Focused Ultrasonic Probe for Crack Detection in Assembled Machinery
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Solution Overview
Problem
Nondestructive testing of machinery is challenging due to the inability to detect cracks and other surface discontinuities in assembled components without disassembly, which is time-consuming and potentially damaging.
Innovation Solution
A method and apparatus using a focused ultrasonic beam with longitudinal waves converted to shear waves to detect cracks by adjusting the focal point's position and distance, allowing for non-invasive inspection of assembled structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If disassembly is performed to detect cracks and surface discontinuities, then measurement precision is improved, but loss of time increases and reliability deteriorates due to potential damage
Solution Approach 1:
The patent replaces mechanical disassembly with ultrasonic wave-based detection. The ultrasonic transducer emits acoustic waves that penetrate the assembled structure, and the reflected waves reveal crack locations without requiring physical disassembly, thus maintaining measurement precision while eliminating time loss and damage risks
Solution Approach 2:
The patent introduces ultrasonic waves as an intermediary medium to detect cracks. The waves serve as a mediator that can penetrate the assembled structure and interact with cracks, allowing indirect detection without direct physical access or disassembly of the components
2Measurement precision
If disassembly is performed to detect cracks and surface discontinuities, then measurement precision is improved, but reliability deteriorates due to potential damage
Solution Approach 1:
The patent replaces mechanical disassembly with ultrasonic wave-based detection. The ultrasonic transducer emits acoustic waves that penetrate the assembled structure, and the reflected waves reveal crack locations without requiring physical disassembly, thus maintaining measurement precision while preserving connection integrity
Solution Approach 2:
The patent converts the inability to directly observe cracks into a benefit by using ultrasonic wave reflection. The waves interact with cracks and reflect back, transforming the hidden defect into a detectable signal that provides information about crack location and severity without damaging the structure
3Measurement precision
If focused ultrasonic beam with wave conversion is used, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent changes the physical parameters of the ultrasonic beam by converting longitudinal waves to shear waves at a specific angle. This parameter change enables the beam to interact differently with cracks, improving detection precision through mode conversion while using standard ultrasonic equipment
Solution Approach 2:
The patent uses a curved or focused transducer surface to concentrate the ultrasonic beam into a focused path. This curvature creates a concentrated beam that targets specific areas with high precision, improving measurement accuracy while the focusing geometry is achieved through standard transducer design
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 the detection of cracks and surface discontinuities without disassembling the machinery, providing accurate and efficient nondestructive testing results through signal response analysis.
Implementation Method 1
configuring a probe to emit a focused ultrasonic beam formed of longitudinal waves
Implementation Method 2
emitting the focused ultrasonic beam into the outer surface, wherein the ultrasonic beam enters the outer surface at an angle that converts the longitudinal waves into shear waves
Implementation Method 3
a coupling fluid filling the chamber, wherein changing an amount of coupling fluid in the chamber changes a focal distance of the focal point
Implementation Method 4
a transducer emitting an ultrasonic beam in response to an applied electrical signal
Data Source
AI summary
A method for testing a body having a feature and an outer surface includes configuring a probe to emit a focused ultrasonic beam; configuring a control unit to control the probe, adjusting a focal distance of a focal point of the beam with reference to a test location; adjusting a position of the focal point along at least one axis with reference to the feature; emitting the beam into the outer surface; and determining a presence of a crack at the test location by evaluating % a signal response from the probe. A related apparatus includes the control unit, the transducer, and a shoe assembly having a shoe member and a shoe adapter. A coupling fluid in a variable volume chamber in the shoe adapter separates the transducer from the shoe member and allows changes in a focal distance of the focal point. The apparatus also includes one or more positioners for adjusting a position of the focal point.