Ultrasonic Sensor Calibration Piece With Sloped Redirecting Portion
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Solution Overview
Problem
Ultrasonic inspection systems face challenges in achieving both sensor thinning and accurate thickness measurement of pipes, particularly due to interference from calibration plates of varying thicknesses, which affect the timing and accuracy of ultrasonic wave reflections.
Innovation Solution
An ultrasonic inspection system with a calibration piece that includes a propagation portion and a propagation redirecting portion with a slope, allowing the ultrasonic wave to be redirected along the surface of the piezoelectric element, delaying the reception timing of the calibration plate reflections and improving measurement accuracy while allowing for sensor thinning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a thin calibration plate is used, then the ultrasonic sensor can be thinned, but the measurement accuracy of the pipe thickness is degraded due to overlapping reflection waves
Solution Approach 1:
The invention introduces a lateral dimension to the calibration plate by adding a reflective side surface that extends horizontally from the top surface. This lateral extension creates an additional reflection path that delays the calibration plate reflection wave in time, separating it from the pipe inner surface reflection wave. The side surface acts as an additional reflective interface that extends the ultrasonic wave's travel path through the calibration plate, effectively timing the reflection to occur after the pipe reflection without requiring a thicker calibration plate or larger sensor.
2Measurement precision
If a thick calibration plate is used, then the measurement accuracy is secured, but the sensor thinning is degraded
Solution Approach 1:
The calibration plate is segmented into multiple functional surfaces: a top surface for initial ultrasonic wave entry and a lateral side surface for delayed reflection. This segmentation allows the calibration function to be distributed across different spatial locations and time moments. The top surface handles early reflection for calibration, while the side surface provides a delayed reflection that occurs after the pipe inner surface reflection, enabling accurate measurement without requiring excessive calibration plate thickness.
Solution Approach 2:
Instead of increasing thickness in the vertical dimension to delay calibration reflections, the invention utilizes the lateral dimension by extending a reflective side surface horizontally. This dimensional shift creates an extended ultrasonic path length without increasing the calibration plate's vertical thickness, allowing the sensor to remain thin while still achieving proper temporal separation of reflection waves for accurate measurement.
3Ease of operation
If the ultrasonic sensor is manually pressed against the pipe, then the inspection can be performed, but it requires careful arrangement and increases labor and time
Solution Approach 1:
The ultrasonic sensor is pre-fixed to the calibration plate, which itself is attached to the pipe under the heat insulating material. This preliminary positioning and fixation of the sensor eliminates the need for manual pressing and careful arrangement during inspection. The sensor is already in the correct position with proper contact pressure established through the calibration plate attachment, allowing immediate inspection operation without time-consuming manual setup.
Solution Approach 2:
The calibration plate serves a dual function: it provides calibration references for measurement accuracy and simultaneously acts as a mounting substrate that holds the ultrasonic sensor in the correct position. This self-service arrangement eliminates the need for separate sensor positioning and fixation operations, reducing labor and inspection time while maintaining proper sensor contact with the pipe through the calibration plate's structural support.
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 achieves both sensor thinning and secure measurement accuracy of pipe thickness by optimizing the calibration piece design, ensuring accurate timing and reducing interference from calibration plate reflections.
Implementation Method 1
an ultrasonic sensor which includes a piezoelectric element to transmit and receive an ultrasonic wave
Implementation Method 2
The propagation redirecting portion includes a slope inclined in a vertical direction to the surface of the piezoelectric element, reflects the ultrasonic wave incident on the propagation redirecting portion from the piezoelectric element on the slope
Data Source
AI summary
An ultrasonic inspection system includes an ultrasonic sensor which includes a piezoelectric element to transmit and receive an ultrasonic wave and a calibration piece, and a control device. The calibration piece includes a propagation portion extending along an upper surface of the piezoelectric element, and a propagation redirecting portion which is formed on one side in an extending direction of the propagation portion, and is connected to the piezoelectric element through a heat resistant adhesive. The propagation redirecting portion includes a slope inclined in a vertical direction to the upper surface of the piezoelectric element. The propagation redirecting portion is configured to reflect the ultrasonic wave incident on the propagation redirecting portion from the piezoelectric element on the slope and emit the ultrasonic wave toward the propagation portion, and reflect the ultrasonic wave which is reflected on an end surface on the other side in the extending direction of the propagation portion and incident on the propagation redirecting portion from the propagation portion on the slope and emit the ultrasonic wave toward the piezoelectric element.