Ultrasonic Flaw Detection Support Mechanism for Composite Inspection
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Solution Overview
Problem
Ultrasonic flaw detectors using metal wires for supporting composite components result in inaccurate inspections due to changes in ultrasonic wave reflectance and require time-consuming re-inspection, and the support mechanism can cause the inspection object to bend or warp, leading to inconsistent distances and imprecise results.
Innovation Solution
An ultrasonic flaw detector with a support mechanism that contacts the inspection object's lower surface, reducing ultrasonic wave reflectance variations to noise levels, allowing precise inspection without the need for re-positioning, using a probe that transmits and receives ultrasonic waves and a moving mechanism for scanning, while maintaining constant distance and reducing inspection time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal wires are used to support inspection objects, then the inspection objects can be supported and conveyed, but the reflectance of ultrasonic waves changes at contact portions resulting in imprecise inspection
Solution Approach 1:
A non-metallic support mechanism (mediator) is introduced between the inspection object and the conveyor system to eliminate ultrasonic wave interference. The support mechanism uses a non-metallic material that does not reflect ultrasonic waves, thereby preventing the harmful effect of metal wire contact while still providing the necessary support and conveyance function.
Solution Approach 2:
The harmful metal component is extracted from the support mechanism. Instead of using metal wires that cause ultrasonic wave reflection, the invention removes the metal element entirely and replaces it with a non-metallic support structure, thereby eliminating the source of inspection interference while maintaining the support function.
2Measurement precision
If portions of inspection objects are moved from contacting wires to perform precise inspection, then inspection accuracy improves, but the work time increases
Solution Approach 1:
The support mechanism is designed in advance to prevent ultrasonic wave reflection from the outset, rather than requiring post-inspection corrections. By using a non-metallic support structure from the beginning, the inspection can be performed accurately without needing to move or re-position the inspection object, thereby saving time.
3Ease of operation
If the flaw detection head scans the inspection object in a contact manner, then inspection is performed, but the inspection object may bend or warp causing inconsistent distance and imprecise inspection
Solution Approach 1:
The support mechanism provides localized support at specific points along the inspection object, distributing the support force to prevent bending or warping. By strategically positioning support points, the mechanism maintains the inspection object's shape consistency during contact scanning, ensuring uniform distance between the flaw detection head and the inspection surface.
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 solution enables precise and efficient ultrasonic flaw detection by minimizing ultrasonic wave reflectance variations caused by the support mechanism, reducing inspection time, and maintaining consistent distances, thus improving the accuracy and speed of the inspection process.
Implementation Method 1
a flaw detection head (10) including a probe that transmits an ultrasonic wave to an inspection object (31) formed by a composite member and receives the ultrasonic wave that has reflected on the inspection object (31)
Implementation Method 2
The support mechanism is configured to come into contact with the inspection object (31) over a predetermined area such that a waveform of the ultrasonic wave that has reflected on a position where the support mechanism is in contact with the inspection object (31) and that is received by the probe is within a noise level
Data Source
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AI summary
An ultrasonic flaw detector includes: a flaw detection head (10) including a probe that transmits an ultrasonic wave to an inspection object (31) formed by a composite member and receives the ultrasonic wave that has reflected on the inspection object (31); a moving mechanism (40), which causes the flaw detection head (10) to perform scanning; and a support mechanism (90) disposed such that the support mechanism (90) comes into contact with a lower surface of the inspection object (31), the support mechanism (90) supporting the inspection object (31). The support mechanism (90) is configured to come into contact with the inspection object (31) over a predetermined area such that a waveform of the ultrasonic wave that has reflected on a position where the support mechanism (90) is in contact with the inspection object (31) and that is received by the probe is within a noise level.