Ultrasonic Inspection of Complex Structures Using Reference Wave Comparison
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Solution Overview
Problem
Current ultrasonic inspection methods for detecting flaws in solid materials lack reliability and are not effectively applicable to complex geometric structures, such as vehicle components, due to their non-homogeneous nature and the need for precise positioning of transducers.
Innovation Solution
A method involving the definition of a coordinate system on a test object with multiple transducers positioned to transmit and receive ultrasonic waves, comparing these signals with those from a reference object known to be defect-free, allowing for accurate detection of defects without requiring the test object to be positioned exactly as the reference object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ultrasonic measurements are performed on solid materials with non-homogeneous structures, then the inspection can be conducted on complex geometric structures, but the reliability of test results deteriorates
Solution Approach 1:
The patent performs preliminary ultrasonic measurements on a reference object with known defect-free status before measuring the test object. This preliminary action establishes a baseline wave pattern that accounts for the non-homogeneous structure and complex geometry, enabling reliable comparison and defect detection in subsequent measurements without requiring repeated reference measurements.
Solution Approach 2:
The patent creates a copy of the reference object's ultrasonic wave pattern through preliminary measurements. This copied wave pattern serves as a reference model that can be stored and reused for comparing against test objects, eliminating the need to physically have the reference object present during inspection while maintaining measurement reliability.
2Measurement precision
If transducers are positioned precisely to match reference object positions, then measurement accuracy improves, but the ease of operation deteriorates
Solution Approach 1:
The patent copies the spatial arrangement and positioning information of transducers from the reference object to the test object. By storing the coordinate system and transducer positions established during reference measurements, the system enables operators to replicate the exact measurement geometry on test objects without requiring complex positioning procedures, thus maintaining high measurement precision while significantly improving ease of operation.
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 method enables reliable ultrasonic inspection of complex structures by comparing wave patterns, improving accuracy and allowing inspection at any desirable position, thus facilitating non-destructive testing of vehicle components without disassembly.
Implementation Method 1
transmitting, by means of the transmitter of each of the plurality of transducers, an ultrasonic wave pattern into the test object along the surface of the test area
Implementation Method 2
receiving, by means of the receiver of each of the plurality of transducers, the ultrasonic wave pattern signal transmitted by the transmitter of the remaining plurality of transducers
Data Source
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AI summary
The present invention relates to method for ultrasonic inspection of a test object, comprising the steps of defining a coordinate system of the test object; selecting, relative to the coordinate system of the test object, at least two positions of a test area; positioning a respective ultrasonic measuring device at the at least two positions within the test area; transmitting, an ultrasonic wave pattern into the test object; receiving an ultrasonic wave pattern signal; acquiring an ultrasonic reference wave pattern signal for a reference area of a reference object, and comparing the received ultrasonic wave pattern signal from the test object with the acquired ultrasonic reference wave pattern signal of the reference object for detecting a defect in the test object.