Ultrasonic Sensor System for Nuclear Pipe Inspection
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Solution Overview
Problem
Current ultrasonic inspection methods for pipes in nuclear power plants require frequent manual intervention, are labor-intensive, and struggle with maintaining signal integrity due to thick heat insulating coatings, which limits the measurement pitch and increases maintenance needs.
Innovation Solution
A sensor system utilizing electromagnetic induction between coils, with a sensor coil attached to the pipe surface, a sensor side coil facing with a gap for electromagnetic induction, and a probe side coil connected via a cable, allowing for non-contact energy supply and signal transmission without battery dependency, enabling detection of thickness reductions and cracks without detaching the heat insulating member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If an ultrasonic sensor with battery and control electric wave transceiver is attached to perform automatic inspection, then automation is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent extracts the battery and control electric wave transceiver from the ultrasonic sensor, separating the power and control functions from the sensing function. This allows the sensor to be simpler in structure while still enabling automatic inspection through external control and power supply via the heat insulating member's existing wiring.
Solution Approach 2:
The heat insulating member is given multiple functions: it provides thermal insulation, serves as a mounting substrate for the sensor, and acts as a conduit for power and control signals through its existing wiring. This eliminates the need for separate battery and transceiver components in the sensor.
2Measurement precision
If sensor coils are placed close together to achieve small measurement pitch, then inspection resolution is improved, but signal interference between adjacent coils increases
Solution Approach 1:
The patent introduces an electromagnetic wave absorbing material as an intermediary between adjacent sensor coils. This material selectively absorbs electromagnetic waves in the ultrasonic frequency range, preventing signal interference between coils while allowing the coils to be positioned close together for high-resolution inspection.
3Measurement precision
If heat insulating member is detached for manual detailed inspection, then inspection accuracy is improved, but labor time and maintenance complexity increase
Solution Approach 1:
The sensor is pre-attached to the heat insulating member during installation, performing preliminary inspection functions continuously. This allows for ongoing monitoring without requiring later detachment for detailed inspection, reducing both labor time and maintenance complexity while maintaining inspection accuracy.
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 solution allows for efficient, maintenance-free ultrasonic inspection of pipes with a measurement pitch of 100 mm or less, reducing labor and maintenance needs while preventing signal interference from adjacent coils and allowing for high-position inspections without scaffolding.
Implementation Method 1
A sensor system used for nondestructive inspection, including a sensor attached to a surface of an inspection target; a sensor coil that is electrically connected to the sensor via a first cable; a first electromagnetic wave blocking member that is disposed between the surface of the inspection target and the sensor coil; a sensor side coil that is disposed to face the sensor coil with a gap and is capable of being coupled to the sensor coil through electromagnetic induction
Data Source
AI summary
Provided is a sensor system which can detect a thickness reduction, a crack, or the like of a pipe or a container covered with a thick coating member through ultrasonic inspection without attachment and detachment of the coating member. A sensor system used for nondestructive inspection includes a sensor attached to a surface of an inspection target, a sensor coil that is electrically connected to the sensor via a first cable, a first electromagnetic wave blocking member that is disposed between the surface of the inspection target and the sensor coil, a sensor side coil that is disposed to face the sensor coil with a gap and is coupled to the sensor coil through electromagnetic induction, and a probe side coil that is disposed to be separated from the sensor side coil and is electrically connected to the sensor side coil via a second cable.