Ultrasonic Gain Correction Map for Flaw Detection
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Solution Overview
Problem
Current ultrasonic inspection methods face challenges in efficiently scanning objects with complex geometries due to variations in echo amplitude caused by object geometry and composition, leading to difficulties in flaw detection and sizing, especially when a fixed amplifier gain is not feasible.
Innovation Solution
A method and apparatus that involve scanning a reference object to create a gain correction map, which is then used to normalize measurements from a test object, allowing for consistent ultrasonic signal amplification across varying material properties and geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed amplifier gain is used, then the device complexity is reduced, but the measurement precision deteriorates due to amplitude variations caused by object geometry and composition
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing optimal gain values for different scanning positions in a gain correction map before actual inspection. During scanning, the system simply retrieves and applies the pre-determined gain value for each position, avoiding real-time complex adjustments while maintaining measurement precision across varying object geometries
Solution Approach 2:
The system dynamically changes the amplifier gain parameter based on the scanning position and object characteristics. By retrieving position-specific gain values from the gain correction map and applying them during scanning, the system adapts the amplification parameter to compensate for geometry-induced amplitude variations without requiring complex real-time control
2Measurement precision
If manual amplifier adjustments are made for each scanning position, then the measurement precision is improved, but the productivity decreases due to time-consuming adjustments
Solution Approach 1:
The gain correction map is pre-calculated and stored before production inspection, containing all necessary gain adjustments for different scanning positions. During actual scanning, the system automatically retrieves and applies the appropriate gain value for each position without manual intervention, maintaining high signal-to-noise ratio while preserving scanning speed
Solution Approach 2:
The system performs self-service by automatically selecting and applying the correct gain value for each scanning position based on the gain correction map, eliminating the need for manual amplifier adjustments. This automation maintains measurement precision while ensuring continuous high-speed scanning without operator intervention
3Measurement precision
If the amplifier gain is set high, then the signal-to-noise ratio is improved, but the reliability decreases due to saturation of the receiver output
Solution Approach 1:
The system applies local quality by using position-specific gain values from the gain correction map tailored to each scanning location. This allows optimal gain settings for local signal characteristics at each position, achieving high signal-to-noise ratio where needed while preventing saturation in areas with stronger signals, thereby maintaining overall signal accuracy
Solution Approach 2:
The amplifier gain parameter is dynamically changed based on scanning position and local signal characteristics. By retrieving position-appropriate gain values from the gain correction map, the system adapts the amplification level to match local conditions, optimizing signal-to-noise ratio while avoiding saturation and maintaining signal accuracy across the entire inspected object
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
This approach enables reliable flaw detection and sizing by minimizing amplitude variations unrelated to flaws, improving the signal-to-noise ratio and reducing the need for manual amplifier adjustments during scanning.
Implementation Method 1
The probe is mounted on the mechanical scanner. The controller operably connected to the mechanical scanner and to the probe
Implementation Method 2
the amplitude of the signal within a selected time interval (for instance the maximum absolute amplitude) or the time of occurrence of an echo within a selected time interval is associated to each position of the grid
Implementation Method 3
The amplifier gain of the receiver apparatus is set at a fixed value that allows monitoring the echo and the variations of amplitude of the echo in the presence of a flaw with an acceptable signal-to-noise ratio
Implementation Method 4
A selected time interval of this outputted signal is converted to digital data using an analog to digital converter apparatus
Data Source
AI summary
A method and an apparatus for scanning a test object are introduced. A reference object is scanned to build a gain correction map including gain values for scanning points on a surface of the reference object. The test object is also scanned to obtain measurements for scanning points on a surface of the test object. Amplitudes of the measurements obtained for the scanning points on the surface of the test object are normalized using the gain values of the gain correction map. The apparatus has a probe mounted on a mechanical scanner, and a controller controlling the scanning and normalizing operations. The method and apparatus can be used to create an image of the test object for non-destructive testing.