Ultrasonic Probe Sensitivity Adjustment via Bottom Surface Echo
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for evaluating and adjusting the flaw detection sensitivity of array ultrasonic probes are inadequate, particularly when installed in an inspection line, and fail to sufficiently detect abnormalities by monitoring synthesized waveform intensity alone.
Innovation Solution
The method involves adjusting the flaw detection sensitivity of ultrasonic probes by transmitting ultrasonic waves towards the bottom surface of a plate or inner surface of a tubular material, ensuring equal echo intensity across transducers, and diagnosing abnormalities by determining the effective beam width relative to a predetermined threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the top surface echo method from flat plate specimen is used to evaluate array ultrasonic probe, then the evaluation procedure is simple, but it is difficult to appropriately evaluate relative sensitivity and adjust flaw detection sensitivity of each transducer
Solution Approach 1:
The patent introduces a bottom surface echo as an intermediary reference that provides consistent echo intensity distribution across all transducers. This intermediary reference plane allows for accurate relative sensitivity evaluation without requiring complex artificial flaws, resolving the contradiction between simple procedure and accurate measurement.
2Measurement precision
If the steel ball or steel wire method is used to evaluate array ultrasonic probe, then relative sensitivity can be appropriately evaluated, but the evaluation and adjustment procedures become too complicated
Solution Approach 1:
The patent extracts the essential function of sensitivity evaluation by removing the complex artificial flaws (steel ball, steel wire) and retaining only the bottom surface echo reference. This extraction maintains measurement accuracy while dramatically simplifying the evaluation procedure, making it suitable for inline inspection systems.
3Ease of operation
If only synthesized waveform intensity monitoring is used for abnormality diagnosis, then the diagnosis method is simple, but abnormalities of array ultrasonic probe cannot be sufficiently detected
Solution Approach 1:
The patent implements feedback by comparing the actual echo intensity distribution across transducers against the reference distribution obtained from bottom surface echoes. This feedback mechanism enables reliable abnormality detection while maintaining simple operation, as the system automatically identifies deviations from the reference pattern.
4Productivity
If array ultrasonic probe is installed in inspection line for flaw detection, then productivity is improved, but it becomes substantially difficult to work on sensitivity adjustment and abnormality diagnosis
Solution Approach 1:
The patent enables the inspection system to perform self-diagnosis and self-adjustment by using the bottom surface echo reference. The system automatically evaluates transducer sensitivity and detects abnormalities without requiring external intervention or removal from the inspection line, maintaining high productivity while enabling easy maintenance.
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 appropriate adjustment of flaw detection sensitivity and effective diagnosis of ultrasonic probes, even when installed in an inspection line, by equalizing echo intensities and monitoring beam widths, thereby enhancing detection accuracy.
Implementation Method 1
transmitters transmit ultrasonic waves toward a measurement target and receivers receive echoes from the measurement target
Implementation Method 2
receivers receive echoes from the measurement target
Data Source
AI summary
A method of adjusting flaw detection sensitivity on an array ultrasonic probe comprises disposing a plate material P1 oppositely to the ultrasonic probe such that an upper surface of the plate material is disposed to be approximately parallel to an array direction of the transducers 11, or disposing a tubular material P2 oppositely to the ultrasonic probe such that an axial direction of the tubular material is disposed to be approximately parallel to the array direction of the transducers. Ultrasonic waves are transmitted from each transducer toward the upper surface of the plate material or an outer surface of the tubular material, and echoes are received from the bottom surface of the plate material or an inner surface of the tubular material on each transducer. Flaw detection sensitivity of each transducer is adjusted to substantially equalize intensity of an echo received on each transducer.