Ultrasonic Inspection Sensor Placement Optimization for Aircraft Coverage
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Solution Overview
Problem
Conventional ultrasonic inspection methods for large structures like aircraft structural objects require numerous transducers and sensors, increasing weight and labor, while inappropriate placement leads to incomplete coverage and reduced detection accuracy.
Innovation Solution
An ultrasonic inspection system design system and program that optimizes the number, position, and frequency of transducers and sensors using finite element method (FEM) simulations and optimization calculations to ensure comprehensive coverage with minimal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If many ultrasonic transducers and sensors are disposed to cover a wide inspection area, then the inspection coverage is improved, but the weight of the aircraft increases
Solution Approach 1:
The patent applies preliminary action by performing ultrasonic wave propagation analysis simulations before the actual inspection system deployment. The simulation predicts ultrasonic wave behavior and identifies optimal sensor/transducer positions in advance, allowing the system to achieve comprehensive coverage with fewer physical components, thereby reducing aircraft weight while maintaining inspection coverage.
2Measurement precision
If trial and error method is used to determine the number and positions of ultrasonic transducers and sensors, then the detection accuracy is improved, but the labor in aircraft design increases
Solution Approach 1:
The patent applies copying by creating a virtual model (FEM model) that replicates the physical aircraft structure. Ultrasonic wave propagation simulations are performed on this copied virtual model to determine optimal sensor positions. This eliminates the need for repeated physical trial and error tests, significantly reducing design time while maintaining the ability to achieve high detection accuracy.
3Quantity of substance
If ultrasonic transducers and sensors are disposed at inappropriate positions, then the number of parts is reduced, but the inspection area coverage becomes insufficient
Solution Approach 1:
The patent applies parameter changes by systematically varying and optimizing the positions of ultrasonic transducers and sensors based on simulated ultrasonic wave propagation characteristics. The optimization process adjusts spatial parameters to identify configurations that achieve complete inspection area coverage with the minimum number of components, avoiding both insufficient coverage and excessive part usage.
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 precise defect detection with fewer parts, reducing weight and improving accuracy by determining optimal sensor and transducer placement through simulation and optimization.
Implementation Method 1
an ultrasonic transducer, oscillating an ultrasonic wave
Implementation Method 2
a sensor, detecting the ultrasonic wave
Data Source
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AI summary
According to one embodiment, a method of producing an ultrasonic inspection system includes creating design information on the ultrasonic inspection system and assembling the ultrasonic inspection system based on the design information. The design information includes numbers, positions and directions of at least one ultrasonic sensor and at least one ultrasonic transducer. The design information is created by an optimization calculation of which at least one parameter includes at least one of the numbers, positions and directions of the at least one ultrasonic sensor and the at least one ultrasonic transducer. The optimization calculation includes a simulation of an ultrasonic inspection for detecting a defect by the ultrasonic inspection system having the at least one ultrasonic sensor and the at least one ultrasonic transducer. The simulation is performed using a model simulating an object of the ultrasonic inspection.