Ultrasonic Probe for Structural Component Crack Testing
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Solution Overview
Problem
Structural components of vehicles, such as aircraft, are difficult to inspect for cracks due to accessibility issues, especially when assembled with other components, making traditional visual or sensor-based inspection methods impractical.
Innovation Solution
A method involving a probe with an ultrasonic transducer and rotation sensor/motor inserted into a circular hole, which rotates to emit ultrasound beams and measure echoes, automatically detecting discontinuities and determining crack dimensions by analyzing signal amplitudes and angular positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional visual inspection or sensor-based inspection methods are used, then the inspection process is simple and direct, but the structural component must be accessible which is not the case for assembled components
Solution Approach 1:
The ultrasonic probe is inserted into an existing hole (fastening hole, inspection hole, or through-hole) that is already present in the structural component. This nesting approach allows the inspection tool to access the component through an existing opening rather than requiring direct surface access, enabling inspection of assembled components without disassembly.
Solution Approach 2:
The patent uses an intermediary substance (couplant or gel) applied to the probe surface to facilitate ultrasonic wave transmission from the probe into the structural component. This intermediary enables effective coupling between the probe and the component material, allowing ultrasonic inspection through the hole interface.
2Measurement precision
If an operator manually inspects the component, then the inspection can be performed with simple equipment, but manual alignment and positioning are difficult and time-consuming
Solution Approach 1:
The system performs self-positioning and self-alignment through automatic rotation. The probe rotates automatically within the hole to scan different angular positions, and the control system automatically processes the ultrasonic signals to identify crack reflections. This eliminates the need for manual alignment and positioning by an operator.
Solution Approach 2:
The control system continuously monitors the ultrasonic echo signals during probe rotation and provides feedback to identify when a crack reflection is detected. Based on this feedback, the system automatically determines the angular position and distance to the crack, enabling precise measurement without manual intervention.
3Loss of information
If the probe rotates manually, then the equipment is simpler, but the angular position control and data recording become inaccurate
Solution Approach 1:
The patent replaces manual mechanical rotation with an automated rotation mechanism (motor or actuator). This mechanical substitution is coupled with a rotation sensor that automatically tracks the angular position, ensuring accurate angular data recording without relying on manual operator skill or attention.
Solution Approach 2:
The probe assembly integrates multiple functions: ultrasonic transmission, automatic rotation, angular position sensing, and data recording. This multi-functional integration allows the single probe system to perform both the inspection and the precise angular measurement functions that would otherwise require separate manual operations.
4Reliability
If multiple inspection points are checked manually, then comprehensive coverage is achieved, but the process becomes lengthy and prone to human error
Solution Approach 1:
The probe rotates continuously (or in continuous angular steps) while the control system continuously emits ultrasonic beams and records echo signals at multiple angular positions. This continuous scanning process ensures comprehensive coverage of all potential crack locations around the hole without interruption, improving both reliability and speed compared to discrete manual inspection points.
Solution Approach 2:
The system performs preliminary scanning at multiple angular positions quickly, and only when an echo signal exceeds the threshold does it proceed to detailed measurement and recording. This preliminary action approach allows rapid screening of multiple inspection points while maintaining comprehensive coverage, improving inspection speed without sacrificing reliability.
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 and characterization of cracks in hard-to-reach structural components without manual alignment, improving the efficiency and accuracy of crack testing by establishing angular references and calculating dimensional characteristics.
Implementation Method 1
inserting into the hole a probe comprising at least one ultrasonic transducer
Implementation Method 2
measuring a signal supplied by the probe, corresponding to an echo of the emitted ultrasound beam
Data Source
AI summary
A method for structural component crack testing comprising: a) identifying a structural component hole and inserting a probe thereinto; b) for different emission directions, automatically performing the following: b1) controlling a probe ultrasound beam emission; b2) measuring a probe signal; b3) if the measured signal amplitude is above a predetermined threshold: determining a distance between the probe and a structural component discontinuity point; recording a data set comprising at least the distance between the probe and the discontinuity point, together with a data element corresponding to the probe emission angular direction, c) automatically searching for data sets corresponding to characteristic discontinuity points, and consequently establishing a correspondence between the probe emission angular directions and an angular reference frame linked to the component; d) based on the recorded data sets, automatically determining the discontinuity point positions; e) determining a dimensional characteristic of a crack based on the discontinuity point positions.