Phased Array Ultrasonic Calibration Block for Faster Setup
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Solution Overview
Problem
Existing inspection systems for industrial surfaces face challenges such as complexity, requiring multiple experts, increased operational risks, and high costs due to personnel exposure to hazardous environments, incomplete inspections, and inefficiencies in configuring phased array ultrasonic payloads.
Innovation Solution
A system with a dual linear phased array payload and modular sensor sleds for rapid configuration and confirmation of correct setup, allowing separation of expert personnel and enabling complete inspections in hazardous environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inspection systems are used with multiple experts, then inspection completeness improves, but operational cost and complexity increase
Solution Approach 1:
The inspection system is segmented into autonomous robotic units, each equipped with specialized sensors and capabilities. Instead of requiring multiple human experts to perform different inspection tasks, the system divides the inspection function into modular robotic components that can operate independently or cooperatively, reducing operational complexity while maintaining comprehensive inspection coverage
Solution Approach 2:
The robotic inspection system performs self-navigation, self-positioning, and self-inspection tasks without requiring continuous human intervention. The autonomous units can independently navigate hazardous environments, position themselves on inspection surfaces, and execute inspection protocols, eliminating the need for multiple human experts to manually perform each inspection step
2Adaptability or versatility
If personnel enter hazardous environments for inspection, then inspection access improves, but safety risks increase
Solution Approach 1:
Autonomous robotic units serve as intermediaries between human operators and hazardous environments. These robots can enter and operate in dangerous conditions such as confined spaces, high temperatures, or toxic atmospheres without exposing human personnel to harm, while still performing the required inspection tasks that require physical access to the inspection surface
Solution Approach 2:
The system uses robotic replicas or digital twins to perform inspections in hazardous environments. Instead of sending human personnel into dangerous areas, identical or similar robotic units are deployed to replicate human inspection capabilities remotely, providing the same inspection access without the associated safety risks to human operators
3Measurement precision
If phased array ultrasonic payloads are manually configured, then inspection precision improves, but configuration time increases
Solution Approach 1:
The phased array ultrasonic payloads are pre-configured with inspection parameters, calibration data, and operational settings before deployment. The robotic units arrive at the inspection location with pre-loaded inspection programs and pre-calibrated sensors, eliminating the need for time-consuming manual configuration while maintaining the precision required for accurate measurements
Solution Approach 2:
The system incorporates automated feedback mechanisms that allow the robotic units to self-adjust and self-calibrate during operation. Sensors provide real-time feedback on inspection conditions, and the system automatically adjusts payload configurations to optimize measurement precision, reducing the need for manual intervention and configuration time
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 rapid and complete inspections with improved safety and reduced operational costs by allowing expert personnel to focus on high-value tasks, reducing manual intervention, and enhancing inspection resolution and automation.
Implementation Method 1
A calibration block for use with a phased array of ultrasonic elements is disclosed. The calibration block includes a first portion and a second portion with a first interface and a second interface, respectively. The calibration block is configured to reflect ultrasonic waves from each of the phased array elements at the first interface
Data Source
AI summary
A calibration block may include an engagement surface having a selected vertical extent along a vertical axis and a selected horizontal extent along a horizontal axis. The block may include a block depth trajectory comprising a variable depth of the block along the vertical axis, the depth of the block at each position along the vertical axis comprising an effective distance between the engagement surface and an opposing surface. The block may include an end face defining at least one vertical feature hole, where the at least one vertical feature hole comprises a plurality of vertical feature holes. Each one of the plurality of vertical feature holes may comprise an angular offset orientation with a vertical axis of the block, where the angular offset orientation comprises an angle between zero degrees and 45 degrees, inclusive. The block may include a side face defining at least one horizontal feature hole.