Ultrasonic Defect Dimensioning Using Enclosed Geometric Templates
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Solution Overview
Problem
Existing ultrasonic inspection methods for determining geometric dimensions of defects in industrial assets are inaccurate and require manual operator adjustment, leading to potential errors and inefficiencies.
Innovation Solution
An automated system and method using ultrasonic data to determine geometric dimensions by optimizing a geometric template figure that is enclosed by a pre-defined threshold contour, eliminating the need for manual adjustments and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual operator adjustment is used to determine geometric dimensions of defects, then flexibility in handling complex defect shapes is improved, but measurement precision deteriorates due to operator bias and potential errors
Solution Approach 1:
The system performs self-adjustment through automated algorithms that iteratively optimize the geometric template figure to match the defect contour. The processor automatically determines the best-fit geometric shape without requiring manual operator intervention, thereby eliminating operator bias while maintaining adaptability to various defect shapes through computational optimization.
2Adaptability or versatility
If manual operator adjustment is used to determine geometric dimensions of defects, then ability to handle non-perfect geometric shapes is improved, but productivity deteriorates due to additional time required for manual adjustment
Solution Approach 1:
The patent replaces the manual mechanical adjustment process with an automated computational system. The processor executes algorithms that automatically fit geometric template figures to defect contours using ultrasonic data, substituting human manual adjustment with machine-based automated dimension determination, thereby improving productivity while maintaining the ability to handle complex shapes.
3Measurement precision
If automated optimization of geometric template figure is implemented, then measurement precision is improved by eliminating operator bias, but device complexity increases due to additional processing requirements
Solution Approach 1:
The processor is designed to perform multiple functions: it processes ultrasonic data, determines defect contours, optimizes geometric template figures, and calculates defect dimensions. By making the processor multi-functional, the system achieves high measurement precision through automated optimization without requiring separate dedicated devices for each function, thereby managing device complexity while improving accuracy.
4Ease of operation
If the 6 dB-drop method is used for amplitude-based C-Scan data, then ease of operation is improved by providing a straightforward calculation method, but measurement precision deteriorates for non-perfectly shaped indications
Solution Approach 1:
The system dynamically adapts the geometric template figure optimization process based on the actual defect contour shape. Rather than applying a fixed method like 6 dB-drop, the system iteratively adjusts the geometric template to best fit the measured contour, providing both ease of operation through automation and high precision by adapting to the specific shape characteristics of each defect.
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
The system provides rapid and accurate determination of defect dimensions, reducing inspection time and costs while minimizing operator bias, enabling automated defect recognition and classification.
Implementation Method 1
An ultrasonic inspection device performs an inspection of an object to generate ultrasonic data representing the object
Data Source
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AI summary
Systems, methods, and a computer readable medium are provided for determining a minimum geometric dimension of an indication of an object being inspected using ultrasonic data. The system can include a computing device configured to receive ultrasonic data from an ultrasonic inspection device and to determine a contour of at least one indication of a defect. The computing device can apply a geometric template figure to the determined contour such that the geometric template figure is enclosed by the contour. At least one minimum geometric dimension of the indication can be determined based on determining a maximum dimension of the geometric template figure enclosed by the contour. The computing device can provide the at least one minimum geometric dimension of the indication.