Ultrasonic Measurement Device with Resilient Contact Layer
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Solution Overview
Problem
Current ultrasonic measurement methods for tightening fasteners are inefficient as they require post-tightening measurements, which slow down high-speed assembly processes and struggle with achieving reliable acoustic contact, leading to uncertainties in tightening force accuracy.
Innovation Solution
An ultrasonic measurement device with a built-in transducer and a resilient contact layer ensures reliable acoustic coupling and frequency optimization to enhance signal reflection, allowing for real-time measurement during the tightening process without the need for external contact mediums like glycerine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic measurement is performed after fastening completion, then acoustic contact can be reliably established, but assembly time increases substantially
Solution Approach 1:
The patent applies preliminary action by establishing acoustic contact before the fastening process begins. The contact layer is positioned and acoustically coupled to the fastener prior to tightening, allowing ultrasonic measurements to be taken during the fastening process rather than after completion. This enables real-time monitoring of tightening force without delaying the assembly process.
2Reliability
If a contact layer with different ultrasonic propagation speed is used, then acoustic coupling is improved, but signal reflection is reduced
Solution Approach 1:
The patent applies parameter changes by systematically varying the thickness of the contact layer to optimize ultrasonic signal characteristics. By adjusting this geometric parameter, the system achieves both reliable acoustic coupling and sufficient signal reflection. The optimal thickness creates constructive interference patterns that enhance the reflected signal while maintaining acoustic contact.
Solution Approach 2:
The patent applies periodic action by utilizing ultrasonic wave interference patterns that create periodic variations in signal amplitude based on contact layer thickness. By tuning the thickness to specific values, the system exploits these periodic interference effects to maximize signal reflection and improve the signal-to-noise ratio while maintaining acoustic coupling.
3Reliability
If fastener dimension is increased, then tightening force requirement is met even with friction variations, but material usage increases
Solution Approach 1:
The patent applies feedback by implementing real-time ultrasonic measurement of tightening force during the fastening process. This feedback mechanism allows the system to monitor the actual tightening force and detect when the desired level is achieved, enabling precise control of the tightening process. Consequently, fasteners can be properly sized without excessive dimensions, reducing material consumption while ensuring reliable tightening force.
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 and efficient measurement of tightening force during fastening processes, reducing assembly time and material usage by ensuring the desired force is achieved with smaller fasteners, while maintaining high signal quality.
Implementation Method 1
A thin piezoelectric sensor consisting of a piezoelectric film sandwiched between two thin electrodes is permanently mechanically and acoustically coupled to the upper surface of a member
Implementation Method 2
utilizing a transducer to impose ultrasonic sound waves into the fastener
Implementation Method 3
A thin piezoelectric sensor consisting of a piezoelectric film sandwiched between two thin electrodes is permanently mechanically and acoustically coupled to the upper surface of a member and is used to determine the length, tensile load, stress or other tensile load dependent characteristic of the member by ultrasonic techniques
Data Source
Figure 1~2b
Figure 2a
Figure 3A~3C
AI summary
According to the invention, it is provided an ultrasonic measurement method wherein an ultrasonic transducer (102; 230; 502) is acoustically coupled to an object (101; 217; 501) to be measured by means of a resilient material contact layer (218). The transducer (102; 230; 502) transmits a plurality of consecutive ultrasonic transmit signals into the said object (101; 217; 501) being measured, the transmit frequency (f ) of each of said plurality of transmit signals being distinct from the frequency of the other transmit signals of said plurality of transmit signals. Signal echoes of said transmitted signals are received, and based on the said received signal echoes, at least one transmit frequency (f) to be used for ultrasonic measurement of the said object (101; 217; 501) is selected. The invention also relates to an ultrasonic measurement device.