Ultrasonic Probe for Composite Delamination Detection
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Solution Overview
Problem
Existing non-destructive ultrasound inspection devices for laminated composite panels, such as those used in aircraft, face challenges in accurately detecting delaminations on panels with non-constant thickness, as they require calibration and do not provide automatic dimensioning of defects.
Innovation Solution
A device and method utilizing an ultrasonic probe with a wheel of elementary transducers and an electronic device for emitting and receiving pulses, which generates C-scan mapping to automatically detect and dimension defects without initial calibration, using a function check part for verification and real-time coupling adjustment, and optionally incorporating digital structural information for accurate defect reporting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration on a healthy panel is performed to obtain reference signal parameters, then inspection accuracy on panels with constant thickness is improved, but the device cannot be used accurately on panels with non-constant thickness
Solution Approach 1:
The patent uses a function check part as a copy model containing artificial defects with known dimensions and locations. This copy allows the device to learn and calibrate its measurement capabilities without requiring a healthy reference panel, enabling accurate defect dimensioning on panels with non-constant thickness.
Solution Approach 2:
The patent changes the calibration approach from using a healthy panel's reflected signal parameters to using artificial defects with known dimensions in a function check part. This parameter transformation enables the system to directly correlate signal characteristics with actual defect dimensions, making it adaptable to varying panel thicknesses.
2Ease of operation
If the device provides only defect detection without dimension information, then the inspection process is simpler, but the operator cannot automatically obtain defect dimensions
Solution Approach 1:
The patent implements a feedback mechanism where the device compares the reflected signal from detected defects with the reference signals from artificial defects of known dimensions stored in the function check part. This feedback loop enables automatic calculation and display of defect dimensions, providing both operational simplicity and complete information.
Solution Approach 2:
The patent performs preliminary calibration using a function check part with artificial defects before actual inspection. This preliminary action establishes reference signal parameters for defects of known dimensions, enabling the device to automatically dimension defects during inspection without requiring operator intervention or estimation.
3Reliability
If manual calibration and operator analysis are required, then the device can handle complex inspection scenarios, but the inspection process becomes more time-consuming and less automated
Solution Approach 1:
The patent enables the device to perform self-calibration using the function check part with artificial defects. The system automatically adjusts its measurement parameters and dimensions without requiring manual operator calibration, thereby maintaining reliability while significantly improving productivity and automation.
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
Enables accurate, non-destructive detection and dimensioning of defects in panels with varying thickness, providing automatic defect reporting and visualization, enhancing operational simplicity and accuracy without the need for manual calibration or operator intervention.
Implementation Method 1
emitting ultrasonic pulses from the elementary transducers into the panel while the ultrasonic probe is in contact with the front face and receiving ultrasonic pulses reflected by the panel
Data Source
AI summary
A device and method for detecting delamination in a panel of laminated composite. The device comprises an ultrasonic probe with a plurality of elementary transducers, an electronic device in communication with the elementary transducers, and a display device. The transducers emit an ultrasonic pulse and receive a pulse reflected by an element in the panel. The received pulses are grouped into clusters of healthy, or non-damaged, zones and damaged zones. The dimensions of the damaged zones are based upon the limits formed by healthy zones. A display of the defect with dimensions is produced on the display device. A scale image of the defect with dimensions, via paper or digital overlay, can be placed on the panel.