Ultrasonic Seal Inspection System for Misalignment Detection

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Solution Overview

Problem

Existing inspection systems fail to detect misaligned cup seals until the entire structure is assembled and pressure tested, leading to labor-intensive and costly disassembly and reinstallation processes.

Innovation Solution

An inspection system utilizing a linear transducer array with ultrasonic transducers that transmit and receive ultrasonic waves, rotated around the sleeve to generate an acoustic representation of seal contact areas, allowing for real-time detection of misaligned seals without disassembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pressure testing is performed after assembly, then seal reliability is verified, but inspection time and labor costs increase due to required disassembly and reinstallation

Engineering Contradiction:

Improveseal reliabilityVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The inspection system performs seal alignment verification during the assembly process itself, before the structure is fully assembled and pressure tested. The ultrasonic transducer array detects seal misalignment in real-time as the seal is installed, allowing corrective action to be taken immediately without requiring subsequent disassembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces mechanical pressure testing with an ultrasonic inspection system. Instead of using mechanical pressure to detect seal failures, the system uses ultrasonic waves to detect seal misalignment, enabling non-contact inspection that can be performed during assembly without damaging the seal or requiring disassembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If manual inspection methods are used, then device complexity is reduced, but measurement precision is insufficient to detect rolled seals early in the assembly process

Engineering Contradiction:

Improveinspection system complexityVSAvoidseal alignment detection precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces manual visual inspection with an automated ultrasonic inspection system. The ultrasonic transducer array provides precise detection of seal misalignment through acoustic signal analysis, enabling early detection of rolled seals with high measurement precision while keeping the overall system relatively simple and non-invasive.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If disassembly and reinstallation are performed, then seal alignment is corrected, but productivity decreases due to time-consuming reassembly processes

Engineering Contradiction:

Improveseal alignmentVSAvoidassembly productivity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The inspection system performs seal alignment verification during the initial assembly process, before the structure is fully assembled. By detecting and correcting seal misalignment early, the system eliminates the need for subsequent disassembly and reinstallation, thereby maintaining high productivity while ensuring proper seal alignment.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The ultrasonic inspection system provides real-time feedback on seal alignment during assembly. The system continuously monitors the seal position and can immediately identify misalignment, allowing operators to correct the issue during the assembly process rather than after, thus avoiding time-consuming reassembly operations.

Inventive Principle:

Principle #23Feedback

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 misaligned seals during assembly, reducing labor and time costs by providing a visual representation of seal alignment, thus preventing costly reassembly.

Implementation Method 1

a linear transducer array including a plurality of ultrasonic transducers... each configured to transmit and receive ultrasonic waves

Methodology Applied

Scientific EffectUltrasonic wave transmission and reception: Ultrasound

Implementation Method 2

generates an acoustic representation of the one or more seals disposed underneath the sleeve based on the ultrasonic waves received

Methodology Applied

Scientific EffectAcoustic signal detection: Acoustic Emission

Data Source

PatentUS11143568B2Inspection system for detecting misaligned seals

Publication Date: 2021.10.12 THE BOEING CO

AI summary

An inspection system for detecting one or more misaligned seals is disclosed and includes a linear transducer array connected to a sleeve. The linear transducer array includes a plurality of ultrasonic transducers each configured to transmit and receive ultrasonic waves. The ultrasonic transducers direct the ultrasonic waves towards one or more seals that are disposed underneath the sleeve. The inspection system also includes a rotational device configured to move the ultrasonic transducers around a circumference of the sleeve, one or more processors in electronic communication with the linear transducer array, and a memory coupled to the one or more processors. The memory stores data into a database and program code that, when executed by the one or more processors, causes the inspection system to instruct the plurality of ultrasonic transducers to transmit and receive the ultrasonic waves.