Ultrasonic Flaw Detection System Using Single Detector and Multiplexer
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Solution Overview
Problem
Current ultrasonic flaw detection systems for tubulars require multiple flaw detectors and multiplexers, making them costly, complex, and inefficient, especially when inspecting tubulars for various orientations of flaws.
Innovation Solution
A compact ultrasonic flaw detection system that uses a single flaw detector with a multi-channel sequencing multiplexer and gain control modules to reduce the number of transducers and multiplexers, allowing for both sequencing and parallel pulsing, and enabling efficient inspection of tubulars with a single set of transducer assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple flaw detectors and multiplexers are used to inspect tubulars for various orientations of flaws, then the detection capability and reliability are improved, but the system cost and complexity increase
Solution Approach 1:
The single ultrasonic flaw detector is designed to perform multiple inspection functions by detecting flaws in various orientations (transverse, longitudinal, oblique) through a single transducer assembly. The system uses a single detector that can identify different flaw types by analyzing echo patterns from multiple directions, eliminating the need for separate detectors for each flaw orientation while maintaining comprehensive detection capability
Solution Approach 2:
The patent combines multiple flaw detection functions into a single integrated system. The transducer assembly integrates multiple ultrasonic transducers that can detect flaws in different orientations simultaneously, and the single flaw detector processes all signals through unified control logic, merging what would traditionally require multiple separate detection systems into one compact unit
2Adaptability or versatility
If multiple transducers and multiplexers are used to achieve comprehensive flaw detection, then the inspection coverage is improved, but the device complexity and cost increase
Solution Approach 1:
The transducer assembly is designed as a universal inspection tool that can detect all types of flaws (transverse, longitudinal, oblique) through a single integrated unit. The assembly includes multiple ultrasonic transducers arranged to provide omnidirectional coverage, allowing one transducer assembly to perform the work of what would traditionally require multiple specialized transducer sets for different flaw orientations
Solution Approach 2:
The transducer assembly segments the detection function into multiple independent ultrasonic transducers within a single integrated unit. Each transducer targets specific flaw orientations, but they are controlled and processed as one unified system rather than requiring separate external control units for each transducer, reducing overall system complexity while maintaining comprehensive coverage
3Device complexity
If a single flaw detector with multi-channel sequencing multiplexer is used, then the device complexity and cost are reduced, but the capability to handle multiple inspection functions simultaneously may be limited
Solution Approach 1:
The system uses sequential pulsing through a multi-channel sequencing multiplexer to activate different transducer groups in a periodic cycle. Each channel is pulsed in sequence, allowing the single flaw detector to process multiple inspection functions by time-multiplexing the signal acquisition. This periodic activation maintains comprehensive inspection capability while using a single detector rather than requiring multiple simultaneous detectors
Solution Approach 2:
The system dynamically switches between different transducer channels using the sequencing multiplexer, allowing the single flaw detector to adaptively handle different inspection functions. The dynamic channel switching and signal routing enable one detector to perform the work of multiple detectors by rapidly alternating between different transducer groups and processing their signals through unified control logic
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 achieves the same detection results and production rate as prior art systems while reducing costs and complexity, allowing for efficient inspection of tubulars with a single set of transducers and multiplexers, and providing options for different inspection functions.
Implementation Method 1
High-frequency sound waves reflect from flaws in predictable ways, producing distinctive echo patterns that can be displayed and recorded by portable instruments
Implementation Method 2
sound waves are simply organized mechanical vibrations traveling through a medium... When they encounter a boundary with a different medium they will be reflected or transmitted according to simple rules
Data Source
AI summary
A flaw detection system has a plurality of ultrasonic flaw detectors adapted to pass pulsed ultrasonic signals, a plurality of sequencing multiplexers electrically connected to the plurality of ultrasonic flaw detectors so as to receive the pulsed ultrasonic signals from the plurality of ultrasonic flaw detectors, a plurality of gain control modules connected to the plurality of sequencing multiplexers, a plurality of transducer assemblies respectively connected to an output of the plurality of gain control modules. The plurality of transducer assemblies are adapted to pass the pulsed ultrasonic signals from the plurality of sequencing multiplexers toward an object to be inspected. The plurality of transducer assemblies receives signals from the object to be inspected and passes the received signal back to the plurality of ultrasonic flaw detectors. The gain control modules has outputs to the transducer assembly that is a multiple of the inputs from the sequencing multiplexer.