Ultrasonic Flaw Detector for Complex Surface Shapes
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Solution Overview
Problem
Ultrasonic flaw detection on complex-shaped objects is challenging due to difficulties in emitting ultrasonic waves at the correct angle, leading to reduced detection accuracy and incorrect flaw indication positions, especially when the surface shape is not considered in analysis.
Innovation Solution
An ultrasonic flaw detector and method that measures the surface shape of the object and adjusts the transmission delay time of ultrasonic waves to ensure uniform refraction angles, allowing for accurate flaw detection by calculating optimal control information for the ultrasonic elements based on the surface shape, thereby maintaining consistent refraction angles and improving detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If phased array technology is used to emit ultrasonic waves on complex-shaped objects, then the ability to cope with complex shapes is improved, but the complexity of calculating delay time and controlling ultrasonic waves increases
Solution Approach 1:
The patent applies preliminary action by measuring the surface shape of the object before ultrasonic wave emission, and pre-calculating the optimal delay time values based on the measured shape data. This allows the system to adapt to complex shapes without requiring real-time complex calculations during the actual detection process, thus reducing operational complexity while maintaining versatility.
Solution Approach 2:
The patent implements feedback by using the measured surface shape information to adjust and optimize the delay time values for each ultrasonic element. The system continuously refines the control parameters based on actual measurements, creating a closed-loop control mechanism that simplifies the overall system complexity while improving adaptability to complex geometries.
2Manufacturing precision
If ultrasonic wave emission is optimized according to surface shape, then the incident angle control is improved, but the accuracy of flaw position identification deteriorates due to incorrect display position
Solution Approach 1:
The patent applies the copying principle by creating a virtual model or representation of the actual ultrasonic wave propagation paths based on the measured surface shape. This virtual copy allows the system to calculate and display flaw positions accurately by simulating the wave behavior, thus resolving the contradiction between optimized incident angle control and accurate position identification.
Solution Approach 2:
The patent resolves the position identification issue by adding a dimensional transformation layer that maps the ultrasonic wave paths in the physical domain to the display domain. This dimensional change allows the system to maintain accurate incident angle control while correctly representing flaw positions on the display, eliminating the discrepancy between controlled angles and displayed positions.
3Device complexity
If electronic scan is used to move elements sequentially, then the device complexity is reduced, but detection accuracy deteriorates due to fixed element arrangement and blind angles
Solution Approach 1:
The patent applies dynamics by making the element arrangement adaptive rather than fixed. Instead of using a static electronic scan with predetermined element sequences, the system dynamically selects and activates ultrasonic elements based on the measured surface shape and required detection zone. This dynamic approach eliminates blind angles and maintains detection accuracy while avoiding the complexity of real-time element repositioning.
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 high detection accuracy on complex-shaped objects by ensuring ultrasonic waves are emitted at the correct angle, reducing errors in flaw position identification and improving the overall accuracy of ultrasonic flaw detection.
Implementation Method 1
an ultrasonic probe 11 for emitting an ultrasonic wave U onto an object 2
Implementation Method 2
ensuring ultrasonic waves are emitted at the correct angle... maintain consistent refraction angles
Data Source
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AI summary
An ultrasonic flaw detector including an ultrasonic probe for emitting an ultrasonic wave on an object to be inspected and receiving a reflected ultrasonic wave from the object, a drive element control unit for controlling a plurality of ultrasonic elements to emit an ultrasonic wave on the ultrasonic probe and to control a reflected ultrasonic wave from the ultrasonic probe, and a calculation unit for obtaining, by using a refraction angle of the ultrasonic wave at a time of the ultrasonic wave entering the object, an incident position of the ultrasonic wave on a surface of the object, and a surface shape of a surface of the object at the incident position, the incident angle of the ultrasonic wave entering the incident position, and obtaining a plurality of ultrasonic elements to be driven, based on the incident position and the incident angle.