-tightening force of bolts are affected by temperature changes and uneven temperature distributions, leading to measurement errors and increased complexity due to the need for additional temperature sensors.
Innovation Solution
A method and device for ultrasonic double-wave measurement that simultaneously determines pre-tightening force and temperature using only ultrasonic waves, eliminating the need for additional temperature sensors by employing first- and second-order Taylor approximations to calculate these values based on ultrasonic time-of-flight differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-point temperature sensor (Pt1000) is used to measure bolt temperature, then the temperature measurement device is simple, but the measurement precision of average temperature is poor due to temperature non-uniformity along the bolt
Solution Approach 1:
The bolt is divided into multiple measurement sections, with temperature sensors placed at different locations (e.g., exposed portion and underground portion). The temperature data from each section is separately measured and then integrated to calculate the average temperature, thereby improving measurement precision while maintaining relatively simple device complexity
Solution Approach 2:
The measurement approach transitions from single-point temperature measurement to multi-point spatial distribution measurement. By adding the spatial dimension of temperature measurement along the bolt length, the system captures temperature non-uniformity and enables accurate calculation of average temperature
2Measurement precision
If multiple temperature sensors are installed at different bolt locations to measure average temperature, then the measurement precision of average temperature improves, but the device complexity and cost increase
Solution Approach 1:
The ultrasonic measurement device is designed to perform multiple functions: it measures both the pre-tightening force of the bolt and the temperature at different locations. By integrating temperature measurement capability into the existing ultrasonic inspection device, the system avoids the need for separate dedicated temperature measurement equipment, thereby improving measurement precision without proportionally increasing device complexity
Solution Approach 2:
The ultrasonic measurement device utilizes its own operational data and environmental sensors to self-determine temperature conditions. The device processes ultrasonic wave propagation data in conjunction with temperature information to simultaneously derive both mechanical and thermal states of the bolt, reducing the need for additional specialized measurement equipment
3Ease of operation
If traditional ultrasonic measurement method is used without temperature compensation, then the measurement process is simple, but the measurement precision of pre-tightening force deteriorates due to temperature effects on ultrasonic wave velocity
Solution Approach 1:
The system implements a feedback mechanism where temperature measurements from multiple locations are continuously obtained and fed into the pre-tightening force calculation algorithm. The temperature data is used to compensate for thermal effects on ultrasonic wave velocity, and the compensated values are fed back to improve the accuracy of pre-tightening force measurement while maintaining automated operation
4Measurement precision
If ultrasonic online monitoring with piezoelectric single-wave probe and thermometer is used for each bolt, then the measurement precision of pre-tightening force can be maintained, but the device complexity and cost increase significantly
Solution Approach 1:
The patent merges temperature measurement and pre-tightening force measurement functions into a single integrated ultrasonic measurement device. By combining multiple measurement capabilities (ultrasonic wave propagation measurement, temperature sensing at multiple points, and data processing) into one unified system, the device complexity is reduced compared to having separate dedicated equipment for each measurement function
Solution Approach 2:
The ultrasonic measurement device is designed as a multi-functional instrument that can simultaneously measure ultrasonic wave velocity, determine temperature at multiple locations, and calculate pre-tightening force. This universal device replaces the need for separate single-wave probes and dedicated thermometers for each bolt, thereby maintaining measurement precision while significantly reducing overall device complexity and cost
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 simplifies the measurement process, reduces errors, and allows for accurate simultaneous determination of pre-tightening force and temperature, applicable to high-strength bolts and pressure vessels, while eliminating the need for additional temperature sensors.
Implementation Method 1
measure a time-of-flight difference of the ultrasonic waves, and deduce changes in the pre-tightening force of the solid material
Implementation Method 2
emit ultrasonic waves into the solid material
Implementation Method 3
using first- and second-order Taylor approximations to calculate changes in time-of-flight
Data Source
AI summary
A method for the ultrasonic double-wave measurement includes: obtaining a first mode wave time-of-flight and a second mode wave time-of-flight of an ultrasonic double-wave of a solid material at a first temperature and stress state; measuring a first mode wave time and a second mode wave time of the ultrasonic double-wave of the solid material in an unknown state; obtaining a first mode wave temperature influence coefficient and a second mode wave temperature influence coefficient of the solid material, and a first mode wave pre-tightening force influence coefficient and a second mode wave pre-tightening force influence coefficient in the solid material to be measured having the same specification and geometric shape; and obtaining a relative change relationship of ultrasonic double-wave time-of-flight according to the first-order or second-order Taylor approximation, and jointly solving to obtain a measured pre-tightening force and a measured temperature.