Ultrasonic Defect Detection in Protective Headgear
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Solution Overview
Problem
Existing protective headgear systems lack an effective and efficient method to detect internal defects such as perforation, deformity, cracking, tearing, aging, and injection defects, which can pose safety risks to workers.
Innovation Solution
Integration of actuator elements and sensor elements within the protective headgear, along with a processor element, to generate and detect ultrasonic waves, allowing for the detection of internal defects by calculating output differences and triggering alerts through audio, visual, or vibration signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If protective headgear is inspected with naked eye, then inspection is simple and quick, but internal defects cannot be detected
Solution Approach 1:
The patent replaces manual visual inspection with an automated ultrasonic detection system. The processor element generates ultrasonic waves that propagate through the protective headgear, and sensor elements detect the waves to identify internal defects automatically, eliminating the need for manual visual inspection.
Solution Approach 2:
The patent introduces ultrasonic waves as an intermediary medium to detect internal defects. The processor element generates ultrasonic waves that travel through the protective headgear material, and sensor elements detect changes in wave propagation caused by internal defects, enabling indirect detection of hidden flaws.
2Reliability
If actuator and sensor elements are integrated within protective headgear, then internal defects can be detected, but device complexity increases
Solution Approach 1:
The patent merges the actuator element, sensor element, and processor element into an integrated detection system within the protective headgear. These components work together as a unified system to generate ultrasonic waves, detect them, and process the signals to identify internal defects, improving reliability while managing complexity through integration.
Solution Approach 2:
The protective headgear performs self-diagnosis through the integrated detection system. The processor element automatically generates ultrasonic waves, detects them through sensor elements, and identifies internal defects without requiring external inspection equipment or manual intervention, enabling the headgear to monitor its own integrity.
3Measurement precision
If multiple ultrasonic waves are generated for detection, then defect detection accuracy improves, but energy consumption increases
Solution Approach 1:
The processor element generates multiple ultrasonic waves in a periodic or sequential manner rather than continuously. By transmitting ultrasonic waves at specific intervals and analyzing the responses, the system achieves accurate defect detection while minimizing energy consumption compared to continuous wave generation.
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 solution enables the reliable detection of internal defects in protective headgear, ensuring worker safety by providing real-time alerts and status management through a user interface.
Implementation Method 1
the processor element may be configured to: cause the actuator element to generate a first ultrasonic wave, and receive a first output from the sensor element in response to the first ultrasonic wave
Data Source
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AI summary
An apparatus (100), comprising: a protective headgear (101); an actuator element (107) integrated within the protective headgear; a sensor element (109A, 109B, 109C, 109D) attached on an inner surface of the protective headgear; a processor element (111) electronically coupled to the actuator element and the sensor element, wherein the processor element is configured to: cause the actuator element to generate a first ultrasonic wave, wherein the first ultrasonic wave is propagated in the protective headgear; receive a first output generated from the sensor element in response to the first ultrasonic wave generated by the actuator element, calculate an output difference by comparing the first output with a pre-determined value; determine whether the output difference satisfies a pre-determined threshold; and in response to determining that the output difference does not satisfy the pre-determined threshold, trigger a warning.