2D Ultrasonic Sensor Array for Automated Structural Inspection
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Solution Overview
Problem
Current non-destructive inspection methods for structures, such as aircraft and composite structures, are time-consuming and prone to human error due to the need for manual scanning with ultrasonic sensors, and lack efficient one-sided inspection capabilities for contoured surfaces.
Innovation Solution
A method utilizing a two-dimensional array of ultrasonic sensors disposed on a structure's surface to send and receive pulses, generating graphical images of damage, determining if it meets predetermined criteria, and selecting a mode for returning the structure to service based on the damage assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual scanning with ultrasonic sensors is used, then inspection flexibility is maintained, but inspection time and human error increase
Solution Approach 1:
The ultrasonic sensor is divided into a two-dimensional array of multiple individual sensors arranged in rows and columns. Each sensor independently collects data at its specific location, allowing parallel processing of inspection data across the entire structure surface simultaneously, thereby increasing inspection speed while maintaining operational flexibility.
Solution Approach 2:
Multiple ultrasonic sensors are combined into a single integrated two-dimensional array system that operates as one unified inspection unit. The array collectively covers a larger inspection area and processes data from multiple locations simultaneously, eliminating the need for manual movement between measurement points and significantly reducing inspection time.
2Device complexity
If manual scanning with ultrasonic sensors is used, then equipment simplicity is maintained, but inspection accuracy and consistency deteriorate
Solution Approach 1:
The two-dimensional sensor array automatically performs data collection and processing without requiring manual intervention. The system self-regulates the inspection process by systematically activating sensors across the array, maintaining consistent measurement conditions, and automatically generating damage assessments, thereby eliminating variability introduced by manual operation while keeping the equipment relatively simple.
3Ease of operation
If traditional ultrasonic inspection methods are used, then one-sided inspection capability is maintained, but inspection completeness for contoured surfaces deteriorates
Solution Approach 1:
The inspection approach transitions from one-dimensional point-by-point scanning to two-dimensional array-based inspection. The two-dimensional array of sensors simultaneously measures multiple locations across the structure surface, enabling complete characterization of contoured surfaces from a single side while maintaining ease of operation and improving inspection reliability through comprehensive data coverage.
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 enables efficient, accurate, and automated inspection of structures without manual movement of the sensor array, allowing for precise damage assessment and effective repair planning, reducing human error and increasing inspection speed.
Implementation Method 1
a structure may be inspected by a pulse-echo (PE) method wherein a sensor device sends ultrasonic pulses into a structure and receives echo pulses that reveal the condition of the structure
Implementation Method 2
receives echo pulses that reveal the condition of the structure
Data Source
AI summary
In a method of inspecting a structure, a two-dimensional array of sensors is disposed onto a surface, ultrasonic pulses are sent into the surface, and echo signals are received. An image of damage within the structure is graphically displayed, a determination of whether the damage satisfies a predetermined criterion is made, and a mode of returning the structure to usage or service is selected. The predetermined criterion may define a length, a depth, and an area. A-scan, B-scan, and C-scan images of the damage may be displayed. Threshold images may be displayed wherein each pixel of a matrix of pixels is colored one of only two colors.