Ultrasonic Probe Alignment Using Echo Amplitude Feedback
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Solution Overview
Problem
Existing ultrasonic testing systems face challenges in aligning ultrasonic probes to achieve normal incidence, which is necessary for maximizing the amplitude of ultrasonic echoes, due to the high degree of freedom of flexible delay lines, making it time-consuming to achieve optimal alignment.
Innovation Solution
The system employs a flexible delay line with an elastic modulus within specific ranges to facilitate alignment, using a processor to determine the maximum amplitude of ultrasonic echoes, scale, bin, and color-code them, generating a Graphical User Interface (GUI) with C-scans to provide real-time feedback for optimal probe alignment, and displaying a 'water-bubble' like graphic for intuitive guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible delay line with high degree of freedom is used to conform to contoured surfaces, then the adaptability to different surface geometries is improved, but the alignment time to achieve normal incidence becomes excessively long
Solution Approach 1:
The system employs a feedback mechanism where the processor analyzes ultrasonic echo amplitudes from multiple transducers and provides real-time guidance to the operator. The display shows which transducers have achieved normal incidence (maximum echo amplitude) and which need adjustment, enabling rapid convergence to optimal alignment without trial-and-error
Solution Approach 2:
The patent replaces manual trial-and-error mechanical alignment with an automated electronic measurement and feedback system. The processor calculates optimal alignment based on ultrasonic echo data and provides directional guidance, substituting mechanical intuition with precise acoustic measurement and computational analysis
2Measurement precision
If manual alignment adjustment is performed to achieve normal incidence, then the measurement precision of echo amplitude is improved, but the productivity and inspection efficiency deteriorate due to time-consuming alignment process
Solution Approach 1:
The system performs preliminary alignment assistance by analyzing ultrasonic echoes from all transducers before formal inspection begins. The processor identifies which transducers are already properly aligned and provides specific guidance for misaligned ones, enabling rapid setup without compromising subsequent measurement precision
Solution Approach 2:
The system changes the parameter being optimized from manual mechanical adjustment to ultrasonic echo amplitude analysis. By measuring echo amplitudes and using them to guide alignment, the system transforms a mechanical alignment task into an acoustic measurement-based optimization process
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 allows for efficient alignment of ultrasonic probes, maximizing echo amplitude without requiring operators to review A-scans, providing visual feedback for optimal inclination and reducing alignment time.
Implementation Method 1
The flexible delay line 110 can possess an elastic modulus that allows it to deform elastically and conform to contours 104 on the surface of the target 102
Implementation Method 2
Ultrasonic echoes resulting from reflection of the transmitted ultrasonic signals from boundaries within the inspected part (e.g., defects and outer boundaries) can be subsequently detected by the ultrasonic transducer
Implementation Method 3
An ultrasonic transducer can be used to emit ultrasonic signals (sound waves) that travel into the inspected target
Implementation Method 4
Properties of the reflected ultrasonic echoes can be measured by the ultrasonic transducer (e.g., amplitude, time of flight, etc.) and subsequently analyzed to identify characteristics of defects detected within the inspected part
Data Source
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AI summary
An ultrasonic inspection system includes an ultrasonic probe and an analyzer. The probe includes a flexible delay line and an ultrasonic transducer array at a first delay line end. A second delay line end can contact a target. The analyzer can receive ultrasonic echoes from the ultrasonic transducers representing amplitude of ultrasonic signals reflected from the target as a function of time from transmission. The analyzer determines a maximum amplitude of the echoes received by each transducer, scale the maximum amplitudes based upon a greatest maximum amplitude, and bin the scaled maximum amplitudes. The analyzer assigns each bin a color and generate a C-scan based upon the scaled amplitudes. Each C-scan pixel can correspond to at least one transducer, and the relative position of each C-scan pixel can correspond to the relative position of the ultrasonic transducer represented by the pixel. Each pixel can be displayed with its assigned color.