Ultrasonic Probe Tilt Display for Accurate Weld Inspection
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Solution Overview
Problem
In welding inspections, the tilt of an ultrasonic probe with respect to the weld portion significantly affects the inspection results, and existing systems lack effective methods to easily inform inspectors about the probe's tilt and necessary adjustments.
Innovation Solution
A display control system that calculates and displays the tilt of the probe using a matrix of ultrasonic sensors, presenting a user interface with a symbol and tolerance range to help inspectors adjust the probe's tilt for accurate inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a human inspector manually grips and positions the probe during inspection, then the inspection can be performed with simple equipment, but the inspector cannot easily ascertain probe tilt information and make accurate adjustments
Solution Approach 1:
The patent implements a feedback mechanism where the system calculates probe tilt based on ultrasonic wave intensity differences detected by multiple sensors, and displays this information to the inspector. The system continuously monitors the ultrasonic signals, computes the tilt angle, and provides real-time visual feedback through a display unit, enabling the inspector to adjust the probe position accurately without increasing manual effort significantly.
Solution Approach 2:
The patent replaces manual mechanical positioning with an automated calculation system. Instead of relying on the inspector's manual skill to position the probe perfectly, the system uses ultrasonic wave intensity measurements from multiple sensors to automatically calculate the probe tilt, substituting mechanical positioning skill with computational analysis.
2Measurement precision
If multiple ultrasonic sensors are used to detect probe tilt, then measurement accuracy improves, but the device complexity and processing requirements increase
Solution Approach 1:
The patent divides the ultrasonic detection function across multiple sensors arranged in a matrix pattern. Each sensor detects ultrasonic wave intensity independently, and the system processes these segmented measurements to calculate tilt in different directions. This segmentation allows accurate three-dimensional tilt detection while maintaining manageable system complexity through modular sensor arrangement.
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
The system enables inspectors to intuitively understand and adjust the probe's tilt, improving the accuracy and reliability of weld inspections by providing real-time feedback on the probe's orientation relative to the weld portion.
Implementation Method 1
An ultrasonic wave is transmitted from the probe toward the weld portion, and an inspection device verifies the existence or absence of the joint based on the reflected wave
Implementation Method 2
an ultrasonic wave is transmitted from the probe toward the weld portion, and an inspection device verifies the existence or absence of the joint based on the reflected wave
Data Source
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AI summary
According to one embodiment, a display control system acquires a tilt of a detector with respect to a weld portion. The detector includes a plurality of detection elements arranged along a first arrangement direction and a second arrangement direction. The first arrangement direction and the second arrangement direction cross each other. The tilt is calculated based on a detection result of a reflected wave obtained by transmitting an ultrasonic wave from the plurality of detection elements. The system displays a user interface, displays a symbol and a tolerance range in a region included in the user interface, and updates the display of the symbol in the region according to the acquiring of the tilt. The region spreads two-dimensionally. The symbol indicates the tilt. The tolerance range is of a target value of the tilt.