Ultrasonic 3D Composite Inspection for Real-Time Foreign Object Detection
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Solution Overview
Problem
Existing non-destructive testing methods struggle to provide real-time visualization of defects, particularly foreign objects, within materials, especially in composite structures, with a focus on optimizing portability, robustness, and resolution.
Innovation Solution
A system utilizing an ultrasonic transducer housed in a sealed fluid chamber, connected to a processor and display, generates A-scans and B-scans to determine ply depth and foreign object positions, and identifies foreign object materials based on characteristic A-scan signals, enabling real-time defect visualization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional ultrasonic NDT methods are used to detect foreign objects, then the detection capability is limited, but the system complexity and calibration requirements increase
Solution Approach 1:
The patent extracts the essential detection function by eliminating calibration blocks and complex reference standards. The system uses a simplified setup where the ultrasonic transducer directly scans the composite material without requiring external calibration artifacts, thereby reducing device complexity while maintaining detection accuracy through advanced signal processing algorithms.
Solution Approach 2:
The system performs self-calibration by using the composite material itself as the reference. The ultrasonic wave propagation characteristics through the material provide inherent calibration information, eliminating the need for separate calibration blocks. The processing system automatically adapts to material variations, making the system self-sufficient and reducing external dependencies.
2Measurement precision
If contact pressure is increased to improve detection near surface, then detection sensitivity improves, but the risk of damage and overdesign increases
Solution Approach 1:
The patent employs ultrasonic vibration at high frequencies to achieve sensitive detection near the surface without requiring high contact pressure. The vibrational energy penetrates the material and reflects off subsurface foreign objects, providing detection capability while maintaining gentle contact that prevents damage to the composite material structure.
Solution Approach 2:
The system replaces mechanical pressure-based detection with ultrasonic wave-based detection. Instead of relying on contact pressure to sense defects, the system uses ultrasonic waves that propagate through the material and interact with foreign objects, eliminating the need for high contact pressure and associated damage risks.
3Measurement precision
If resolution is increased to detect small foreign objects, then detection accuracy improves, but the need for overdesigning parts increases
Solution Approach 1:
The system achieves high resolution detection by optimizing ultrasonic frequency parameters and signal processing settings rather than increasing physical inspection stringency. The advanced processing algorithms enhance the resolution of detected features, allowing accurate identification of small foreign objects without requiring tighter manufacturing tolerances or overdesigning the composite parts.
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 real-time detection and material identification of foreign objects within composite materials, with a resolution capable of identifying objects smaller than 3 mm, enhancing the efficiency and accuracy of non-destructive inspection.
Implementation Method 1
an ultrasonic transducer operable to emit ultrasonic waves into and receive ultrasonic waves from a test object to produce scan data
Implementation Method 2
using a spherically focused transducer and advanced data processing techniques
Data Source
AI summary
The present disclosure provides a system and method for real-time visualization of a material during ultrasonic non-destructive testing. The system is capable of producing A-scans, B-scans, and C-scans of the test object and automatically highlighting potential foreign objects within the test object based on the scan data. The system includes a graphical user interface (GUI) capable of displaying a three-dimensional (3-D) image of a composite laminate constructed of a series of two-dimensional (2-D) cross sections. In one embodiment, the system includes an artificial intelligence module capable of highlighting foreign objects in order to provide size data, shape data, and/or depth data of the foreign object.