Ultrasonic Phased Array Weld Inspection System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current nondestructive testing methods for weld joints, particularly resistance spot welds, require skilled operators and are subjective, making it difficult to reliably identify poor quality joints without human intervention and providing efficient characterization and evaluation.
Innovation Solution
A three-dimensional matrix phased array spot weld inspection system using a curved array of ultrasonic transducer elements with a phased array excitation unit and a computerized controller to generate and process ultrasonic signals, allowing for automated characterization of welds by calculating weld metrics and differentiating fused and unfused locations on a weld fusion map.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If acoustic methods are used for weld inspection, then surface and internal information can be obtained with deep penetration and high sensitivity, but skilled operators are required and the process becomes subjective
Solution Approach 1:
The system performs self-evaluation by automatically analyzing ultrasonic signals to determine weld quality. The processor autonomously evaluates reflection patterns, calculates fusion metrics, and generates quality assessments without requiring operator interpretation, thereby eliminating subjectivity while maintaining high detection sensitivity
Solution Approach 2:
The patent replaces the manual mechanical inspection process with an automated electronic system. Ultrasonic transducers transmit sound waves and electronic processors analyze the reflected signals, substituting human operator judgment with objective computational analysis of acoustic data
2Reliability
If skilled operators are involved in weld inspection, then subjective interpretation can be applied, but the process becomes less efficient and more time-consuming
Solution Approach 1:
The system enables continuous automated inspection by processing ultrasonic signals in real-time without interruption. Multiple transducers can operate simultaneously, and the processor continuously evaluates weld quality metrics, eliminating the discontinuous nature of manual inspection and significantly increasing productivity while maintaining reliability
Solution Approach 2:
The system incorporates feedback mechanisms where the processor analyzes ultrasonic reflection patterns and provides immediate automated evaluation of weld quality. This closed-loop feedback system replaces subjective human judgment with objective, consistent computational analysis that maintains reliability while operating at higher speeds
3Extent of automation
If automated systems are implemented for weld inspection, then operator dependency is reduced, but system complexity increases
Solution Approach 1:
The automated inspection system is divided into distinct functional modules: ultrasonic transducers for signal transmission, processors for signal analysis, and evaluation systems for quality determination. This segmentation allows each component to perform its specific function efficiently, reducing overall system complexity while maintaining high automation levels
Solution Approach 2:
The ultrasonic inspection system is designed with multi-functional capabilities that allow the same hardware components to perform multiple tasks. The transducers can transmit and receive signals, the processors can analyze various signal parameters, and the system can evaluate different weld types, reducing the need for multiple specialized devices and simplifying the overall system architecture
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 system enables rapid, efficient, and reliable characterization of spot welds, reducing operator dependency and subjective interpretation, and providing accurate assessment of weld quality by generating weld fusion maps and calculating relevant metrics.
Implementation Method 1
a plurality of ultrasonic transducer elements arranged in a curved array at one end of the acoustic probe, wherein the transducer elements are operative to both generate ultrasonic signals and to receive reflections
Implementation Method 2
providing a phased array excitation unit in electrical communication with the array of transducer elements for ultrasonically exciting the transducer elements in a phased manner
Implementation Method 3
a combination of materials for allowing the probe to conform to a contoured surface of the spot weld while enabling sound energy to be transferred directly into the spot weld under test conditions
Data Source
AI summary
A method for characterizing a spot weld, including acquiring a sequence of A-scans from an ultrasonic phased array, wherein the A-scans describe individual portions of a field of view of the phased array; manually applying an interface gate and a flaw gate to each individual A-scan within the sequence of A-scans; calculating a gate ratio between a maximum amplitude under the interface gate and a maximum amplitude under the flaw gate for each individual A-scan; plotting the gate ratio for each individual A-scan as a function of location within the phased array field of view to generate a weld fusion map; using a predetermined threshold to differentiate fused locations from unfused locations on the weld fusion map; and calculating predetermined weld metrics, wherein the predetermined weld metrics include area, diameter, width, length, percent fused, or combinations thereof.